Magnet module, sensor module, and method of manufacturing magnet module

Abstract

The problem to be solved by the present disclosure is to facilitate more accurate positioning of a detection target. The magnet module (10) is designed for a magnetic sensor (3). The magnetic sensor (3) outputs a signal representing the detected magnetic field. The magnet module (10) comprises a first magnet (1) and a second magnet (2). The first magnet (1) and the second magnet (2) are both magnetized in a first direction (D1) and a second direction (D2). The first magnet (1) and the second magnet (2) are disposed separately and are coupled to each other in a third direction (D3) to have magnetization directions different from each other.

Description

Technical Field

[0001] The present disclosure generally relates to a magnet module, a sensor module, and a method of manufacturing the magnet module, and more particularly to a magnet module for a magnetic sensor, a sensor module, and a method of manufacturing the magnet module. Background Art

[0002] Patent document 1 discloses a magnetic sensor device, which includes a first bias magnet, a second bias magnet and a magnetic sensor. The second bias magnet is arranged to form a predetermined angle relative to the first bias magnet. The magnetic sensor is interposed between the bottom surface of the first bias magnet and the upper surface of the second bias magnet.

[0003] Reference List

[0004] Patent Literature

[0005] Patent Document 1: JP 2017-173236 A Summary of the invention

[0006] There is an increasing demand for magnetic sensor devices such as the one disclosed in Patent Document 1 to more accurately locate a magnet (as a detection target).

[0007] An object of the present disclosure is to provide a magnet module, a sensor module, and a method of manufacturing the magnet module, all of which help to more accurately locate a detection target.

[0008] A magnet module according to one aspect of the present disclosure is designed for a magnetic sensor. The magnetic sensor outputs a signal representing a detected magnetic field. The magnet module includes a first magnet and a second magnet. The first magnet and the second magnet are both magnetized in a first direction and a second direction. The second direction is perpendicular to the first direction. The first magnet and the second magnet are separately arranged and coupled to each other in a third direction to have mutually different magnetization directions. The third direction is perpendicular to the first direction and the second direction.

[0009] A sensor module according to another aspect of the present disclosure includes: the magnet module described above; the magnetic sensor described above; and a sensor covering resin member. The sensor covering resin member covers the magnet module and the magnetic sensor.

[0010] A method for manufacturing a magnet module according to another aspect of the present disclosure is a method for manufacturing a magnet module for a magnetic sensor. The magnetic sensor outputs a signal representing a detected magnetic field. The method for manufacturing a magnet module includes a generation step and a coupling step. The generation step includes: manufacturing a first magnet and a second magnet by magnetizing a magnetic material in a first direction and a second direction. The second direction is perpendicular to the first direction. The coupling step includes: coupling the first magnet and the second magnet to each other in a third direction so that the first magnet and the second magnet have mutually different magnetization directions. The third direction is perpendicular to both the first direction and the second direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 A is a front view of a magnet module according to the first embodiment;

[0012] Figure 1 B is a side view of the magnet module;

[0013] Figure 2 A is a front view of the first magnet of the magnet module;

[0014] Figure 2 B is a side view of the first magnet;

[0015] Figure 3 A is a front view of the second magnet of the magnet module;

[0016] Figure 3 B is a side view of the second magnet;

[0017] Figure 4 is a schematic diagram showing a magnetization method of a magnet module;

[0018] Figure 5 is a flow chart showing a method of manufacturing a magnet module;

[0019] Figure 6 is a front view of a magnet module according to a second embodiment;

[0020] Figure 7 A is a front view of a magnet module according to a third embodiment;

[0021] Figure 7 B is a side view of the magnet module;

[0022] Figure 8 A is a front view of a sensor module according to a fourth embodiment; and

[0023] Figure 8 B is a side view of the sensor module. DETAILED DESCRIPTION

[0024] The first to fourth embodiments of the magnet module, the sensor module, and the method for manufacturing the magnet module will be described with reference to the accompanying drawings. The drawings referred to in the following description of the first to fourth embodiments are schematic representations. Therefore, the ratio of the size (including thickness) of the various constituent elements shown in the drawings does not always reflect their actual size ratio. It should be noted that the configurations described below for the first to fourth embodiments are only examples of the present disclosure and should not be interpreted as limiting. On the contrary, the first to fourth exemplary embodiments can be easily modified in various ways according to design choices or any other factors without departing from the scope of the present disclosure.

