Composite forming member

Abstract

An object is to minimize the number of positioning pins for positioning the inner forming portion when die-forming the outer forming portion around the inner forming portion. A composite forming member includes an inner forming portion and an outer forming portion covering the inner forming portion. An anti-rotation hole that opens on the surface of the inner forming portion is formed in the inner forming portion, and a through-hole that reaches the anti-rotation hole from the surface of the outer forming portion is formed in the outer forming portion. The anti-rotation hole is a hole surrounded by an inner peripheral surface and a bottom surface, and at least a part of the inner peripheral surface is formed in a non-circular shape.

Description

Technical Field

[0001] The present disclosure relates to a composite molded member. Background Art

[0002] Patent Document 1 discloses the following technique: After an electronic component and a circuit are provided on an insulating bracket and the electronic component and the circuit are covered with an elastic resin, the bracket is supported by support pins to perform positioning in an injection molding die, and they are integrally resin-molded to form a housing.

[0003] Prior Art Documents

[0004] Patent Documents

[0005] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2003-177171 Summary of the Invention

[0006] Problems to be Solved by the Invention

[0007] In Patent Document 1, in the die, a plurality of support pins are used to position the bracket. However, traces of the support pins being pulled out will appear at the boundary between the bracket and the outer housing, so this boundary portion may become a water ingress path. Therefore, it is required to minimize the positioning portion using the support pins as much as possible.

[0008] Therefore, an object of the present disclosure is to minimize the number of positioning pins for positioning the inner molded portion when the outer molded portion is die-molded around the inner molded portion.

[0009] Technical Solution for Solving the Problems

[0010] The composite molded member of the present disclosure includes an inner molded portion and an outer molded portion covering the inner molded portion. A rotation-stopping hole that opens on the surface of the inner molded portion is formed in the inner molded portion, and a through-hole that reaches the rotation-stopping hole from the surface of the outer molded portion is formed in the outer molded portion. The rotation-stopping hole is a hole surrounded by an inner peripheral surface and a bottom surface, and at least a part of the inner peripheral surface is formed in a non-circular shape.

[0011] Advantages of the Invention

[0012] According to the present disclosure, when the outer molded portion is die-molded around the inner molded portion, the number of positioning pins for positioning the inner molded portion can be minimized as much as possible. Brief Description of the Drawings

[0013] Figure 1 is a perspective view showing the composite molded member according to the embodiment.

[0014] Figure 2It is a perspective view showing a composite forming member according to an embodiment.

[0015] Figure 3 is Figure 1 a sectional view taken along line III - III.

[0016] Figure 4 It is a perspective view showing the inner forming part in the composite forming member.

[0017] Figure 5 It is a perspective view showing the inner forming part in the composite forming member.

[0018] Figure 6 It is an explanatory view showing a state where the inner forming part is positioned by a positioning pin.

[0019] Figure 7 It is an explanatory view showing the state of molten resin in a mold for forming the outer forming part.

[0020] Figure 8 It is an explanatory view showing a rotation - preventing hole, a through - hole, and a positioning pin according to a modified example.

[0021] Figure 9 It is an explanatory view showing a rotation - preventing hole, a through - hole, and a positioning pin according to another modified example.

[0022] Figure 10 It is an explanatory view showing a rotation - preventing hole, a through - hole, and a positioning pin according to still another modified example. Detailed Embodiments

[0023] [Description of Embodiments of the Present Disclosure]

[0024] First, embodiments of the present disclosure will be listed and described.

[0025] The composite forming member of the present disclosure is as follows.

[0026] (1) A composite forming member including an inner forming part and an outer forming part covering the inner forming part, a rotation - preventing hole opening on the surface of the inner forming part is formed in the inner forming part, a through - hole reaching the rotation - preventing hole from the surface of the outer forming part is formed in the outer forming part, the rotation - preventing hole is a hole surrounded by an inner peripheral surface and a bottom surface, and at least a part of the inner peripheral surface is formed in a non - circular shape.

[0027] According to this composite forming member, since at least a part of the inner peripheral surface of the rotation - preventing hole is non - circular, the rotation of the inner forming part can be prevented by inserting a positioning pin into the non - circular inner peripheral surface. Thus, when the outer forming part is mold - formed around the inner forming part, the number of positioning pins for positioning the inner forming part can be reduced as much as possible.

[0028] (2) The composite forming member according to (1) may also be such that the inner peripheral surface of at least a part of the through hole is formed into a non-circular shape that gradually widens in width as it goes from one side to the other along the first direction and gradually narrows in width as it goes toward the other side on the way. In this case, the through hole is a part that remains as a relic of the positioning pin when the outer forming portion is formed by die casting. Therefore, the outer peripheral surface shape of at least a part of the positioning pin also becomes a shape that gradually widens in width as it goes from one side to the other along the first direction and gradually narrows in width as it goes toward the other side on the way. When the outer forming portion is formed by die casting, the molten resin flows from this one side to the other side, so that the molten resin can smoothly flow past the periphery of the positioning pin.

