Insert molded article and sensor device

Abstract

The invention relates to an insert molded article and a sensor device. The insert-molded article (90) has: a terminal (48) configured so as to be connected to the substrate (47); and a resin member (40A) that covers a part of the terminal (48). The terminal (48) has: a pin section (48A) configured so as to be connected to the substrate (47); a connection part (48B) configured to connect an electric wire (46); and a connection section (48C) that connects the pin section (48A) and the connection section (48B). The connecting section (48C) has a protruding section (82) that protrudes laterally in a direction orthogonal to a direction from the connecting section (48B) toward the pin section (48A). The resin member (40A) covers at least the connecting portion (48C) of the terminal (48).

Description

Technical Field

[0001] The present invention relates to an insert molded product and a sensor device. Background Art

[0002] For example, the torque sensor of Patent Document 1 includes a sensor substrate, a wiring harness, and a substrate holder. The substrate holder accommodates a portion of the wiring harness and the sensor substrate. The wiring harness is pulled out from the inside of the substrate holder. The inner end of the wiring harness is connected to the sensor substrate via a terminal. The terminal is fixed to the sensor substrate in a state of penetrating the sensor substrate in the thickness direction.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2017-075920

[0004] When a sensor of the type in which a wire harness is pulled out to the outside of a substrate holder is mounted on a mechanical device, such as the torque sensor of Patent Document 1, there is a concern that a tensile force may be applied to the wire harness due to wiring work at the outer end of the wire harness, etc. The tensile force is a force in the direction in which the wire harness is pulled out. When a tensile force is applied to the wire harness, there is a concern that the tensile force may be transmitted to the terminal, thereby affecting the connection portion between the terminal and the sensor substrate. Summary of the invention

[0005] An insert molded product according to one embodiment of the present invention comprises: a terminal configured to be connected to a substrate, and a resin component covering a portion of the terminal. The terminal comprises: a pin portion configured to be connected to the substrate, a connection portion configured to be connected to an electric wire, and a connection portion connecting the pin portion and the connection portion. The connection portion comprises an extension portion extending in a direction perpendicular to a direction from the connection portion toward the pin portion, that is, in a lateral direction. The resin component covers at least the connection portion of the terminal.

[0006] A sensor device according to one embodiment of the present invention includes the above-mentioned insert molded article. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 This is an exploded perspective view of a sensor device according to one embodiment.

[0008] Figure 2 This is an exploded perspective view of a detection unit according to one embodiment.

[0009] Figure 3 is a perspective view of an onboard connector according to one embodiment.

[0010] Figure 4 is an exploded perspective view of an onboard connector according to an embodiment.

[0011] Figure 5 1 is a front view of a terminal according to an embodiment.

[0012] Figure 6 This is a perspective view of a terminal according to one embodiment.

[0013] Figure 7 is a side view of a terminal according to one embodiment.

[0014] Figure 8 is a cross-sectional view of an on-board connector according to one embodiment.

[0015] Fig. 9 This is a cross-sectional view of an insert molded product according to one embodiment.

[0016] Fig.10 It is a perspective view showing a first range and a second range of each terminal according to one embodiment.

[0017] Fig.11 It is a side view showing the projection area of ​​the terminal according to one embodiment.

[0018] Fig.12 It is a side view of a terminal according to another embodiment.

[0019] Fig.13 It is a side view of a terminal according to another embodiment.

[0020] Fig.14 It is a perspective view of a terminal according to another embodiment.

[0021] Fig.15 It is a front view of a terminal according to another embodiment. DETAILED DESCRIPTION

[0022] A sensor device according to one embodiment will be described. The sensor device is, for example, a torque sensor.

[0023] <Overall Structure of Sensor Device 10>

[0024] like Figure 1 As shown, the sensor device 10 is provided on a rotating shaft 11 as a detection object. The rotating shaft 11 has an input shaft 12, a torsion bar 13, and an output shaft 14. The input shaft 12 and the output shaft 14 are connected to each other via the torsion bar 13. The input shaft 12, the torsion bar 13, and the output shaft 14 are located on the same axis O. The rotating shaft 11 is, for example, a steering shaft constituting a steering device of a vehicle. The steering wheel is connected to the steering shaft in a manner that allows it to rotate integrally.

[0025] The sensor device 10 detects torque applied to the rotating shaft 11 by the operation of the steering wheel. The sensor device 10 includes a permanent magnet 21 , a yoke 22 , and a detection unit 23 .

[0026] The permanent magnet 21 is cylindrical and has a circular cross-sectional shape. The permanent magnet 21 has S poles and N poles alternately magnetized in the circumferential direction. The inner circumference of the permanent magnet 21 is fixed in a state of being fitted to the outer circumference of the input shaft 12. The permanent magnet 21 can rotate integrally with the input shaft 12.

