Insert molded article and sensor device

Abstract

The invention relates to an insert molded article and a sensor device. An insert molded article (40) is provided with: a terminal (48) having a pin section (48A); a first holding member (60) having a terminal holding portion (62) for holding the terminal; a second holding member (70) having a covering portion (71) that covers the terminal holding portion; and a resin member (40A) that covers the periphery of a part of the terminal located inside the terminal holding part and the peripheries of the first holding member and the second holding member. The covering portion has: a resin inflow hole (71A) configured so as to introduce a molten resin into the terminal holding portion at the time of molding the resin member; and a protruding portion (73) which is provided at a position close to the pin portion with respect to the resin inflow hole and which is combined with the first holding member. The terminal holding portion and the pin portion are shielded from each other by a portion of the protruding portion and the terminal.

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 has a sensor substrate, a wiring harness, and a substrate holder. The substrate holder houses a part of the wiring harness and the sensor substrate. The wiring harness is pulled out from the inside of the substrate holder to the outside. 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. The torque sensor is magnetic and has a yoke. The yoke and the substrate holder are integrated by a synthetic resin.

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

[0004] In a sensor of the type in which components are integrated by a synthetic resin as in the torque sensor of Patent Document 1, there is a concern that the molten synthetic resin may protrude into an unwanted part during molding. Summary of the Invention

[0005] An insert-molded product according to an embodiment of the present invention includes: a terminal having a first end provided with a pin portion and a second end opposite to the first end; a first holding member having a terminal holding portion that holds the terminal in a state where the terminal is inserted; a second holding member combined with the first holding member and having a covering portion that covers the terminal holding portion; and a resin member that covers the periphery of a part of the terminal located inside the terminal holding portion and the peripheries of the first holding member and the second holding member. The covering portion has: a resin inflow hole configured to introduce molten resin into the inside of the terminal holding portion during molding of the resin member; and a protrusion provided at a position close to the pin portion with respect to the resin inflow hole and combined with the first holding member. The terminal holding portion and the pin portion are mutually blocked by the protrusion and a part of the terminal.

[0006] A sensor device according to an embodiment of the present invention includes the above insert-molded product. Brief Description of the Drawings

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

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

[0009] Figure 3 is a perspective view of a board-mounted connector according to an embodiment.

[0010] Figure 4 Exploded perspective view of a board-mounted connector of an embodiment.

[0011] Figure 5 Front view of a terminal of an embodiment.

[0012] Figure 6 Perspective view of a terminal of an embodiment.

[0013] Figure 7 Side view of a terminal of an embodiment.

[0014] Figure 8 Cross-sectional view of a board-mounted connector of an embodiment.

[0015] Figure 9 Perspective view of a cover of an embodiment.

[0016] Figure 10 Perspective view of a cover in a state where terminals are mounted of an embodiment.

[0017] Figure 11 Cross-sectional perspective view of a board-mounted connector of an embodiment.

[0018] Figure 12 Cross-sectional perspective view of a board-mounted connector of an embodiment. Detailed implementation manners

[0019] A sensor device of an embodiment will be described. The sensor device is, for example, a torque sensor.

[0020] <Overall structure of sensor device 10>

[0021] As Figure 1 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 control device of a vehicle. The steering wheel is connected to the steering shaft so as to be rotatable integrally.

[0022] The sensor device 10 detects the torque applied to the rotating shaft 11 by the operation of the steering wheel. The sensor device 10 has a permanent magnet 21, a yoke 22, and a detection unit 23.

[0023] The permanent magnet 21 is cylindrical and has a circular cross-sectional shape. The permanent magnet 21 is magnetized with S poles and N poles alternately in its circumferential direction. The inner circumferential surface of the permanent magnet 21 is fixed in a state of being embedded in the outer circumferential surface of the input shaft 12. The permanent magnet 21 can rotate integrally with the input shaft 12.

[0024] The yoke 22 is cylindrical and has a circular cross-sectional shape. The permanent magnet 21 is maintained inside the yoke 22 in a state where the permanent magnet 21 is inserted. The yoke 22 includes a first yoke 31, a second yoke 32, and a bracket 33. The first yoke 31 and the second yoke 32 are annular members made of a magnetic material. The first yoke 31 and the second yoke 32 are arranged along the axis O of the rotation shaft 11. The yoke 22 is formed by molding the first yoke 31 and the second yoke 32 with synthetic resin. The bracket 33 is a part formed by the 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.

[0025] The first yoke 31 has a plurality of tooth portions 31a. The tooth portions 31a are arranged at equal intervals in the circumferential direction of the first yoke 31. The second yoke 32 has a plurality of tooth portions 32a. The tooth portions 32a are arranged at equal intervals in the circumferential direction of the second yoke 32. The tooth portions 31a and the tooth portions 32a extend in opposite directions along the axis O of the rotation shaft 11. In addition, the tooth portions 31a and the tooth portions 32a are alternately arranged in the circumferential directions of the first yoke 31 and the second yoke 32. In a state where the torsion bar 13 does not generate torsional deformation, the centers in the circumferential directions of the tooth portions 31a and 32a coincide 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.