[0029] (3) The composite forming member according to (2) may also be such that the inner peripheral surface of at least a part of the through hole is formed into a shape in which the maximum dimension in the first direction is larger than the maximum dimension in the second direction orthogonal to the first direction. In this case, the through hole is a part that remains as a relic of the positioning pin when the outer forming portion is formed by die casting. Therefore, the outer peripheral surface shape of at least a part of the positioning pin also becomes a shape in which the maximum dimension in the first direction is larger than the maximum dimension in the second direction orthogonal to the first direction. In this case, when the outer forming portion is formed by die casting, the projected area of the positioning pin in the direction of the flow of the molten resin can be reduced, and the molten resin can flow smoothly.

[0030] (4) The composite forming member according to (2) or (3) may also be such that the outer forming portion is formed into a long strip shape that is long in one direction, and the first direction is the direction along the length direction of the outer forming portion. In the case where the outer forming portion is a long strip shape that is long in one direction, it is assumed that the molten resin used to form the outer forming portion flows along the length direction of the outer forming portion. Therefore, the molten resin flowing in the first direction along the length direction of the outer forming portion can smoothly flow past the periphery of the positioning pin.

[0031] (5) The composite forming member according to any one of (1) to (4) may also be such that the same inner peripheral surface shape is continuous on both sides of the boundary between the anti-rotation hole and the through hole. In this case, since the same inner peripheral surface shape is continuous on both sides of the boundary between the anti-rotation hole and the through hole, the shape of the positioning pin can be simplified.

[0032] (6) According to any one of the composite forming members in (1) to (5), it is also possible to form a first hole that reaches from the surface of the outer forming portion to the inside of the inner forming portion, and on the opposite side of the first hole, form a second hole that reaches from the surface of the outer forming portion to the inside of the inner forming portion. At least one of the inner side portions of the first hole and the inner side portion of the second hole is the anti-rotation hole. A first positioning pin can be inserted into the hole in the inner forming portion corresponding to the first hole. A second positioning pin can be inserted into the hole in the inner forming portion corresponding to the second hole on the opposite side of the first hole. As a result, positioning can be performed in the extending direction of the first hole and the second hole and in the direction orthogonal thereto. In addition, since at least one of the inner side portions of the first hole and the inner side portion of the second hole is the anti-rotation hole, the inner forming portion can be positioned in a state where it has been anti-rotated by using at least one of the inner side portions of the first hole and the inner side portion of the second hole. Therefore, the inner forming portion can be positioned with a small number of positioning pins.

[0033] (7) According to the composite forming member in (6), it is also possible that the deeper one of the inner side portion formed in the inner forming portion of the first hole and the inner side portion formed in the inner forming portion of the second hole is the anti-rotation hole. In this case, the inner forming portion can be more reliably anti-rotated by the deep anti-rotation hole.

[0034] (8) According to any one of the composite forming members in (1) to (7), it is also possible to further include an electrical component covered by the inner forming portion. In this case, the waterproofing of the electrical component covered by the inner forming portion can be made more reliable.

[0035] (9) According to any one of the composite forming members in (1) to (8), it is also possible that at least a part of the inner peripheral surface has a diamond shape, an elliptical shape, or a droplet shape. Thereby, anti-rotation of the inner forming portion can be performed.

[0036] [Details of the embodiments of the present disclosure]

[0037] Hereinafter, with reference to the drawings, specific examples of the composite forming member of the present disclosure will be described. In addition, the present disclosure is not limited to these examples, and is represented by the claims, and is intended to include all changes within the meaning and scope equivalent to the claims.

[0038] [Embodiment]

[0039] Hereinafter, the composite forming member according to the embodiment will be described. Figure 1 And Figure 2 is a perspective view showing the composite forming member 10. Figure 3 is Figure 1 a cross-sectional view taken along line III-III. Figure 4And Figure 5 is a perspective view showing the inner forming portion 30 in the composite forming member. Figure 1 And Figure 4 is a perspective view observed from the same direction. Figure 2 And Figure 5 is a perspective view observed from the same direction.

[0040] The composite forming member 10 includes an inner forming portion 30 and an outer forming portion 40. The outer forming portion 40 is a member that covers the inner forming portion 30. The inner forming portion 30 is covered by the outer forming portion 40, thereby improving the waterproof property inside the inner forming portion 30.

[0041] In the present embodiment, the composite forming member 10 includes an electrical component 20 covered by the inner forming portion 30. The inner forming portion 30 is a resin part that covers the electrical component 20, and the outer forming portion 40 is a resin part that covers the electrical component 20 and the inner forming portion 30. The electrical component 20 is covered by the inner forming portion 30, and further covered by the outer forming portion 40, thereby improving the waterproof property for the electrical component 20. For example, in a state where the electrical component 20 is positioned by a positioning pin, the inner forming portion 30 is formed by die molding. Thereafter, in a state where the inner forming portion 30 is positioned by a positioning pin, the outer forming portion 40 can be formed by die molding. Thereby, the positioning accuracy of the inner forming portion 30 and the positioning accuracy of the electrical component 20 inside the outer forming portion 40 can be improved, and the entire periphery of the electrical component 20 is covered by the inner forming portion 30 and the outer forming portion 40, improving the waterproof property.