[0027] The yoke 22 is cylindrical and has a circular cross-sectional shape. The interior of the yoke 22 is maintained in a state where the permanent magnet 21 is inserted. The yoke 22 has a first yoke 31, a second yoke 32 and a bracket 33. The first yoke 31 and the second yoke 32 are annular components made of magnetic bodies. The first yoke 31 and the second yoke 32 are arranged along the axis O of the rotating shaft 11. The yoke 22 is formed by molding the first yoke 31 and the second yoke 32 with a synthetic resin. The bracket 33 is a portion formed of a synthetic resin of the yoke 22. The bracket 33 maintains the positional relationship between the first yoke 31 and the second yoke 32. The yoke 22 is fixed to the output shaft 14.

[0028] The first yoke 31 has a plurality of teeth 31a. The teeth 31a are arranged at equal intervals in the circumferential direction of the first yoke 31. The second yoke 32 has a plurality of teeth 32a. The teeth 32a are arranged at equal intervals in the circumferential direction of the second yoke 32. The teeth 31a and the teeth 32a extend to opposite sides of each other in the direction along the axis O of the rotating shaft 11. In addition, the teeth 31a and the teeth 32a are alternately arranged in the circumferential direction of the first yoke 31 and the second yoke 32. When the torsion bar 13 is not torsionally deformed, the circumferential center of the teeth 31a and 32a coincides with the boundary between the N pole and the S pole of the permanent magnet 21. The permanent magnet 21, the first yoke 31 and the second yoke 32 form a magnetic circuit.

[0029] The detection unit 23 generates an electric signal corresponding to the amount of torsion of the torsion bar 13. The detection unit 23 includes a first sensor housing 40 and a second sensor housing 50. The first sensor housing 40 and the second sensor housing 50 are combined with each other in the axial direction.

[0030] The first sensor housing 40 is a resin molded product. The first sensor housing 40 has a first housing body 41 and a first protrusion 42. The first housing body 41 is cylindrical and has a first insertion hole 43 that penetrates in the axial direction. The inner diameter of the first insertion hole 43 is slightly larger than the outer diameter of the yoke 22. The portion of the yoke 22 provided with the first yoke 31 is maintained in a state of being axially inserted into the first insertion hole 43. The first protrusion 42 is a rectangular parallelepiped and protrudes radially outward from the outer peripheral surface of the first housing body 41.

[0031] A first magnetic focusing ring 44 is provided on the first shell body 41. The first magnetic focusing ring 44 is in the shape of an arc plate that is bent along the inner circumference of the first insertion hole 43. The inner circumference of the first magnetic focusing ring 44 is exposed inside the first insertion hole 43. The first magnetic focusing ring 44 is maintained at a position corresponding to the first magnetic yoke 31 in the axial direction. The first magnetic focusing ring 44 surrounds the first magnetic yoke 31. The first magnetic focusing ring 44 guides the magnetic flux from the first magnetic yoke 31.

[0032] An onboard connector 45 is provided inside the first protrusion 42. The first end of the onboard connector 45 is exposed to the outside. The first end is the end of the onboard connector 45 on the side opposite to the first housing body 41 in the radial direction. The onboard connector 45 holds a plurality of wires 46. The wires 46 are, for example, covered wires in which a core wire is covered by an insulator. The plurality of wires 46 are arranged at intervals in a direction orthogonal to the direction in which the first protrusion 42 extends. The first end of the wire 46 is pulled out from the first end of the onboard connector 45 to the outside. The first end is connected to an external device. The external device is, for example, a control device for a steering device.

[0033] In addition, the first magnetic focusing ring 44 and the onboard connector 45 are integrally provided with the first sensor housing 40 by insert molding. Insert molding is a molding technology that installs an insert in an open mold, and then closes the mold and performs injection molding. The first magnetic focusing ring 44 and the onboard connector 45 are inserts.

[0034] The second sensor housing 50 is a resin molded product. The second sensor housing 50 has a second housing body 51 and a second protrusion 52. The second housing body 51 is cylindrical and has a second insertion hole 53 that penetrates in the axial direction. The inner diameter of the second insertion hole 53 is the same as the inner diameter of the first insertion hole 42, and is slightly larger than the outer diameter of the yoke 22. The portion of the yoke 22 where the second yoke 32 is provided is maintained in a state of being inserted in the second insertion hole 53 in the axial direction. The second protrusion 52 is a rectangular flat plate and protrudes radially outward from the outer peripheral surface of the second housing body 51. The second protrusion 52 overlaps with the first protrusion 42 in the axial direction.

[0035] A second magnetic focusing ring 54 is provided on the second housing body 51. The second magnetic focusing ring 54 is the same as the first magnetic focusing ring 44, and is integrally provided with the second sensor housing 50 by insert molding. The second magnetic focusing ring 54 is in the shape of an arc plate that is bent along the inner circumferential surface of the second insertion hole 53. The inner circumferential surface of the second magnetic focusing ring 54 is exposed to the inside of the second insertion hole 53. The second magnetic focusing ring 54 is maintained at a position corresponding to the second magnetic yoke 32 in the axial direction. The second magnetic focusing ring 54 surrounds the second magnetic yoke 32. The second magnetic focusing ring 54 guides the magnetic flux from the second magnetic yoke 32.