[0025] As used herein, if two objects are "perpendicular to each other (or intersect each other at right angles)", this expression refers not only to the case where the angle formed between the two objects is exactly 90 degrees, but also to the case where the angle formed between the two objects is not 90 degrees and the difference between the angle formed between the two objects and 90 degrees falls within a predetermined range (such as ±10 degrees). Similarly, as used herein, if a certain object is "parallel to" another certain object, this expression refers not only to the case where the two objects never intersect in a strict sense, but also to the case where the angle formed between the two objects falls within a predetermined difference range (such as ±10 degrees).

[0026] (First embodiment)

[0027] (1) Overview

[0028] First, refer to Figure 1 A to Figure 3 B describes an overview of the magnet module 10 according to the first embodiment.

[0029] The magnet module 10 according to the first embodiment can be used together with the magnetic sensor 3 for example, a motor. For example, the motor can be used to adjust the focus of a camera (camera module) built into a mobile device (such as a smart phone). The motor can be, for example, a voice coil motor (VCM). In the first embodiment, the detection target of the magnetic sensor 3 is the motor.

[0030] That is, the magnet module 10 is designed for the magnetic sensor 3. The magnetic sensor 3 outputs a signal (such as a voltage signal) representing the detected magnetic field. In the first embodiment, the magnet module 10 is a bias magnet. That is, the magnet module 10 is a magnet for generating a bias magnetic field for the magnetic sensor 3.

[0031] The magnet module 10 according to the first embodiment includes a first magnet 1 and a second magnet 2. Figure 1 A to Figure 3As shown in B. The first magnet 1 and the second magnet 2 are magnetized in the first direction D1 and the second direction D2. The second direction D2 is perpendicular to the first direction D1. The first magnet 1 and the second magnet 2 are separately arranged and coupled to each other in the third direction D3 to have mutually different magnetization directions. The third direction D3 is perpendicular to the first direction D1 and the second direction D2.

[0032] In the magnet module 10 according to the first embodiment, the first magnet 1 and the second magnet 2 are coupled to each other in the third direction D3 to have mutually different magnetization directions. This can reduce the neutral zone 102 generated between the first magnet 1 and the second magnet 2 in the third direction D3, thereby being able to increase the bias magnetic field to be applied to the magnetic sensor 3 by the magnet module 10. This enables the magnetic sensor 3 to have improved detection accuracy, thereby facilitating more accurate positioning of a detection target (such as a motor).

[0033] (2) Details

[0034] Next, we will refer to Figure 1 A to Figure 3 B describes the configuration of the magnet module 10 according to the first embodiment. In the following description, the longitudinal axis of each of the first magnet 1 and the second magnet 2 is defined as the first direction D1, the thickness axis thereof is defined as the second direction D2, and the transverse axis thereof (i.e., the width axis thereof) is defined as the third direction D3. It should be noted that these definitions should not be interpreted as limiting the directions in which the first magnet 1 and the second magnet 2 should be used. In addition, these directions are shown on the drawings for illustration purposes only and are all insubstantial directions.

[0035] The magnet module 10 according to the first embodiment is designed for, for example, the magnetic sensor 3 as described above. The magnet module 10 can be, for example, a bias magnet. That is, the magnet module 10 is a magnet for generating a bias magnetic field for the magnetic sensor 3. In short, the first magnet 1 and the second magnet 2 included in the magnet module 10 generate a bias magnetic field for the magnetic sensor 3.

[0036] The magnet module 10 includes a first magnet 1 and a second magnet 2. Figure 1 A and Figure 1 B. In the magnet module 10 according to the first embodiment, the first magnet 1 and the second magnet 2 are provided separately from each other. Each of the first magnet 1 and the second magnet 2 is a double-sided quadrupole magnet.

[0037] (2.1) First magnet

[0038] The first magnet 1 may be, for example, a neodymium magnet. The first magnet 1 has a rectangular parallelepiped shape, such as Figure 2 A and Figure 2 As shown in B. Figure 2As shown in A, when viewed in a plane in the second direction D2, the first magnet 1 has a rectangular shape that is longer in the first direction D1 than in the third direction D3. Figure 2 As shown in B, when viewed in a plane in the third direction D3, the first magnet 1 has a rectangular shape which is longer in the first direction D1 than in the second direction D2.

[0039] In the first embodiment, when viewed in a plane in the second direction D2, the first magnet 1 is magnetized to have an S pole and an N pole from left to right, as shown in FIG. Figure 2 In addition, in the first embodiment, when viewed in a plane in the third direction D3, the first magnet 1 is magnetized to have an N pole opposite to the S pole (ie, Figure 2 B below), and has an S pole opposite to the N pole (i.e., in Figure 2 B below), such as Figure 2 As shown in B. That is, the first magnet 1 is magnetized in a first direction D1 and a second direction D2 perpendicular to the first direction D1.