[0042] When the outer forming portion 40 is formed by die molding, the inner forming portion 30 is positioned by a positioning pin. After the outer forming portion 40 is formed by die molding, if the positioning pin is pulled out, holes, which are traces of the pin reaching from the surface of the outer forming portion 40 to the inner forming portion 30, remain. If the boundary between the inner forming portion 30 and the outer forming portion 40 is exposed inside the holes which are traces of the pin, this boundary may become a water intrusion path. Therefore, it is required to minimize the holes which are traces of the pin. The present disclosure relates to a technique for positioning the inner forming portion 30 with as few positioning pins as possible when the outer forming portion 40 is formed by die molding.

[0043] Each part will be described more specifically.

[0044] The electrical component 20 is, for example, a sensor element 20. The sensor element 20 is an element that detects physical quantities such as magnetism, light, temperature, or changes in them. Here, a description is given assuming that the sensor element 20 is a magnetic sensor. A magnetic field is not easily affected by a resin which is a non-magnetic material. Therefore, when the sensor element 20 is a magnetic sensor, the entire periphery of the sensor element 20 can also be covered by the inner molding portion 30 and the outer molding portion 40.

[0045] The sensor element 20 includes an element main body portion 22 and lead portions 24. The element main body portion 22 is formed, for example, in a flat rectangular parallelepiped shape. The element main body portion 22 outputs a signal corresponding to the surrounding environment, such as the magnitude and direction of the surrounding magnetic field. The lead portions 24 extend from the element main body portion 22. Here, the two lead portions 24 extend from the element main body portion 22 in a parallel posture. Here, the lead portions 24 are formed of a metal or the like into an elongated plate shape. The detection output at the element main body portion 22 is output to the outside via the two lead portions 24.

[0046] The output of the sensor element 20 is transmitted via a cable 60. The cable 60 includes a plurality (here, two) of electric wires 62 and an outer covering portion 61. The electric wires 62 are covered electric wires in which a covering portion is formed around a core wire. The outer covering portion 61 covers the two electric wires 62. At the end of the cable 60, the outer covering portion 61 is removed, and the two electric wires 62 are exposed. At the ends of the two electric wires 62, the covering portion is removed, and the core wires are exposed. The ends of the two electric wires 62 are arranged above the two lead portions 24, and the respective core wires are electrically and mechanically connected to the lead portions 24. Here, the core wires are welded to the lead portions 24. The core wires and the lead portions 24 can also be electrically and mechanically connected by fusion welding, pressure welding, or the like.

[0047] It is not necessary to gather the electric wires connected to the sensor element 20 into one by an outer covering portion or the like. The electric wires connected to the sensor element can also be led out separately to the outside. The number of electric wires connected to the sensor element can also be increased or decreased according to the number of lead portions in the sensor element or the like. It is not necessary to connect the electric wires to the sensor element, and other FPCs (Flexible printed circuit) or the like can also be connected to the sensor.

[0048] The inner molding portion 30 is a portion formed of a resin. The inner molding portion 30 can also be formed, for example, of a polyamide resin, PE (polyethylene), PBT (polybutylene terephthalate), or the like.

[0049] More specifically, the inner molding portion 30 is a portion formed by molding the sensor element 20 as an embedded member with a resin. The inner molding portion 30 includes an element housing portion 35 and a lead portion housing portion 36.

[0050] The component housing portion 35 is formed in a rectangular parallelepiped shape. At a position near one main surface of one end portion in the component housing portion 35, the component main body portion 22 of the sensor component 20 is housed. Here, on one main surface of one end portion of the component housing portion 35, one main surface of the component main body portion 22 is exposed. The lead portion 24 extending from the component main body portion 22 passes through the inside of the component housing portion 35 and extends toward the other end side of the component housing portion 35.

[0051] The lead portion housing portion 36 is provided to be connected to the other end portion of the component housing portion 35. The lead portion housing portion 36 includes a bottom plate portion 37 and a partitioning portion 38. The bottom plate portion 37 is formed in a plate shape extending from the other end portion of the component housing portion 35. Two lead portions 24 extend onto the bottom plate portion 37 and are exposed. The partitioning portion 38 is provided to partition the two lead portions 24 at the middle portion in the width direction of the bottom plate portion 37.

[0052] When the inner forming portion 30 is die-formed with the sensor component 20 as an embedded member, the exposed portion in the sensor component 20 is set to be in contact with a die surface or a positioning portion in the die. Thus, with the sensor component 20 positioned in the die, the inner forming portion 30 is die-formed. Therefore, the sensor component 20 is held at a constant position with high precision with respect to the inner forming portion 30.

[0053] In addition, the above-mentioned core wire can also be welded to the lead portion 24 in a state where the sensor component 20 is embedded in the inner forming portion 30. The core wire can also be welded to the lead portion 24 in a state before the sensor component 20 is embedded in the inner forming portion 30. It is not necessary to die-form the inner forming portion 30 with the sensor component 20 as an embedded member. It is also possible to first die-form the inner forming portion 30 into a shape capable of embedding the sensor component 20, and then embed the sensor component 20 therein. That is, the inner forming portion 30 only needs to be a member that holds the electrical component 20.

[0054] The outer forming portion 40 is a portion formed of resin. The outer forming portion 40 can also be formed of, for example, polyamide resin, PE (polyethylene), PBT (polybutylene terephthalate), etc., in the same manner as the inner forming portion 30. It is not necessary for the outer forming portion 40 and the inner forming portion 30 to be formed of the same resin. If the outer forming portion 40 and the inner forming portion 30 are formed of the same resin, the adhesion between the two becomes good.