[0036] <Supplementary explanation of the detection unit 23>

[0037] like Figure 2 As shown, the first protrusion 42 has a substrate storage portion 42A. The substrate storage portion 42A is open in the axial direction. The opening of the substrate storage portion 42A is closed by the second protrusion 52. Two first magnetic collecting protrusions 44A are exposed to the interior of the substrate storage portion 42A. The first magnetic collecting protrusion 44A is a part of the first magnetic collecting ring 44. The first magnetic collecting protrusion 44A protrudes outward from the peripheral wall of the first shell body 41. In addition, the pin portions 48A of the plurality of terminals 48 described later are arranged inside the substrate storage portion 42A. The terminal 48 is mounted on the second end of the electric wire 47. The pin portion 48A extends in the axial direction. The plurality of pin portions 48A are arranged in a row along the long side direction of the substrate storage portion 42A.

[0038] The substrate 47 is stored inside the substrate storage portion 42A. The substrate 47 is, for example, a rectangular flat plate. The substrate 47 has a first magnetic sensor 47A, a second magnetic sensor 47B, and a plurality of terminal connection holes 47C. The first magnetic sensor 47A and the second magnetic sensor 47B are arranged along the first long side of the substrate 47. The first magnetic sensor 47A and the second magnetic sensor 47B are sensors for detecting the rotation angle of the rotating shaft 11, such as Hall sensors. The rotation angle of the rotating shaft 11 is a physical quantity related to the rotational motion of the rotating shaft 11. A plurality of terminal connection holes 47C are arranged in a row along the second long side of the substrate 47. The pin portion 48A is inserted into the terminal connection hole 47C. The pin portion 48A is joined to the substrate 47 by welding.

[0039] Although omitted from the illustration, the second magnetic collecting ring 54 is the same as the first magnetic collecting ring 44 and has two second magnetic collecting protrusions. The second magnetic collecting protrusion is arranged along the surface of the second protrusion 52 on the side facing the substrate storage portion 42A. The second magnetic collecting protrusion protrudes outward from the peripheral wall of the second shell body 51. The second magnetic collecting protrusion is axially opposite to the first magnetic collecting protrusion 44A. The first magnetic sensor 47A and the second magnetic sensor 47B are respectively clamped between the first magnetic collecting protrusion 44A and the second magnetic collecting protrusion. The first magnetic sensor 47A detects the magnetic flux guided by the first magnetic collecting ring 44. The second magnetic sensor 47B detects the magnetic flux guided by the second magnetic collecting ring 52.

[0040] By applying a torque to the input shaft 12, the torsion bar 13 is twisted and deformed. According to the torque applied to the input shaft 12, a relative rotational displacement is generated between the input shaft 12 and the output shaft 14. As a result, the relative position of the permanent magnet 21 and the first magnetic yoke 31 in the rotation direction changes. Therefore, the magnetic flux from the permanent magnet 21 through the first magnetic yoke 31 and guided by the first magnetic focusing ring 44 changes. In addition, the relative position of the permanent magnet 21 and the second magnetic yoke 32 in the rotation direction changes. Therefore, the magnetic flux from the permanent magnet 21 through the second magnetic yoke 32 and guided by the second magnetic focusing ring 54 changes.

[0041] The first magnetic sensor 47A and the second magnetic sensor 47B respectively generate electrical signals corresponding to the magnetic flux leaked between the first magnetic collecting protrusion 44A of the first magnetic collecting ring 44 and the second magnetic collecting protrusion of the second magnetic collecting ring 54. The electrical signal changes according to the torsional deformation of the torsion bar 13, that is, the torsion angle of the torsion bar 13. For example, the control device of the steering control device calculates the torque acting on the torsion bar 13 based on the electrical signals generated by the first magnetic sensor 47A and the second magnetic sensor 47B. Torque is a physical quantity related to the rotational motion of the rotating shaft 11.

[0042] <Structure of the on-board connector 45>

[0043] Next, the structure of the onboard connector 45 will be described in detail.

[0044] like Figure 3 The board-mounted connector 45 shown has a housing 60 and a cover 70. The housing 60 and the cover 70 are combined with each other. The second end of the electric wire 46 is held by being clamped by the housing 60 and the cover 70. The terminal 48 is accommodated inside the board-mounted connector 45. The pin portion 48A protrudes from the surface of the housing 60 to which the cover 70 is mounted. The first end (not shown) of the electric wire 46 is pulled out to the outside of the board-mounted connector 45.

[0045] like Figure 4 As shown, the housing 60 is a rectangular parallelepiped resin molded product. The housing 60 has a first wire clamping portion 61, a terminal holding portion 62, and an exposed portion 63. In the short side direction of the housing 60, the terminal holding portion 62 is located between the first wire supporting portion 61 and the exposed portion 63.