[0040] The first magnet 1 magnetized as described above has a plurality of neutral regions 11. The plurality of neutral regions 11 include a first neutral region 111 and a second neutral region 112. When viewed in a plane in the second direction D2, the first neutral region 111 is between the S pole and the N pole arranged along a line in the first direction D1. When viewed in a plane in the third direction D3, the second neutral region 112 is between the S pole and the N pole arranged along a line in the second direction D2.

[0041] As used herein, the "neutral region" refers to a portion located between the S pole and the N pole, where the polarity switches from the S pole to the N pole and vice versa, and the "neutral region" is a portion located between the interface of the S pole facing the N pole and the interface of the N pole face facing the S pole. That is, neither the first neutral region 111 nor the second neutral region 112 is magnetized to the S pole or the N pole. It should be noted that in Figure 2 A and Figure 2 In FIG. 1B , the first neutral region 111 and the second neutral region 112 are indicated by dashed hatching so as to be easily distinguished from the rest of the first magnet 1 , but the dashed hatching does not represent a cross section. The same statement applies to Figure 1 A. Figure 1 B. Figure 3 A and Figure 3 B.

[0042] (2.2) Second magnet

[0043] The second magnet 2 and the first magnet 1 can be, for example, neodymium magnets. The second magnet 2 has a rectangular parallelepiped shape, such as Figure 3 A and Figure 3 As shown in B. Figure 3 As shown in A, when viewed in a plane in the second direction D2, the second magnet 2 has a rectangular shape that is longer in the first direction D1 than in the third direction D3. Figure 3 As shown in FIG. 1B , when viewed in a plane in the third direction D3 , the second magnet 2 has a rectangular shape which is longer in the first direction D1 than in the second direction D2 . In the first embodiment, the first magnet 1 and the second magnet 2 have the same size.

[0044] In the first embodiment, when viewed in a plane in the second direction D2, the second magnet 2 is magnetized to have an N pole and an S pole from left to right, as shown in FIG. Figure 3 In addition, in the first embodiment, when viewed in a plane in the third direction D3, the second magnet 2 is magnetized to have an S pole opposite to the N pole (ie, Figure 3 B below) and has an N pole opposite to the S pole (ie, Figure 3 B below), such as Figure 3 As shown in B. That is, the second magnet 2 is magnetized in the first direction D1 and the second direction D2 perpendicular to the first direction D1.

[0045] The second magnet 2 magnetized as described above has a plurality of neutral regions 21. The plurality of neutral regions 21 include a first neutral region 211 and a second neutral region 212. When viewed in a plane in the second direction D2, the first neutral region 211 is between the N pole and the S pole arranged along a line in the first direction D1. When viewed in a plane in the third direction D3, the second neutral region 212 is between the N pole and the S pole arranged along a line in the second direction D2.

[0046] (2.3) Magnet module

[0047] In the first embodiment, the magnet module 10 is produced by coupling the first magnet 1 and the second magnet 2 to each other. More specifically, as Figure 1 As shown in A, the first magnet 1 and the second magnet 2 are coupled to each other in a third direction D3 so that the magnetization direction of the first magnet 1 and the magnetization direction of the second magnet 2 are different from each other. In other words, the first magnet 1 and the second magnet 2 are coupled to each other so that the magnetic pole of the first magnet 1 and the magnetic pole of the second magnet 2 opposite to the magnetic pole of the first magnet 1 are opposite to each other in the third direction D3. In this case, the first magnet 1 and the second magnet 2 are coupled to each other by the magnetic attraction generated between the first magnet 1 and the second magnet 2. As used in the text, the expression "the first magnet and the second magnet are coupled to each other" refers to both the case where the first magnet and the second magnet are directly coupled to each other and the case where the first magnet and the second magnet are indirectly coupled to each other via another member (such as a coupling member 4 (described later)).

[0048] like Figure 1 A and Figure 1 As shown in B, the magnet module 10 has multiple (such as, Figure 1 A and Figure 1 In the example shown in FIG. 1 , there are two first neutral zones 101 and second neutral zones 102. Each of the plurality of first neutral zones 101 is a neutral zone provided for each of the first magnet 1 and the second magnet 2. The second neutral zone 102 is a neutral zone provided between the first magnet 1 and the second magnet 2 when the first magnet 1 and the second magnet 2 are coupled to each other. In the first embodiment, the width of the second neutral zone 102 is 0 mm, as shown in FIG. Figure 1 As shown in A. Therefore, when viewed in a plane in the second direction D2, the width of the second neutral zone 102 provided between the first magnet 1 and the second magnet 2 is narrower than the width W1 of the first neutral zone 101 in each of the first magnet 1 and the second magnet 2.