[0055] The outer forming part 40 covers the inner forming part 30. The outer forming part 40 can cover the entire periphery of the inner forming part 30, or can cover a part of the outer forming part 40. Here, the outer forming part 40 covers the entire periphery of the inner forming part 30 except for the part of the inner forming part 30 used for positioning. That is, at least one of the inner forming part 30 and the outer forming part 40 covers the entire periphery of the sensor element 20. Here, the outer shape of the outer forming part 40 is formed into an elongated rectangular parallelepiped shape. The element main body part 22 is in a state of being buried in a part near one end in the outer forming part 40. The front end part of the outer covering part 61 in the cable 60 is in a state of being buried in a part near the other end in the outer forming part 40. The part of the cable 60 covered by the outer covering part 61 extends outward from the other end of the outer forming part 40. In addition, it is not necessary that the outer shape of the outer forming part 40 is a rectangular parallelepiped.

[0056] A first hole 51 is formed from the outer surface of the outer forming part 40 to the inside of the inner forming part 30. On the opposite side of the first hole 51, a second hole 52 is formed from the outer surface of the outer forming part 40 to the inside of the inner forming part 30. That is, the openings of the first hole 51 and the second hole 52 face opposite sides to each other. The second hole 52 may also be on the extension of the central axis of the first hole 51. Thus, by the positioning pin disposed in the first hole 51 and the positioning pin disposed in the second hole 52, the inner forming part 30 can be stably positioned in a manner of sandwiching the inner forming part 30. From this viewpoint, the extension line of the central axis of the first hole 51 and the extension line of the central axis of the second hole 52 may also coincide. In the present embodiment, the first hole 51 is formed to reach the inside of the surface on the side where the sensor element 20 is exposed among the four surrounding side surfaces of the inner forming part 30. The second hole 52 is formed to reach the inside of the surface on the side opposite to the side where the sensor element 20 is exposed among the four surrounding side surfaces of the inner forming part 30.

[0057] The formation positions of the first hole 51 and the second hole 52 are not limited to the above examples. For example, the first hole and the second hole may also be formed from the outer side surface of the outer forming part 40 on the outer side in the width direction of the sensor element 20 (that is, the outer side surface along the direction in which the two lead parts 24 are arranged side by side) to the inside of the inner forming part 30.

[0058] In addition, other holes may also be formed from the outer surface of the outer forming part 40 to the inside of the inner forming part 30. As the holes from the outer surface of the outer forming part 40 to the inside of the inner forming part 30, the composite forming member 10 may also have only the above first hole 51 and second hole 52.

[0059] At least one of the inner side portions of the first hole 51 formed in the inner forming portion 30 and the inner side portion of the second hole 52 formed in the inner forming portion 30 is a rotation stopping hole 52a. In the present embodiment, an example in which the inner side portion of the second hole 52 formed in the inner forming portion 30 is the rotation stopping hole 52a will be described. However, both the inner side portion of the first hole 51 formed in the inner forming portion 30 and the inner side portion of the second hole 52 formed in the inner forming portion 30 may be rotation stopping holes, or the inner side portion of the first hole 51 formed in the inner forming portion 30 may be a rotation stopping hole.

[0060] More specifically, the portion of the second hole 52 formed in the outer forming portion 40 is a through hole 52b, and the portion of the second hole 52 that opens on the surface of the inner forming portion 30 and is recessed into the inner forming portion 30 is the rotation stopping hole 52a.

[0061] The rotation stopping hole 52a is a bottomed hole surrounded by an inner peripheral surface 52a1 and a bottom surface 52a2. In the direction along the central axis of the rotation stopping hole 52a, at least a part of the inner peripheral surface 52a1 is formed in a non-circular shape. In other words, the cross-sectional shape (the cross-section in the direction orthogonal to the central axis) of at least a part of the rotation stopping hole 52a in the direction along its central axis is formed in a non-circular shape. Non-circular means not circular. In other words, it means a shape in which the distance between the geometric center of the internal area delimited by the boundary of the delimited area and the boundary changes and is not constant. Examples of non-circular shapes are an ellipse, a square, a rectangle, a rhombus, a star shape, a droplet shape, a keyhole shape, etc. It is also possible that the entire inner peripheral surface 52a1 of the rotation stopping hole 52a in the central axis direction is formed in a non-circular shape. In addition, it is also possible that only a part, for example, the inner side portion of the inner peripheral surface 52a1 of the rotation stopping hole 52a is formed in a non-circular shape.

[0062] In the present embodiment, the entire inner peripheral surface 52a1 of the rotation stopping hole 52a is formed as a non-circular inner peripheral surface. More specifically, the inner peripheral surface 52a1 of the rotation stopping hole 52a is formed in a rhombus shape in which one diagonal is longer than the other diagonal. The longer diagonal of the rhombus shape extends along the length direction of the inner forming portion 30, and the shorter diagonal extends along the width direction of the inner forming portion 30.

[0063] The through hole 52b reaches the rotation stopping hole 52a from the outer surface of the outer forming portion 40. That is, if the outer forming portion 40 is considered, the through hole 52b penetrates from the outer surface of the outer forming portion 40 to the inner surface.