[0026] 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.

[0027] The first sensor housing 40 is a resin molded product. The first sensor housing 40 has a first housing main body 41 and a first protrusion 42. The first housing main 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 inserted into the first insertion hole 43 in the axial direction. The first protrusion 42 is rectangular parallelepiped-shaped and protrudes radially outward from the outer peripheral surface of the first housing main body 41.

[0028] A first magnetic focusing ring 44 is provided on the first housing main body 41. The first magnetic focusing ring 44 is an arc plate shape that is bent along the inner peripheral surface of the first insertion hole 43. The inner peripheral surface of the first magnetic focusing ring 44 is exposed to the inside of the first insertion hole 43. The first magnetic focusing ring 44 is held at a position corresponding to the first yoke 31 in the axial direction. The first magnetic focusing ring 44 surrounds the periphery of the first yoke 31. The first magnetic focusing ring 44 guides the magnetic flux from the first yoke 31.

[0029] Inside the first protrusion 42, a board-mounted connector 45 is provided. The first end of the board-mounted connector 45 is exposed to the outside. The first end is the end of the board-mounted connector 45 on the side opposite to the first housing main body 41 in the radial direction. The board-mounted connector 45 holds a plurality of electric wires 46. The electric wires 46 are, for example, coated wires in which a core wire is covered with an insulator. The plurality of electric wires 46 are arranged at intervals in a direction orthogonal to the direction in which the first protrusion 42 protrudes. The first ends of the electric wires 46 are pulled out from the first end of the board-mounted connector 45 to the outside. The first ends are connected to external devices. The external devices are, for example, control devices of a steering device.

[0030] In addition, the first magnetic focusing ring 44 and the board-mounted connector 45 are integrally provided with the first sensor housing 40 by insert molding. Insert molding is a molding technique in which an insert is installed in an open mold, and then the mold is closed and injection molding is performed. The first sensor housing 40 is an insert molded product. The first magnetic focusing ring 44 and the board-mounted connector 45 are inserts.

[0031] The second sensor housing 50 is a resin molded product. The second sensor housing 50 has a second housing main body 51 and a second protrusion 52. The second housing main body 51 is cylindrical and has a second insertion hole 53 penetrating 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 magnetic yoke 22. The portion of the magnetic yoke 22 provided with the second magnetic yoke 32 is maintained in a state of being inserted into the second insertion hole 53 in the axial direction. The second protrusion 52 is a rectangular flat plate shape and protrudes radially outward from the outer peripheral surface of the second housing main body 51. The second protrusion 52 overlaps the first protrusion 42 in the axial direction.

[0032] A second magnetic focusing ring 54 is provided in the second housing main 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 an arc plate shape bent along the inner peripheral surface of the second insertion hole 53. The inner peripheral 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 held at a position corresponding to the second magnetic yoke 32 in the axial direction. The second magnetic focusing ring 54 surrounds the periphery of the second magnetic yoke 32. The second magnetic focusing ring 54 guides the magnetic flux from the second magnetic yoke 32.

[0033] <Supplementary description of the detection unit 23>

[0034] As Figure 2As shown, the first protruding portion 42 has a substrate accommodating portion 42A. The substrate accommodating portion 42A is axially open. The opening of the substrate accommodating portion 42A is closed by the second protruding portion 52. Two first magnetic flux concentrating protrusions 44A are exposed inside the substrate accommodating portion 42A. The first magnetic flux concentrating protrusion 44A is a part of the first magnetic flux concentrating ring 44. The first magnetic flux concentrating protrusion 44A protrudes outward from the peripheral wall of the first housing body 41. In addition, the pin portions 48A of a plurality of terminals 48 described later are arranged inside the substrate accommodating portion 42A. The terminal 48 is attached to the second end portion of the electric wire 47. The pin portion 48A extends axially. A plurality of pin portions 48A are arranged in a row along the long side direction of the substrate accommodating portion 42A.

[0035] The substrate 47 is accommodated inside the substrate accommodating 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, and are, for example, Hall sensors. The rotation angle of the rotating shaft 11 is a physical quantity related to the rotational movement 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.

[0036] Although not shown in the figure, the second magnetic flux concentrating ring 54 is the same as the first magnetic flux concentrating ring 44 and has two second magnetic flux concentrating protrusions. The second magnetic flux concentrating protrusions are arranged along the surface of the second protruding portion 52 on the side facing the substrate accommodating portion 42A. The second magnetic flux concentrating protrusions protrude outward from the peripheral wall of the second housing body 51. The second magnetic flux concentrating protrusions are axially opposed to the first magnetic flux concentrating protrusions 44A. The first magnetic sensor 47A and the second magnetic sensor 47B are respectively sandwiched between the first magnetic flux concentrating protrusions 44A and the second magnetic flux concentrating protrusions. The first magnetic sensor 47A detects the magnetic flux guided by the first magnetic flux concentrating ring 44. The second magnetic sensor 47B detects the magnetic flux guided by the second magnetic flux concentrating ring 52.