[0049] In addition, the magnet module 10 may have a rectangular parallelepiped shape, for example. Figure 1 A and Figure 1 As shown in B. The dimension X1 of the magnet module 10 measured in the first direction D1 may be, for example, 5 mm. The dimension X2 of the magnet module 10 measured in the third direction D3 may be, for example, 5 mm. The dimension X3 of the magnet module 10 measured in the second direction D2 may be, for example, 1 mm. The dimension X1 of the magnet module 10 measured in the first direction D1 is preferably less than or equal to 5 mm, and the dimension X2 of the magnet module 10 measured in the third direction D3 is preferably less than or equal to 5 mm. This helps to reduce the size of the magnet module 10.

[0050] In the first embodiment, the magnet module 10 is arranged along the second direction D2 with the magnetic sensor 3. The surface of the magnetic sensor 3 facing the magnet module 10 (i.e. Figure 1 The upper surface in B) is the magnetically sensitive surface 31.

[0051] (3) Magnetization method

[0052] Next, we will refer to Figure 4 The magnetization method of the first magnet 1 and the second magnet 2 is described.

[0053] First, the yokes 61 and 62 are fixed to both ends of the magnetic material 100 in the first direction D1. In this embodiment, the magnetic material 100 is a metal compound containing, for example, neodymium, iron, and boron as its main components. The coil 71 is wound around the yoke 61. On the other hand, the coil 72 is wound around the yoke 62.

[0054] Then, a current is passed through the coils 71 and 72, so that the magnetic material 100 is magnetized via the yokes 61 and 62, thereby generating the first magnet 1 and the second magnet 2. In this case, the direction of the current passed through the coil 71 is opposite to the direction of the current passed through the coil 72, so that the magnetic material 100 is magnetized in both the first direction D1 and the second direction D2. In this case, the width of the neutral zone 11 and 21 can be narrowed by increasing the amount of current passed through the coils 71 and 72. In addition, the width of the neutral zone 11 and 21 can also be narrowed by increasing the contact area between the yokes 61 and 62 and the magnetic material 100.

[0055] It should be noted that the first magnet 1 and the second magnet 2 magnetized by this magnetization method can have the same magnetization direction or two different magnetization directions, whichever is appropriate. In any case, the magnet module 10 can be produced by coupling the first magnet 1 and the second magnet 2 to each other so that their magnetization directions are different from each other.

[0056] (4) Method for manufacturing magnet module

[0057] Next, we will refer to Figure 5 A method of manufacturing the magnet module 10 according to the first embodiment is described.

[0058] The method of manufacturing the magnet module 10 according to the first embodiment is a method of manufacturing the magnet module 10 for the magnetic sensor 3. The magnetic sensor 3 outputs a signal (such as a voltage signal) representing the detected magnetic field. The method of manufacturing the magnet module 10 includes a generation step S1 and a coupling step S2. The generation step S1 includes: magnetizing the magnetic material 100 (refer to the first direction D1 and the second direction D2) by Figure 4 ) to produce the first magnet 1 and the second magnet 2. The coupling step S2 includes: coupling the first magnet 1 and the second magnet 2 to each other in the third direction D3 so that the first magnet 1 and the second magnet 2 have mutually different magnetization directions.

[0059] In the method of manufacturing the magnet module 10 according to the first embodiment, the coupling step S2 includes: coupling the first magnet 1 and the second magnet 2 to each other in the third direction D3 so that the first magnet 1 and the second magnet 2 have mutually different magnetization directions. This can reduce the neutral zone 102 (refer to Figure 1 A), thereby being able to increase the bias magnetic field to be applied to the magnetic sensor 3 by the magnet module 10. This enables the magnetic sensor 3 to have improved detection accuracy, thereby facilitating more accurate positioning of a detection target (such as a motor).

[0060] Figure 51 is a flowchart showing the process of the method of manufacturing the magnet module 10 according to the first embodiment. The method of manufacturing the magnet module 10 includes Figure 5 Now, we will refer to the steps S1 and S2 shown in FIG. Figure 5 A method of manufacturing the magnet module 10 according to the first embodiment is described.

[0061] First, the manufacturer of the magnet module 10 performs a production step S1. The production step S1 includes: allowing current to flow through the coils 71 and 72 in opposite directions to each other so that the magnetic material 100 is magnetized via the yokes 61 and 62. As a result, Figure 2 A to Figure 3 As shown in B, the first magnet 1 and the second magnet 2 magnetized in the first direction D1 and the second direction D2 are generated.