[0064] The through-hole 52b can be formed either as a non-circular hole or as a circular hole. The inner peripheral surface of at least a part of the through-hole 52b can also be formed into a non-circular shape that gradually widens in width as it goes from one side to the other along the first direction F1 and then gradually narrows in width as it approaches the other side. In other words, the inner peripheral surface of at least a part of the through-hole 52b can also be formed into a shape that is widest at the middle part along the first direction F1 and gradually narrows in width as it extends from this widest part along the first direction F1 to both sides. The above non-circular shapes are, for example, an ellipse, a rhombus (when one diagonal is arranged along the first direction F1), a droplet shape (when the direction connecting the front end of the curve to the rear end forming an acute angle is arranged along the first direction F1), etc.

[0065] The above first direction F1 can also be a direction that coincides with the length direction of the outer forming part 40. The length direction of the outer forming part 40 can also be the direction in which the molten resin flows when the outer forming part 40 is mold-formed. If, taking the first direction F1 in which the molten resin flows as a reference, the inner peripheral surface shape of at least a part of the through-hole 52b is the above shape, the molten resin can smoothly flow into the rear side in the length direction while avoiding the positioning pins arranged in the part corresponding to the through-hole 52b.

[0066] The inner peripheral surface of at least a part of the through-hole 52b can also be formed into a shape in which the maximum dimension L1 in the first direction F1 is greater than the maximum dimension L2 in the second direction F2 orthogonal to the first direction F1. In other words, for at least the inner peripheral surface of the through-hole 52b, the width when observed along the first direction F1 is smaller than the width when observed along the second direction F2 orthogonal to the first direction F1.

[0067] Here, the first direction F1 can also be, as described above, a direction that coincides with the length direction of the outer forming part 40. Additionally, as described above, the length direction of the outer forming part 40 can also be the direction in which the molten resin flows when the outer forming part 40 is mold-formed. If, taking the first direction F1 in which the molten resin flows as a reference, the inner peripheral surface shape of at least a part of the through-hole 52b is the above shape, in the direction in which the molten resin flows, the projected area of the positioning pins arranged in the part corresponding to the through-hole 52b can be reduced, and the molten resin can smoothly flow while avoiding the positioning pins. The above shapes that are longer in the first direction F1 are, for example, an ellipse (when the long axis direction is arranged along the first direction F1), a rhombus with different diagonal lengths (when the longer diagonal is arranged along the first direction F1), a droplet shape (when the direction connecting the front end of the curve to the rear end forming an acute angle is arranged along the first direction F1), a rectangular shape (when the long side is arranged along the first direction F1), etc.

[0068] The inner peripheral surface of at least a part of the through-hole 52b may also be formed into a non-circular shape that gradually widens in width as it goes from one side to the other along the first direction F1 and gradually narrows in width as it approaches the other side on the way, and is formed into a shape in which the maximum dimension L1 in the first direction F1 is larger than the maximum dimension L2 in the second direction F2 orthogonal to the first direction F1. For example, the inner peripheral surface of at least a part of the through-hole 52b is an ellipse (when the major axis direction is arranged along the first direction F1), a rhombus with different diagonal lengths (when the longer diagonal is arranged along the first direction F1), a droplet shape (when the direction connecting the front end depicting the curve and the rear end forming an acute angle is arranged along the first direction F1), etc.

[0069] The above inner peripheral surface shape may be either a part or the whole in the length direction of the through-hole 52b.

[0070] The anti-rotation hole 52a and the through-hole 52b may be the same shape or different shapes. For example, the anti-rotation hole 52a may be formed into a non-circular hole shape, and the through-hole 52b may be formed into a cylindrical shape. In the present embodiment, the same inner peripheral surface shape is continuous on both sides of the boundary between the anti-rotation hole 52a and the through-hole 52b (that is, the boundary between the inner forming portion 30 and the outer forming portion 40). Here, the anti-rotation hole 52a and the through-hole 52b are formed into the same inner peripheral surface shape. Therefore, the positioning pin arranged from the through-hole 52b to the anti-rotation hole 52a can be formed into a columnar shape with the same outer peripheral surface shape continuous.

[0071] The part of the first hole 51 formed in the outer forming portion 40 is the through-hole 51b, and the part of the first hole 51 that opens on the surface of the inner forming portion 30 and is recessed into the inner forming portion 30 is the positioning hole 51a.

[0072] The positioning hole 51a is formed into a bottomed circular hole shape. The positioning hole 51a may also be formed into a non-circular shape in the same way as the above anti-rotation hole 52a. The depth d1 of the positioning hole 51a is smaller than the depth d2 of the anti-rotation hole 52a (refer to Figure 3 ). That is, the deeper one of the inner side part (positioning hole 51a) of the first hole 51 formed in the inner forming portion 30 and the inner side part (anti-rotation hole 52a) of the second hole 52 formed in the inner forming portion 30 is set as the anti-rotation hole. This example is an example in which when one of the two positioning holes is formed into a non-circular shape, the deeper hole is formed into a non-circular shape. Thereby, one of the two positioning pins can be set as a non-circular shape, and the other can be set as an easily machined circular shape. In addition, at the deeper anti-rotation hole 52a, the contact area between the positioning pin and the anti-rotation hole 52a can be increased, and anti-rotation can be stably performed.