[0046] The first wire clamping portion 61 is flat. The first wire clamping portion 61 has a plurality of first guide grooves 61A. The first guide grooves 61A are arc-shaped grooves extending along the short side direction of the housing 61. The plurality of first guide grooves 61A are arranged at intervals along the long side direction of the housing 61. The first guide grooves 61A support the wires 47.

[0047] The terminal holding portion 62 has a plurality of partition walls 62A. The partition walls 62A are arranged corresponding to the first guide groove 61A. The partition wall 62A has a first wall portion and a second wall portion. The first wall portion is a wall extending in the thickness direction of the housing 61. The second wall portion is a wall provided at the front end of the first wall portion and extending in the long side direction of the housing 60. The partition wall 62A is formed with a terminal insertion portion 62B. The terminal insertion portion 62B is a rectangular space portion extending in the short side direction of the housing 61. The terminal insertion portion 62B is located on the extension line of the first guide groove 61A. A gap 62C is formed between the second wall portions of two adjacent partition walls 62A in the long side direction of the housing 61. The size of the gap 62C is slightly larger than the outer diameter of the pin portion 48A of the terminal 48. The pin portion 48A extends in a direction orthogonal to the electric wire 47.

[0048] The exposed portion 63 has an opening portion 63A and a plurality of positioning grooves 63B. The opening portion 63A extends along the long side direction of the housing 60. The interior of the opening portion 63A is connected to each terminal insertion portion 62B of the terminal holding portion 62. The positioning groove 63B is provided on the inner side surface of the opening portion 63A on the side opposite to the terminal holding portion 62 in the short side direction of the housing 60. The plurality of positioning grooves 63B are arranged at intervals along the long side direction of the housing 61. The positioning groove 63B is a cutout groove open in the protruding direction of the opening portion 63A and the dividing wall 62A. The size of the positioning groove 63B in the long side direction of the housing 60 is the same as or slightly larger than the outer diameter of the pin portion 48A.

[0049] like Figure 4 As shown, the cover 70 is attached to the housing 60 from the opening 63A side. The cover 70 is a resin molded product, and has a covering portion 71 and a second wire clamping portion 72.

[0050] The covering portion 71 is a portion for covering the terminal holding portion 62 of the housing 60. The covering portion 71 is in the shape of an L-shaped plate. The covering portion 71 includes a first portion in the shape of a plate and a second portion in the shape of a plate. The first portion is a portion of the covering portion 71 for covering the front end portion of the second wall portion including the terminal holding portion 62. The second portion is a portion orthogonal to the first portion and is a portion of the covering portion 71 that covers the side surface of the terminal holding portion 62 on the side opposite to the opening 63A.

[0051] The cover 71 has a plurality of resin inflow holes 71A. The resin inflow holes 71A are, for example, rectangular holes. The resin inflow holes 71A are arranged in two rows along the long side direction of the housing 60. The resin inflow holes 71A of the first row penetrate the first portion of the cover 71 in the thickness direction. The resin inflow holes 71A of the second row are arranged at the corners of the cover 71. The corners are the portions where the first portion and the second portion intersect. The resin inflow holes 71A of the second row penetrate the first portion and the second portion of the cover 71 in the same direction as the resin inflow holes 71A of the first row.

[0052] The cover portion 71 includes a first arm portion 71B and a second arm portion 71C. The first arm portion 71B and the second arm portion 71C are provided at two side edge portions of the cover portion 71 located on opposite sides in the longitudinal direction. The first arm portion 71B and the second arm portion 71C are flat plate-shaped and extend in the mounting direction of the cover 70. Claws (not shown) are provided at the front ends of the first arm portion 71B and the second arm portion 71C.

[0053] The second wire clamping portion 72 is a portion corresponding to the first wire clamping portion 61 of the housing 60, and is a portion for clamping the wire 46 between the second wire clamping portion 72 and the first wire clamping portion 61. The second wire clamping portion 72 is a rectangular flat plate. The second wire clamping portion 72 has a plurality of second guide grooves 72A. The second guide grooves 72A are arc-shaped grooves extending along the short side direction of the second wire clamping portion 72. The plurality of second guide grooves 72A are arranged at intervals along the long side direction of the second wire clamping portion 72. The second guide grooves 72A are arranged at a position corresponding to the first guide groove 61A of the housing 60.

[0054] The second wire clamping portion 72 includes a third arm portion 72B and a fourth arm portion 72C. The third arm portion 72B and the fourth arm portion 72C are provided at both side edge portions of the second wire clamping portion 72 located on opposite sides in the longitudinal direction. The third arm portion 72B and the fourth arm portion 72C are flat plate-shaped and extend in the mounting direction of the cover 70. Claw portions (not shown) are provided at the front ends of the third arm portion 72B and the fourth arm portion 72C.

[0055] <Structure of terminal 48>

[0056] Next, the structure of the terminal 48 will be described in detail.