[0062] Next, the manufacturer of the magnet module 10 performs a coupling step S2. The coupling step S2 includes: coupling the first magnet 1 and the second magnet 2 to each other so that the corresponding magnetic poles of the first magnet 1 and the second magnet 2 are opposite to each other in the third direction D3, such as Figure 1 As shown in A. In this process step, the first magnet 1 and the second magnet 2 are coupled to each other via the magnetic attraction force generated between the first magnet 1 and the second magnet 2.

[0063] (5) Advantages

[0064] In the magnet module 10 according to the first embodiment, the first magnet 1 and the second magnet 2 are coupled to each other in the third direction D3 to have mutually different magnetization directions. This can reduce the neutral zone 102 generated between the first magnet 1 and the second magnet 2 in the third direction D3, thereby being able to increase the bias magnetic field to be applied to the magnetic sensor 3 by the magnet module 10. This enables the magnetic sensor 3 to have improved detection accuracy, thereby facilitating more accurate positioning of a detection target (such as a motor).

[0065] Furthermore, in the magnet module 10 according to the first embodiment, when viewed in a plane in the second direction D2, the width of the second neutral zone 102 provided between the first magnet 1 and the second magnet 2 is narrower than the width W1 of the first neutral zone 101 in each of the first magnet 1 and the second magnet 2. This can increase the bias magnetic field compared to the case where the width of the first neutral zone is equal to the width of the second neutral zone.

[0066] Furthermore, in the magnet module 10 according to the first embodiment, the first magnet 1 and the second magnet 2 are bias magnets for generating a bias magnetic field for the magnetic sensor 3 , so that the detection accuracy of the magnetic sensor 3 can be improved.

[0067] (6) Variant

[0068] Note that the first embodiment described above is only an exemplary embodiment of the various embodiments of the present disclosure and should not be interpreted as limiting. On the contrary, the first embodiment can be easily modified in various ways according to design selection or any other factors without departing from the scope of the present disclosure. Next, the variations of the first embodiment will be listed one by one. Note that the variations to be described below can be appropriately combined and adopted.

[0069] In the first embodiment described above, the width of the second neutral zone 102 generated between the first magnet 1 and the second magnet 2 is 0 mm. However, this is only an example and should not be construed as limiting. The width of the second neutral zone 102 does not have to be 0 mm, and may be greater than 0 mm, as long as the width of the second neutral zone 102 is narrower than the width W1 of the first neutral zone 101 generated in each of the first magnet 1 and the second magnet 2.

[0070] In the first embodiment described above, the magnet module 10 is a bias magnet. However, this is only an example and should not be construed as limiting. The magnet module 10 does not have to be a bias magnet, but may also be a driving magnet for driving an object such as a lens.

[0071] (Second embodiment)

[0072] Next, we will refer to Figure 6 The magnet module 10 according to the second embodiment is described. In the following description, the magnet module 10 according to the second embodiment has the same structure as the magnet module 10 according to the first embodiment described above (refer to Figure 1 A and Figure 1 B) Any constituent element having the same function as a corresponding portion will be designated by the same reference numeral as that of the corresponding portion, and description thereof will be omitted here.

[0073] The magnet module 10 according to the second embodiment further includes a coupling member 4 for coupling the first magnet 1 and the second magnet 2 together, which is different from the magnet module 10 according to the first embodiment.

[0074] The magnet module 10 according to the second embodiment includes the following Figure 6 The first magnet 1 and the second magnet 2 are shown. In addition, the magnet module 10 according to the second embodiment further includes a coupling member 4.

[0075] The joining member 4 may include epoxy resin, for example. Figure 6As shown, the joining member 4 is applied to the end face of the first magnet 1 facing the second magnet 2 and / or the end face of the second magnet 2 facing the first magnet 1. Then, the first magnet 1 and the second magnet 2 coupled to each other are heated so that the joining member 4 is thermally cured, thereby joining the first magnet 1 and the second magnet 2 together. That is, the joining member 4 is a member for joining the first magnet 1 and the second magnet 2 together. In this case, the width of the joining member 4 (i.e., the dimension measured in the third direction D3) is preferably smaller than the width of the first neutral zone 101 (i.e., the dimension measured in the first direction D1).