[0073] In addition, the anti-rotation hole 52a and the positioning hole 51a are set to have a depth that does not reach the electrical component 20 within the inner forming portion 30.

[0074] The through-hole 51b reaches the positioning hole 51a from the outer surface of the outer forming portion 40. That is, when focusing on the outer forming portion 40, the through-hole 51b penetrates from the outer surface of the outer forming portion 40 to the inner surface.

[0075] The through-hole 51b can be formed in a circular hole shape or can be formed in a non-circular hole shape similar to the above-mentioned through-hole 52b. Here, the through-hole 51b is formed in a circular hole shape. The through-hole 51b can also be formed in a circular hole shape continuous with the shape of the inner peripheral surface of the positioning hole 51a.

[0076] In addition, in the present embodiment, the inner forming portion 30 includes annular rib portions 33, 34 that protrude toward the outer forming portion 40 side. The annular rib portions 33, 34 are parts that play a role in more reliably suppressing water from infiltrating along the boundary between the inner forming portion 30 and the outer forming portion 40.

[0077] Here, an annular rib portion 33 is formed in a portion of the surface of the inner forming portion 30 that surrounds the positioning hole 51a. In addition, an annular rib portion 34 is formed in a portion of the surface of the inner forming portion 30 that surrounds the anti-rotation hole 52a. Multiple annular rib portions can also be provided concentrically in at least one of the positioning hole 51a and the anti-rotation hole 52a.

[0078] Here, the annular rib portions 33, 34 are formed in a circular protrusion shape. The annular rib portions can also be formed in an oblong protrusion shape or a polygonal protrusion shape. The annular rib portions 33, 34 are preferably formed to be thinner in width toward the front end side in the protruding direction.

[0079] When the outer forming portion 40 is mold-formed with the inner forming portion 30 as an insert, the resin that has melted due to heating melts the above-mentioned annular rib portions 33, 34, especially their front end portions. Thereby, it is easy to form a portion where the front end portions of the annular rib portions 33, 34 in the inner forming portion 30 are integrated with the outer forming portion 40. Thereby, around the portions where the annular rib portions 33, 34 are formed, that is, around the positioning hole 51a and the anti-rotation hole 52a, the boundary between the inner forming portion 30 and the outer forming portion 40 can be waterproofed more effectively.

[0080] In particular, if the widths of the front end portions of the annular ribs 33 and 34 are narrow, the front end portions of the annular ribs 33 and 34 are liable to melt into the outer forming portion 40. Therefore, at the boundary between the inner forming portion 30 and the outer forming portion 40, better waterproofing can be achieved along the annular ribs 33 and 34. The above-mentioned annular ribs 33 and 34 are sometimes referred to as melting ribs. In order to facilitate the fusion of the annular ribs 33 and 34 with the outer forming portion 40, the inner forming portion 30 and the outer forming portion 40 are preferably formed of the same material.

[0081] Figure 6 FIG. is an explanatory view showing a state in which the inner forming portion 30 is positioned by the positioning pins 70 and 72. In Figure 6 it, the outer forming portion 40 is indicated by a two-dot chain line. Figure 7 FIG. is an explanatory view showing the state of the molten resin in the mold 80 for forming the outer forming portion 40. In addition, in Figure 6 subsequently, the inner forming portion 30 is schematically depicted.

[0082] When the outer forming portion 40 is mold-formed with the inner forming portion 30 as an insert, in the mold 80, the inner forming portion 30 is positioned by the positioning pins 70 and 72. The positioning pin 70 is inserted into the positioning hole 51a. The positioning pin 70 is formed in a shape corresponding to the inner peripheral surface shape of the positioning hole 51a, and here it is cylindrical. The positioning pin 72 is formed in a shape corresponding to the inner peripheral surface shape of the anti-rotation hole 52a, and here it is columnar with a rhombic cross-section in which one diagonal is longer than the other diagonal.

[0083] The positioning pin 72 is provided to protrude from below in the mold space 82 in the mold 80. The positioning pin 70 is provided to protrude from above within the mold space 82. Preferably, the positioning pin 70 is opposed to the positioning pin 72.

[0084] The front end portion of the positioning pin 72 is fitted into the anti-rotation hole 52a. The front end portion of the positioning pin 70 is fitted into the positioning hole 51a. Thereby, a state is formed in which the inner forming portion 30 is clamped between the front end portions of the positioning pins 70 and 72, and the inner forming portion 30 is positioned at a fixed position in the vertical direction. In addition, since the front end portions of the positioning pins 70 and 72 are fitted into the positioning hole 51a or the anti-rotation hole 52a, the inner forming portion 30 is positioned at a fixed position in the direction orthogonal to the extending direction of the positioning pins 70 and 72. Further, since the non-circular columnar positioning pin 72 is fitted into the corresponding non-circular hole-shaped anti-rotation hole 52a, rotation of the inner forming portion 30 about the axes of the positioning pins 70 and 72 is restricted.

[0085] In this state, molten resin for forming the outer molded portion 40 is injected into the mold space 82. The mold space 82 is a long space along the extending direction of the outer molded portion 40. The injection port 83 for injecting the molten resin into the mold space 82 is provided at a position near one end in the extending direction of the mold space 82. The molten resin injected through the injection port 83 flows toward the other end side along the extending direction of the mold space 82.