[0057] like Figure 5 As shown, the terminal 48 is formed by, for example, plastically deforming a metal plate material punched into a predetermined shape. The terminal 48 includes a pin portion 48A, a connecting portion 48B, and a coupling portion 48C.

[0058] The pin portion 48A is provided at the first end portion of the terminal 48. The pin portion 48A is rod-shaped and is formed by, for example, plastically deforming a portion of a metal plate material corresponding to the pin portion 48A into a cylindrical shape having a circular cross-sectional shape.

[0059] The connection portion 48B is provided at the second end of the terminal 48. The second end is the end of the terminal 48 on the side opposite to the first end. The connection portion 48B is a portion of the terminal 48 to which the second end of the power supply line 46 is connected. At the second end of the power supply line 46, the core wire is exposed from the covering layer. The connection portion 48B and the power supply line 46 are connected by riveting a portion of the connection portion 48B so as to wrap the exposed core wire. The connection portion 48B has a flat portion. The flat portion is a portion of the connection portion 48B that is flat and extends along the core wire exposed from the riveted portion of the connection portion 48B.

[0060] The connection portion 48C is a middle portion of the terminal 48 that connects the pin portion 48A and the connection portion 48B.

[0061] like Figure 6 As shown, the connecting portion 48C has a connecting portion body 81 and a protruding portion 82 .

[0062] The connecting portion body 81 is a rectangular flat plate. The short side of the connecting portion body 81 extends along the pin portion 48A. The long side of the connecting portion body 81 extends in a direction orthogonal to the pin portion 48A. The first end of the connecting portion body 81 in the long side direction is connected to the base end of the pin portion 48A. The first corner is formed by the pin portion 48A and the connecting portion body 81. The second end of the connecting portion body 81 in the long side direction is connected to the flat portion of the connecting portion 48B. When viewed from a direction orthogonal to the connecting portion body 81, the connecting portion body 81 is connected to a portion of the flat portion located on the side opposite to the first guide groove 51A in a state where the electric wire 46 is supported by the first guide groove 61A. The second corner is formed by the connecting portion body 81 and the connecting portion 48B.

[0063] The extension part 82 extends to the side of the connection part body 81. The extension part 82 extends along the longitudinal direction of the connection part body 81 and has a cylindrical shape having a polygonal cross-sectional shape. The extension part 82 has a first extension piece 83 and a second extension piece 84.

[0064] The first extension piece 83 is arranged on the first long side of the connecting portion body 81. The first extension piece 83 has a first wall portion and a second wall portion. The first wall portion is a rectangular plate. The first wall portion is orthogonal to the connecting portion body 81. The second wall portion is a rectangular plate. The second wall portion is connected to the end of the first wall portion on the opposite side of the connecting portion body 81. The second wall portion is parallel to the connecting portion body 81.

[0065] The first wall portion has a protrusion 83A. The protrusion 83A is a rectangular plate. The protrusion 83A is formed by cutting and bending. That is, the protrusion 83A is formed by providing cuts corresponding to the three sides of the protrusion 83A in the first wall portion and bending the remaining portion after cutting. The bending direction is the opposite direction to the second wall portion. The protrusion 83A opens to the side opposite to the pin portion 48A.

[0066] The second extension piece 84 is arranged on the second long side of the connecting portion main body 81. The length of the connecting portion main body 81 in the long side direction is shorter than the length of the first extension piece 83 in the long side direction. The second extension piece 84 has a third wall portion and a fourth wall portion. The third wall portion is in the shape of a rectangular plate. The third wall portion is orthogonal to the connecting portion main body 81. The fourth wall portion is in the shape of a rectangular plate. The fourth wall portion is connected to the end of the third wall portion on the opposite side of the connecting portion main body 81. The fourth wall portion is parallel to the connecting portion main body 81. The end of the fourth wall portion on the side opposite to the third wall portion is maintained in a state of contact with the end of the second wall portion on the opposite side of the first wall portion throughout its entire length.

[0067] like Figure 7 As shown in FIG. 1 , when viewed from the connection portion 48B toward the pin portion 48A, the extension portion 82 has a closed loop shape. The shape of the loop is a quadrilateral. The first extension piece 83 and the second extension piece 84 form a tube. The tube has a polygonal cross-sectional shape. Figure 7 , the connection portion 48B before riveting is shown.

[0068] like Figure 5 As shown, when viewed from a direction perpendicular to the direction from the connecting portion 48B toward the pin portion 48A, the terminal 48 has a crank shape. The crank shape is a shape formed by alternately connecting two right-angle curves. The first corner formed by the pin portion 48A and the connecting portion body 81, and the second corner formed by the connecting portion body 81 and the connecting portion 48B are the parts of the terminal 48 equivalent to the right-angle curve.

[0069] <Assembly procedure of on-board connector 45>

[0070] Next, the assembly procedure of the on-board connector 45 will be described.