[0076] In the magnet module 10 according to the second embodiment, the first magnet 1 and the second magnet 2 are coupled to each other via the coupling member 4. This contributes to a reduction in size compared to a case where the first magnet 1 and the second magnet 2 are covered with a resin member 5 (described later). In addition, this allows the first magnet 1 and the second magnet 2 to be more firmly coupled to each other than a case where the first magnet 1 and the second magnet 2 are coupled to each other only via a magnetic attraction force generated between the first magnet 1 and the second magnet 2.

[0077] It should be noted that the bonding member 4 does not necessarily need to include epoxy resin, and may include, for example, silicone resin. Even in this case, the bonding member 4 may be thermally cured by heating, thereby bonding the first magnet 1 and the second magnet 2 together.

[0078] It should be noted that the various configurations (including modifications) that have been described with respect to the second embodiment may be adopted in appropriate combination with the various configurations (including modifications) that have been described with respect to the first embodiment.

[0079] (Third embodiment)

[0080] Next, we will refer to Figure 7 A and Figure 7 B describes the magnet module 10 according to the third embodiment. In the following description, the magnet module 10 according to the third embodiment has the same structure as the magnet module 10 according to the first embodiment described above (refer to Figure 1 A and Figure 1 B) Any constituent element having the same function as a corresponding portion will be designated by the same reference numeral as that of the corresponding portion, and description thereof will be omitted here.

[0081] In the magnet module 10 according to the third embodiment, the first magnet 1 and the second magnet 2 are covered with a resin member 5 , which is a difference from the magnet module 10 according to the first embodiment.

[0082] The magnet module 10 according to the third embodiment includes a first magnet 1 and a second magnet 2. Figure 7 A and Figure 7B. Furthermore, the magnet module 10 according to the third embodiment further includes a resin member 5 (magnet covering resin member).

[0083] The material of the resin member 5 may be, for example, epoxy resin. In the third embodiment, the magnet module 10 may be formed by, for example, transfer molding. That is, the resin member 5 covers the first magnet 1 and the second magnet 2 .

[0084] In the third embodiment, the first magnet 1 and the second magnet 2 may be coupled to each other only via the magnetic force generated between the first magnet 1 and the second magnet 2, or via the above-mentioned joining member 4 (refer to Figure 6 ) are coupled to each other, whichever is appropriate.

[0085] The magnet module 10 according to the third embodiment, like the magnet module 10 according to the first embodiment described above, can also reduce the neutral zone 102 generated between the first magnet 1 and the second magnet 2, thereby being able to increase the bias magnetic field to be applied to the magnetic sensor 3. This allows the magnetic sensor 3 to have improved detection accuracy, thereby facilitating more accurate positioning of a detection target (such as a motor).

[0086] Furthermore, the first magnet 1 and the second magnet 2 are covered with the resin member 5 and can thus be protected.

[0087] It should be noted that the resin member 5 does not have to be formed by transfer molding using an epoxy resin, and may be formed by injection molding using a polyphenylene sulfide resin, a polybutylene terephthalate resin, or a liquid crystal polymer.

[0088] It should be noted that the various configurations (including modifications) that have been described with respect to the third embodiment may be adopted in appropriate combination with the various configurations (including modifications) that have been described with respect to the first embodiment and the second embodiment.

[0089] (Fourth embodiment)

[0090] Next, we will refer to Figure 8 A and Figure 8 B describes the sensor module 20 according to the fourth embodiment. In the following description, the sensor module 20 according to the fourth embodiment has the same structure as the magnet module 10 according to the first embodiment (refer to Figure 1 A and Figure 1 B) Any constituent element having the same function as a corresponding portion will be designated by the same reference numeral as that of the corresponding portion, and description thereof will be omitted here.

[0091] The sensor module 20 according to the fourth embodiment has an integrated structure in which the magnet module 10 and the magnetic sensor 3 are covered with a resin member 6, as shown in FIG. Figure 8 A and Figure 8 As shown in FIG. 1B , this is a magnet module 10 (see FIG. 1B ) provided separately from the magnetic sensor 3 according to the first embodiment. Figure 1 A and Figure 1 B) differences.

[0092] The sensor module 20 according to the fourth embodiment includes a magnet module 10, a magnetic sensor 3, and a resin member 6 (sensor covering resin member). Figure 8 A and Figure 8 As shown in B.

[0093] The material of the resin member 6 may be, for example, epoxy resin. In the fourth embodiment, the sensor module 20 may be formed, for example, by transfer molding. That is, the resin member 6 covers the magnet module 10 and the magnetic sensor 3 .

[0094] In the fourth embodiment, the first magnet 1 and the second magnet 2 may be coupled to each other only via the magnetic force generated between the first magnet 1 and the second magnet 2, or via the coupling member 4 (refer to Figure 6 ) are coupled to each other, whichever is appropriate.