[0086] In the mold space 82 outside the inner molded portion 30, the above-described positioning pins 70 and 72 are present. Therefore, when the molten resin flows through the mold space 82, it passes around the above-described positioning pins 70 and 72.

[0087] When the molten resin reaches the positioning pin 72, since the positioning pin 72 is formed in a shape where the width gradually becomes wider as it goes from one side to the other along the first direction F1, the molten resin smoothly flows while separating to both sides of the positioning pin 72. The positioning pin 72 gradually narrows in width as it goes from one side to the other along the first direction F1 and then toward the other side. Therefore, the molten resin smoothly flows into the rear of the positioning pin 72. Thus, the molten resin can smoothly bypass the periphery of the positioning pin 72 and the molten resin is smoothly filled into the mold space 82, particularly the periphery of the positioning pin 72. In addition, thereby, it is possible to expect that the annular rib portion 34 melts well and fuses into the outer molded portion 40, and it is possible to expect an improvement in waterproof performance brought about by the annular rib portion 34.

[0088] In addition, in the first direction F1 in which the molten resin flows in, the projected area of the positioning pin 72 in the mold space 82 is small, so the flow resistance generated by the positioning pin 72 when the molten resin flows through the mold space 82 can be reduced.

[0089] After the molten resin is cooled and solidified, the inner molded portion 30 and the outer molded portion 40 are taken out from the mold 80, thereby manufacturing the composite molded member 10. In the composite molded member 10, the remains of the positioning pin 70 are formed as the first hole 51, and the remains of the positioning pin 72 are formed as the second hole 52.

[0090] In the composite forming member 10 configured as described above, at least a part of the inner peripheral surface of the anti-rotation hole 52a has a non-circular shape. Therefore, by inserting the positioning pin 72 into the non-circular inner peripheral surface, anti-rotation of the inner forming portion 30 can be achieved. Thus, when die-forming the outer forming portion 40 around the inner forming portion 30, the number of positioning pins for positioning the inner forming portion 30 can be reduced as much as possible. If the number of positioning pins can be reduced, the portion where the boundary between the inner forming portion 30 and the outer forming portion 40 is exposed to the external space can be reduced. As a result, the ingress of water into the portion between the inner forming portion 30 and the outer forming portion 40 can be reduced, and the waterproof performance inside the inner forming portion 30 can be improved.

[0091] In addition, the through-hole 52b is a part that remains as a relic of the positioning pin 72. If the through-hole 52b, i.e., the positioning pin 72, has a shape in which the width gradually widens from one side toward the other along the first direction F1 and gradually narrows toward the other side on the way, the molten resin can flow smoothly around the positioning pin 72 and wrap around to its rear. Thus, the molten resin can be smoothly filled into the die cavity 82 for forming the outer forming portion 40. In addition, from the perspective that the annular rib portion 34 around the anti-rotation hole 52a can be smoothly melted and incorporated into the outer forming portion 40, the waterproof performance is also improved.

[0092] In addition, if the through-hole 52b, i.e., the positioning pin 72, has a shape in which the maximum dimension L1 in the first direction F1 is larger than the maximum dimension L2 in the second direction F2, the projected area of the positioning pin 72 becomes smaller when the molten resin flows through. From this perspective, the molten resin can also flow smoothly around the positioning pin 72.

[0093] In the case where the outer forming portion 40 has a shape that is long in one direction, it is assumed that the molten resin for forming the outer forming portion 40 flows along its length direction. Therefore, if the first direction F1 is the direction along the length direction of the outer forming portion 40, the molten resin can flow smoothly around the positioning pin 72.

[0094] In addition, at the boundary between the anti-rotation hole 52a and the through-hole 52b, if the same inner peripheral surface shape is continuous, the corresponding portion of the positioning pin 72 can also be made into a shape with a continuous outer peripheral surface shape. Thus, the shape of the positioning pin 72 can be simplified, and cost reduction in manufacturing and ease of demolding can be achieved.

[0095] In addition, a first hole 51 is formed from the surface of the outer forming portion 40 to the inside of the inner forming portion 30, and on the opposite side thereof, a second hole 52 is formed from the surface of the outer forming portion 40 to the inside of the inner forming portion 30. Thus, the inner forming portion 30 is positioned in the axial direction of the positioning pins 70 and 72 inserted into the first hole 51 and the second hole 52 and in the direction orthogonal thereto. In addition, by providing at least one of the inner portions of the first hole 51 and the second hole 52 as an anti-rotation hole 52a, the inner forming portion 30 is anti-rotated by a small number of positioning pins 70 and 72.

[0096] Other positioning pins may also be provided according to the size, shape complexity, etc. of the composite forming member 10.

[0097] In addition, if the inner portion of the lower second hole 52 is an anti-rotation hole 52a, it is preferable to insert the front end portion of the positioning pin 72 into the anti-rotation hole 52a with the inner forming portion 30 placed on the positioning pin 72. Thus, in the initial stage of assembling the inner forming portion 30 to the mold 80, the inner forming portion 30 can be assembled in a predetermined posture.

[0098] In addition, when the inner forming portion 30 covers the electrical component 20, it is effective in effectively waterproofing the electrical component 20.