[0071] like Figure 4 As shown, first, the terminal 48 is inserted into each terminal insertion portion 62B of the terminal holding portion 62 from the side opposite to the opening portion 63A. The terminal 48 is inserted into each terminal insertion portion 62B until the pin portion 48A reaches the position of the end wall of the positioning groove 63B in the insertion direction. Thus, the insertion direction of the terminal 48, that is, the position of the terminal 48 in the short side direction of the housing 60 is determined. In addition, the positioning groove 63B has two inner side surfaces facing each other in the long side direction of the housing 60. In the long side direction of the housing 60, the pin portion 48A is abutted against the inner side surface of the positioning groove 63B to limit the movement of the pin portion 48A in the long side direction of the housing 60. Thus, the position of the terminal 48 in the long side direction of the housing 60 is determined. The second end portion of the electric wire 46 is maintained in a state supported by the first guide groove 61A. In this state, the cover 70 is mounted on the housing 60 from the opening portion 63A side.

[0072] The claws of the first arm 71B, the second arm 71C, the third arm 72B, and the fourth arm 72C of the cover 70 are elastically engaged with a portion of the housing 60 in the direction opposite to the mounting direction. This prevents the cover 70 from falling off the housing 60. The cover 70 is maintained in a state of being mounted on the housing 60. The assembly operation of the on-board connector 45 is completed as described above.

[0073] <Assembly status of the on-board connector 45>

[0074] Next, the assembled state of the on-board connector 45 will be described.

[0075] like Figure 3 As shown in FIG. 1 , when the cover 70 is mounted on the housing 60, the exposed portion 63 is not covered by the cover 70 and is exposed to the outside. The pin portion 48A protrudes from the positioning groove 63B to the side opposite to the mounting direction of the cover 70. The opening 63A and the terminal holding portion 62 of the housing 60 are covered by the covering portion 71. However, the opening 63A and the terminal insertion portion 62B are open to the outside via the resin inflow hole 71A of the cover 70.

[0076] When the cover 70 is mounted on the housing 60, the second wire clamping portion 72 is maintained in a state of overlapping with the first wire clamping portion 61 in the mounting direction of the cover 70. The second end of the wire 46 is clamped by the first guide groove 61A and the second guide groove 72A. Thus, the movement of the second end of the wire 46 in the long side direction of the on-board connector 45 is restricted. The second end of the wire 46 is held at the determined position.

[0077] <Method of Manufacturing First Sensor Case 40>

[0078] Next, a method for manufacturing the first sensor housing 40 will be described.

[0079] First, the insert, i.e., the first magnetic focusing ring 44 and the onboard connector 45, are placed in the mold in the open state. The onboard connector 45 is in a state of holding the wire 46. After that, the mold is closed for injection molding. In the state of the mold being closed, a cavity is formed inside the mold. The cavity is a space corresponding to the outer shape of the first sensor housing 40.

[0080] Next, molten resin is injected into the cavity. Molten resin is a synthetic resin that is heated and melted. Inside the mold, the first magnetic focusing ring 44 is wrapped with molten resin except for its inner circumference. The onboard connector 45 is wrapped with molten resin except for at least the first end. The molten resin flows into the terminal insertion portion 62B and the opening portion 63A through the resin inflow hole 71A of the cover 70.

[0081] After the cavity is filled with molten resin, the filled molten resin is cooled and solidified. Then, the mold is opened to remove the resin molded product, that is, the first sensor housing 40. Figure 2 The first sensor housing 40 shown is the first sensor housing 40 in which the first magnetic focusing ring 44 and the onboard connector 45 are embedded.

[0082] The manufacturing of the first sensor housing 40 is completed as described above.

[0083] like Figure 8 As shown, after the first sensor housing 40 is removed from the mold, the pin portion 48A is inserted into the terminal connection hole 47C of the substrate 47. The pin portion 48A is bonded to the substrate 47 by solder 47D. The pin portion 48A and the pattern wiring of the substrate 47 are electrically connected.

[0084] <State of the inside of the on-board connector 45>

[0085] The state of the interior of the onboard connector 45 is as follows.

[0086] like Figure 8 As shown in FIG. 1 , inside the on-board connector 45, the connection portion 48C of the terminal 48 is covered with synthetic resin. That is, the opening 63A of the housing 61 and each terminal insertion portion 62B are filled with synthetic resin. The inside of the extension portion 82 is also filled with synthetic resin. In addition, the connection portion 48C and the partition wall 62A (see FIG. 1 ) are also filled with synthetic resin. Figure 4 The gap 62C between two adjacent partition walls 62A in the long side direction of the housing 61 is also filled with synthetic resin (see Figure 4 The protrusion 83A enters the synthetic resin in a direction opposite to the insertion direction of the terminal 48 into the terminal insertion portion 62B. The terminal 48 is held inside the terminal insertion portion 62B by filling the periphery of the connecting portion 48C with the resin without any gap. Figure 8 The onboard connector 45 is temporarily pulled out, and the synthetic resin etc. filled in the onboard connector 45 are shown. The synthetic resin portion 40A covering at least the periphery of the connecting portion 48C of the terminal 48 is a part of the first sensor housing 40 and corresponds to a resin member.