[0095] The sensor module 20 according to the fourth embodiment has an integrated structure in which the magnet module 10 and the magnetic sensor 3 are covered with the resin member 6, and the magnet module 10 and the magnetic sensor 3 are arranged along a line in the second direction D2. In addition, in the sensor module 20 according to the fourth embodiment, the surface of the magnetic sensor 3 facing the magnet module 10 (i.e., Figure 8 The upper surface in B) is the magnetically sensitive surface 31.

[0096] The sensor module 20 according to the fourth embodiment includes the magnet module 10, and therefore, the neutral zone 102 generated between the first magnet 1 and the second magnet 2 can also be reduced, thereby being able to increase the bias magnetic field to be applied to the magnetic sensor 3. This allows the magnetic sensor 3 to have improved detection accuracy, thereby facilitating more accurate positioning of a detection target (such as a motor).

[0097] Furthermore, the magnet module 10 and the magnetic sensor 3 are covered with the resin member 6 , and thus can be protected.

[0098] Furthermore, the magnet module 10 and the magnetic sensor 3 are positioned by the resin member 6 , thereby reducing misalignment of the magnet module 10 relative to the magnetic sensor 3 .

[0099] It should be noted that the resin member 6 does not have to be formed by transfer molding using an epoxy resin, and may be formed by injection molding using a polyphenylene sulfide resin, a polybutylene terephthalate resin, or a liquid crystal polymer.

[0100] It should be noted that the various configurations (including modifications) that have been described with respect to the fourth embodiment may be adopted in appropriate combination with the various configurations (including modifications) that have been described with respect to the first to third embodiments.

[0101] (aspect)

[0102] The above description provides specific embodiments of the following aspects of the present disclosure.

[0103] The magnet module (10) according to the first aspect is designed for a magnetic sensor (3). The magnetic sensor (3) outputs a signal representing a detected magnetic field. The magnet module (10) includes a first magnet (1) and a second magnet (2). The first magnet (1) and the second magnet (2) are both magnetized in a first direction (D1) and a second direction (D2). The second direction (D2) is perpendicular to the first direction (D1). The first magnet (1) and the second magnet (2) are separately arranged and coupled to each other in a third direction (D3) to have mutually different magnetization directions. The third direction (D3) is perpendicular to the first direction (D1) and the second direction (D2).

[0104] This aspect can reduce the neutral zone (102) generated between the first magnet (1) and the second magnet (2) in the third direction (D3), thereby increasing the bias magnetic field to be applied to the magnetic sensor (3) by the magnet module (10). This enables the magnetic sensor (3) to have improved detection accuracy, thereby facilitating more accurate positioning of a detection target (such as a motor).

[0105] In a magnet module (10) according to a second aspect that can be implemented in combination with the first aspect, when viewed in a plane in a second direction (D2), a width of a neutral zone (102) between the first magnet (1) and the second magnet (2) is narrower than a width (W1) of a neutral zone (101) in each of the first magnet (1) and the second magnet (2).

[0106] This aspect can increase the bias magnetic field to be applied to the magnetic sensor (3), compared to the case where the width of the neutral zone (102) is equal to the width (W1) of the neutral zone (101).

[0107] In the magnet module (10) according to the third aspect which can be implemented in combination with the first aspect or the second aspect, the first magnet (1) and the second magnet (2) generate a bias magnetic field for the magnetic sensor (3).

[0108] This aspect enables the magnetic sensor (3) to have improved detection accuracy.

[0109] The magnet module (10) according to the fourth aspect, which may be implemented in combination with any one of the first to third aspects, further comprises a joining member (4). The joining member (4) joins the first magnet (1) and the second magnet (2) together.

[0110] This aspect helps to reduce the size of the magnet module (10).

[0111] In the magnet module (10) according to the fifth aspect which can be implemented in combination with the fourth aspect, the engaging member (4) includes epoxy resin or silicone resin.

[0112] This aspect achieves the advantage of making the engaging member (4) easy to handle.

[0113] The magnet module (10) according to the sixth aspect which can be implemented in combination with any one of the first to fifth aspects further includes a magnet covering resin member (5). The magnet covering resin member (5) covers the first magnet (1) and the second magnet (2).

[0114] This aspect not only secures the first magnet (1) and the second magnet (2), but also protects them.

[0115] In the magnet module (10) according to the seventh aspect which can be implemented in combination with any one of the first to sixth aspects, the dimension (X1) of the magnet module (10) measured in the first direction (D1) is equal to or less than 5 mm, and the dimension (X2) measured in the third direction (D3) is equal to or less than 5 mm.