[0099] Describe a modification example of the anti-rotation hole 52a, the through hole 52b, and the positioning pin 72 disposed in their corresponding portions.

[0100] As Figure 8 shown, the anti-rotation hole 152a, the through hole 152b, and the positioning pin 172 corresponding to the anti-rotation hole 52a, the through hole 52b, and the positioning pin 72 may also be a rhombus with rounded corners. That is, in the rhombus, it includes not only the rhombus with sharp corners but also the rhombus with rounded corners.

[0101] As Figure 9 shown, the anti-rotation hole 252a, the through hole 252b, and the positioning pin 272 corresponding to the anti-rotation hole 52a, the through hole 52b, and the positioning pin 72 may also be an elliptical shape. In this case, it is preferably set such that the long axis direction is along the first direction F1.

[0102] In addition, as Figure 10 shown, the anti-rotation hole 352a, the through hole 352b, and the positioning pin 372 corresponding to the anti-rotation hole 52a, the through hole 52b, and the positioning pin 72 may also be droplet-shaped. The droplet shape refers to the shape when a liquid drips, which is a shape with a semi-circular arc on one side and a sharp corner on the other side. The droplet shape may also be such that the dimension from the central portion of the semi-circular arc to the corner on the other side is longer than the direction orthogonal to this direction. In addition, its length direction may also be along the first direction F1.

[0103] With these modified examples, it is also possible to prevent the rotation of the inner forming portion 30 by the positioning pins 172, 272, and 372. In addition, the molten resin can smoothly flow into the periphery of the positioning pins 172, 272, and 372.

[0104] In addition, as long as the respective structures described in the above-described embodiments and the modified examples do not conflict with each other, they can be appropriately combined. For example, both the upper and lower first holes and the second hole 52 may be non-circular anti-rotation holes, and each may be formed as a non-circular anti-rotation hole different from each other as shown in the above-described embodiments and modified examples.

[0105] Explanation of Reference Numerals

[0106] 10 Composite forming member

[0107] 20 Electrical component (sensor element)

[0108] 22 Element main body portion

[0109] 24 Lead portion

[0110] 30 Inner forming portion

[0111] 33, 34 Annular rib portions

[0112] 35 Element housing portion

[0113] 36 Lead portion housing portion

[0114] 37 Bottom plate portion

[0115] 38 Partition portion

[0116] 40 Outer forming portion

[0117] 51 First hole

[0118] 51a Positioning hole

[0119] 51b Through hole

[0120] 52 Second hole

[0121] 52a, 152a, 252a, 352a Anti-rotation holes

[0122] 52a1 Inner peripheral surface

[0123] 52a2 Bottom surface

[0124] 52b, 152b, 252b, 352b Through holes

[0125] 60 Cable

[0126] 61 Outer covering portion

[0127] 62 Electric wire

[0128] 70, 72, 172, 272, 372 Locating pins

[0129] 80 Mold

[0130] 82 Mold space

[0131] 83 Injection port

[0132] F1 First direction

[0133] F2 Second direction

[0134] L1, L2 Maximum dimensions

[0135] d1, d2 Depths

Claims

1. A composite formed member, comprising: An inner formed portion; and An outer formed portion that covers the inner formed portion, A rotation prevention hole that opens on the surface of the inner formed portion is formed in the inner formed portion, A through hole that reaches the rotation prevention hole from the surface of the outer formed portion is formed in the outer formed portion, The rotation prevention hole is a hole surrounded by an inner peripheral surface and a bottom surface, At least a part of the inner peripheral surface is formed in a non-circular shape, At least a part of the inner peripheral surface of the through hole is formed in a non-circular shape that gradually widens in width as it goes from one side to the other along a first direction and gradually narrows in width as it goes toward the other side on the way.

2. The composite formed member according to claim 1, wherein At least a part of the inner peripheral surface of the through hole is formed in a shape in which the maximum dimension in the first direction is larger than the maximum dimension in a second direction orthogonal to the first direction.

3. The composite formed member according to claim 1, wherein The outer formed portion is formed in a long strip shape that is long in one direction, The first direction is a direction along the length direction of the outer formed portion.

4. The composite formed member according to claim 2, wherein The outer formed portion is formed in a long strip shape that is long in one direction, The first direction is a direction along the length direction of the outer formed portion.

5. The composite formed member according to any one of claims 1 to 4, wherein On both sides of the boundary between the rotation prevention hole and the through hole, the same inner peripheral surface shape is continuous.

6. The composite formed member according to any one of claims 1 to 4, wherein A first hole that reaches inside the inner formed portion from the surface of the outer formed portion is formed, On the opposite side of the first hole, a second hole that reaches inside the inner formed portion from the surface of the outer formed portion is formed, At least one of the inner side portions of the first hole and the inner side portion of the second hole is the rotation prevention hole.

7. The composite formed member according to claim 6, wherein The deeper one of the inner side portion formed in the inner formed portion of the first hole and the inner side portion formed in the inner formed portion of the second hole is the rotation prevention hole.

8. The composite formed member according to any one of claims 1 to 4, wherein It further includes an electrical component covered by the inner formed portion.

9. The composite formed member according to any one of claims 1 to 4, wherein At least a part of the inner peripheral surface is in a diamond shape, an elliptical shape, or a droplet shape.

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