[0087] like Fig. 9 As shown, the terminal 48 and the synthetic resin portion 40A covering at least the periphery of the connecting portion 48C of the terminal 48 constitute an insert molded product 90 . Fig. 9 The terminal 48 is temporarily pulled out, and the synthetic resin covering at least the periphery of the connecting portion 48C of the terminal 48 is shown.

[0088] In addition, if Fig.10As shown, in the first range S1, each terminal 48 is covered with synthetic resin. The first range S1 is a rectangular range, and is a range including the opening 63A of the exposed portion 63 and the terminal holding portion 62. In addition, in the second range S2, each pin portion 48A is connected to the substrate 47. The second range is a rectangular range, and is a range including each terminal connection hole 47 of the substrate 47.

[0089] <Effects of implementation methods>

[0090] This embodiment achieves the following effects.

[0091] For example, when the sensor device 10 is assembled to the steering device, or when the steering device is assembled to the vehicle, an external force is sometimes applied to the wire 46 due to the wiring operation of the wire 46. The external force includes a tensile force. The tensile force is a force in the direction of pulling out the wire 46 from the onboard connector 45. The pulling-out direction of the wire 46 is the opposite direction to the insertion direction of the terminal 48 relative to the terminal insertion portion 62B. When the tensile force is applied to the wire 46, the part of the terminal 48 facing the pulling-out direction meshes with the synthetic resin covering the periphery of the terminal 48. In particular, the extension portion 82 extends to the side of the connecting portion main body 81, so it is easy to mesh with the synthetic resin.

[0092] like Fig.11 As shown by the multiple points, in the projection area S3 where the terminal 48 is projected from the direction opposite to the pulling direction, the terminal 48 is meshed with the synthetic resin covering the periphery thereof. In the pulling direction of the electric wire 46, the synthetic resin covering the periphery of the terminal 48 is subjected to a pressure corresponding to the tensile force via the projection area S3 of the terminal 48. The projection area S3 is an area including the connecting portion 48C. Therefore, compared with the case where the structure in which the extension portion 80 is omitted is adopted as the connecting portion 48C, the area of ​​the projection area S3 is increased by the area of ​​the end surface of the extension portion 80.

[0093] Therefore, the tensile force is appropriately blocked by the synthetic resin covering the periphery of the terminal 48 via the projection area S3 of the terminal 48. That is, the tensile force is appropriately transmitted to the synthetic resin covering the periphery of the terminal 48 via the projection area S3 of the terminal 48 and is released. Therefore, it is possible to suppress the tensile force from being directly transmitted to the connection portion between the tube pin portion 48A and the substrate 47. Thus, it is possible to suppress the tensile force from affecting the connection portion between the tube pin portion 48A and the substrate 47. For example, it is difficult to transmit the tensile force to the tube pin portion 48A, and thus the stress generated at the connection portion between the tube pin portion 48A and the substrate 47 is suppressed. In addition, the change in the position of the tube pin portion 48A relative to the substrate 47 can also be reduced.

[0094] <Effects of implementation>

[0095] This embodiment achieves the following effects.

[0096] (1) The connection portion 48C of the terminal 48 has a projection 82 that extends to the side of the connection portion body 81. The connection portion 48C is covered with a synthetic resin. Therefore, when a tensile force is applied to the electric wire 46, the portion of the terminal 48 facing the direction of extraction of the electric wire 46 meshes with the synthetic resin covering the periphery of the terminal 48. In particular, the projection 82 is extended to the side of the connection portion body 81, so it is easy to mesh with the synthetic resin. In addition, the portion of the terminal 48 that meshes with the synthetic resin is a projection area S3 of the terminal 48 projected in the direction opposite to the extraction direction. The area of ​​the projection area S3 is enlarged by the area where the projection 80 is provided. Therefore, the tensile force is appropriately blocked by the synthetic resin covering the periphery of the terminal 48 via the projection area S3 of the terminal 48. It is possible to suppress the tensile force from being directly transmitted to the connection portion between the pin portion 48A and the substrate 47, thereby suppressing the tensile force from affecting the connection portion between the pin portion 48A and the substrate 47. In addition, the resistance of the electric wire 46 to pulling is improved.

[0097] (2) When viewed from the connection portion 48B toward the pin portion 48A, the extension portion 80 has a closed loop shape. Therefore, when manufacturing the first sensor housing 40, molten resin easily enters the interior of the connection portion 80. This also helps increase the projection area S3 of the terminal 48.