[0116] This aspect helps to reduce the size of the magnet module (10).

[0117] A sensor module (20) according to an eighth aspect comprises: a magnet module (10) according to any one of the first to seventh aspects; a magnetic sensor (3); and a sensor covering resin member (6). The sensor covering resin member (6) covers the magnet module (10) and the magnetic sensor (3).

[0118] This aspect can not only protect the magnet module (10) and the magnetic sensor (3), but also reduce the misalignment of the magnet module (10) relative to the magnetic sensor (3).

[0119] The method for manufacturing a magnet module (10) according to the ninth aspect is a method for manufacturing a magnet module (10) for a magnetic sensor (3). The magnetic sensor (3) outputs a signal representing a detected magnetic field. The method for manufacturing a magnet module (10) includes a generation step (S1) and a coupling step (S2). The generation step (S1) includes: generating a first magnet (1) and a second magnet (2) by magnetizing a magnetic material (100) in a first direction (D1) and a second direction (D2). The second direction (D2) is perpendicular to the first direction (D1). The coupling step (S2) includes: coupling the first magnet (1) and the second magnet (2) to each other in a third direction (D3) so that the first magnet (1) and the second magnet (2) have mutually different magnetization directions. The third direction (D3) is perpendicular to the first direction (D1) and the second direction (D2).

[0120] This aspect can reduce the neutral zone (102) generated between the first magnet (1) and the second magnet (2) in the third direction (D3), thereby increasing the bias magnetic field to be applied to the magnetic sensor (3) by the magnet module (10). This enables the magnetic sensor (3) to have improved detection accuracy, thereby facilitating more accurate positioning of a detection target (such as a motor).

[0121] Note that the constituent elements according to the second aspect to the seventh aspect are not essential constituent elements of the magnet module ( 10 ), but may be appropriately omitted.

[0122] Reference numerals list

[0123] 1First magnet

[0124] 2 Second magnet

[0125] 3Magnetic sensor

[0126] 4Joint components

[0127] 5. Resin member (magnet-covered resin member)

[0128] 6Resin member (sensor covering resin member)

[0129] 10 Magnet Modules

[0130] 20 sensor modules

[0131] 100 Magnetic Materials

[0132] 101 First Neutral Zone (Neutral Zone)

[0133] 102 Second Neutral Zone (Neutral Zone)

[0134] D1 first direction

[0135] D2 Second direction

[0136] D3 third direction

[0137] X1, X2 Size

[0138] S1 generation steps

[0139] S2 coupling steps

[0140] W1 width.

Claims

1. A magnet module for a magnetic sensor, the magnetic sensor being configured to output a signal representing a detected magnetic field, the magnet module comprising: a first magnet and a second magnet, wherein the first magnet and the second magnet are magnetized in a first direction and a second direction, wherein the second direction is perpendicular to the first direction, The first magnet and the second magnet are separately disposed and are coupled to each other in a third direction, which is perpendicular to the first direction and the second direction, to have mutually different magnetization directions.

2. The magnet module according to claim 1, wherein: When viewed in a plane in the second direction, a width of a neutral zone between the first magnet and the second magnet is narrower than a width of a neutral zone in each of the first magnet and the second magnet.

3. The magnet module according to claim 1 or 2, wherein: The first magnet and the second magnet are configured to generate a bias magnetic field for the magnetic sensor.

4. The magnet module according to any one of claims 1 to 3, further comprising: A joining member joins the first magnet and the second magnet together.

5. The magnet module according to claim 4, wherein: The joining member includes epoxy resin or silicone resin.

6. The magnet module according to any one of claims 1 to 5, further comprising: The magnet covering resin member covers the first magnet and the second magnet.

7. The magnet module according to any one of claims 1 to 6, wherein: The magnet module has a size equal to or smaller than 5 mm measured in the first direction, and a size equal to or smaller than 5 mm measured in the third direction.

8. A sensor module, comprising: The magnet module according to any one of claims 1 to 7; the magnetic sensor; and The sensor covering resin member covers the magnet module and the magnetic sensor.

9. A method of manufacturing a magnet module for a magnetic sensor, the magnetic sensor being configured to output a signal representing a detected magnetic field, the method comprising: A generating step, comprising: generating a first magnet and a second magnet by magnetizing a magnetic material in a first direction and a second direction, the second direction being perpendicular to the first direction; and The coupling step includes coupling the first magnet and the second magnet to each other in a third direction perpendicular to both the first direction and the second direction so that the first magnet and the second magnet have mutually different magnetization directions.

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