[0098] (3) The connecting portion 48C has a connecting portion body 81 that connects the tube pin portion 48A and the connecting portion 48B. The connecting portion body 81 is a plate having a first long side extending in a direction from the connecting portion 48B toward the tube pin portion 48A, and a second long side parallel to the first long side. The extension portion 82 has a first extension piece 83 provided on the first long side, and a second extension piece 84 provided on the second long side. The first extension piece 83 and the second extension piece 83 are provided to constitute a single tube. Therefore, the tubular extension portion 82 can be simply formed by the first extension piece 83 and the second extension piece 83.

[0099] (4) The terminal 48 is formed by plastically deforming a single metal plate. The extension 82 is formed by plastically deforming a portion of the metal plate corresponding to the first extension piece 83 and the second extension piece 84. Therefore, the terminal 48 including the extension 82 can be easily manufactured.

[0100] (5) The synthetic resin is filled into the opening 63A of the housing 61 and each terminal insertion portion 62B without any gap. Therefore, it is possible to suppress dust and the like from entering the interior of the on-board connector 45. The dustproof property of the on-board connector 45 can be improved.

[0101] <Other embodiments>

[0102] This embodiment can also be implemented by changing as follows.

[0103] ·like Fig.12 As shown, the extension portion 80 may be a structure having only the first extension piece 83. The second wall portion of the first extension piece 83 may be slightly extended in the direction opposite to the protrusion 83A. The second wall portion is a wall portion of the first extension piece 83 parallel to the connection portion body 81.

[0104] ·like Fig.13 As shown, the extension portion 80 may be configured to include only the first extension piece 83. The first extension piece 83 may include only the first wall portion. The first wall portion is a wall portion of the first extension piece 83 that is orthogonal to the connection portion main body 81.

[0105] ·like Fig.14 As shown, the extension portion 80 may be configured to include only the first extension piece 83. The second wall portion of the first extension piece 83 may be provided at the end of the first wall portion on the side opposite to the pin portion 48A.

[0106] ·and Figure 12-13 Contrary to the illustrated extending portion 80 , a structure having only the second extending piece 84 may be adopted as the extending portion 80 .

[0107] ·like Fig.15 As shown, the pin portion 48A may also be a crimping terminal. The crimping terminal is a terminal that can be connected to the substrate 47 only by being pressed into the terminal connection hole 47C of the substrate 47. The crimping terminal is held by the terminal connection hole 47C by the restoring force generated by the elastic deformation when pressed in. In this way, welding is not required.

[0108] The sensor device 10 may also be a rotation angle sensor that detects the rotation angle of the rotating shaft 11. In this case, for example, the driving gear is mounted on the outer peripheral surface of the rotating shaft 11 in a manner that allows it to rotate as a whole. The two driven gears are supported by the substrate storage portion 42A of the first sensor housing 40 so as to be rotatable. The number of teeth of each driven gear is different from each other. A sensor that generates an electrical signal corresponding to the rotation angle of each driven gear is provided on the substrate 47. The driven gear meshes with the driving gear via an opening portion of a portion of the first sensor housing 40 provided between the substrate storage portion 42A and the first insertion hole 43. Therefore, the two driven gears rotate in conjunction with the rotation of the driving gear. Since the number of teeth of the two driven gears is different from each other, the rotation angles of the two driven gears relative to the rotation angle of the driving gear are different. Therefore, the phases of the electrical signals generated by the first sensor and the second sensor are different from each other. For example, the control device of the steering device detects the rotation angle of the rotating shaft 11 based on the electrical signals generated by the first sensor and the second sensor.

[0109] The term "tube" or "tube-shaped" used in this specification may refer to any structure having a peripheral wall. The term "tube" or "tube-shaped" may refer to any structure having a circular, elliptical, or sharp-angled or rounded cross-sectional shape, but is not limited thereto.

Claims

1. An insert molded product comprising a terminal configured to be connected to a substrate and a resin member covering a portion of the terminal, wherein: The terminal includes a pin portion configured to be connected to the substrate, a connecting portion configured to be connected to an electric wire, and a connecting portion connecting the pin portion and the connecting portion. The connecting portion has a protruding portion that protrudes in a direction that is orthogonal to a direction from the connecting portion toward the pin portion, that is, in a lateral direction. The resin member covers at least the connecting portion of the terminal.

2. The insert molded article according to claim 1, wherein The extending portion has a closed loop shape when viewed from the connecting portion toward the pin portion.

3. The insert molded article according to claim 2, wherein: The connecting portion includes a connecting portion body connecting the pin portion and the connecting portion. The connecting portion body is formed in a plate shape having a first long side extending in a direction from the connecting portion toward the pin portion and a second long side parallel to the first long side. The extension portion includes a first extension piece provided on the first long side and a second extension piece provided on the second long side. The first extending piece and the second extending piece are arranged to constitute a single tube.

4. The insert molded article according to claim 3, wherein The terminal is formed by plastic deformation of a single metal plate. The protruding portion is formed by plastically deforming a portion of the metal plate material corresponding to the first protruding piece and the second protruding piece.

5. A sensor device comprising: The insert molded article according to any one of claims 1 to 4.

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