[0037] By applying a torque to the input shaft 12, the torsion bar 13 is torsionally 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 positions of the permanent magnet 21 and the first magnetic yoke 31 in the rotational direction change. Therefore, the magnetic flux guided by the first magnetic flux concentrating ring 44 from the permanent magnet 21 through the first magnetic yoke 31 changes. In addition, the relative positions of the permanent magnet 21 and the second magnetic yoke 32 in the rotational direction change. Therefore, the magnetic flux guided by the second magnetic flux concentrating ring 54 from the permanent magnet 21 through the second magnetic yoke 32 changes.

[0038] The first magnetic sensor 47A and the second magnetic sensor 47B respectively generate electrical signals corresponding to the magnetic flux leaking between the first magnetic concentrating protrusion 44A of the first magnetic concentrating ring 44 and the second magnetic concentrating protrusion of the second magnetic concentrating ring 54. The electrical signals vary according to the torsional deformation of the torsion bar 13, that is, the torsional angle of the torsion bar 13. For example, the control device of the steering 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. The torque is a physical quantity related to the rotational motion of the rotating shaft 11.

[0039] <Structure of the board - mounted connector 45>

[0040] Next, the structure of the board - mounted connector 45 will be described in detail.

[0041] As Figure 3 shown, the board - mounted connector 45 has a housing 60 and a cover 70. The housing 60 and the cover 70 are combined with each other. By being clamped between the housing 60 and the cover 70, the second end of the electric wire 46 is held. The terminal 48 is housed inside the board - mounted connector 45. The pin portion 48A protrudes from the surface of the housing 60 where the cover 70 is installed. The first end (not shown) of the electric wire 46 is pulled out to the outside of the board - mounted connector 45.

[0042] As Figure 4 shown, the housing 60 is a rectangular parallelepiped - shaped 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.

[0043] The first wire - clamping portion 61 is flat - plate - shaped. The first wire - clamping portion 61 has a plurality of first guide grooves 61A. The first guide grooves 61A are arc - surface - 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 electric wire 47.

[0044] The terminal - holding portion 62 has a plurality of partition walls 62A. The partition walls 62A are arranged corresponding to the first guide grooves 61A. The partition wall 62A has a first wall portion and a second wall portion. The first wall portion is a wall extending along 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 along the long - side direction of the housing 60. The partition wall 62A forms a terminal insertion portion 62B. The terminal insertion portion 62B is a rectangular parallelepiped - shaped space portion extending along 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.

[0045] The exposed portion 63 has an opening 63A and a plurality of positioning grooves 63B. The opening 63A extends along the long side direction of the housing 60. The inside of the opening 63A communicates with each terminal insertion portion 62B of the terminal holding portion 62. The positioning grooves 63B are provided on the inner side surface of the opening 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 cut groove that opens in the direction of the opening 63A and the protruding direction of the partition 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.

[0046] As Figure 4 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.

[0047] The covering portion 71 is a portion for covering the terminal holding portion 62 of the housing 60. The covering portion 71 is in an L-shaped plate form. The covering portion 71 has a flat plate-shaped first portion and a flat plate-shaped second portion. The first portion is the 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 the portion of the covering portion 71 for covering the side surface of the terminal holding portion 62 on the side opposite to the opening 63A.

[0048] The covering portion 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 in the first row penetrate the first portion of the covering portion 71 in the thickness direction. The resin inflow holes 71A in the second row are provided at the corners of the covering portion 71. The corners are the portions where the first portion and the second portion intersect. The resin inflow holes 71A in the second row penetrate the first portion and the second portion of the covering portion 71 in the same direction as the resin inflow holes 71A in the first row.

[0049] The covering portion 71 has 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 covering portion 71 that are opposite to each other in the long side direction. The first arm portion 71B and the second arm portion 71C are flat plate-shaped and extend along the mounting direction of the cover 70. Claw portions (not shown) are provided at the front ends of the first arm portion 71B and the second arm portion 71C.

[0050] 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 it and the first wire clamping portion 61. The second wire clamping portion 72 is in the shape of a rectangular flat plate. The second wire clamping portion 72 has a plurality of second guide grooves 72A. The second guide grooves 72A are grooves in the shape of an arc surface 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 positions corresponding to the first guide grooves 61A of the housing 60.

[0051] The second wire clamping portion 72 has a third arm portion 72B and a fourth arm portion 72C. The third arm portion 72B and the fourth arm portion 72C are arranged at two side edge portions of the second wire clamping portion 72 that are opposite to each other in the long side direction. The third arm portion 72B and the fourth arm portion 72C are in the shape of flat plates and extend along 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.

[0052] <Structure of the terminal 48>

[0053] Next, the structure of the terminal 48 will be described in detail.

[0054] As Figure 5 shown, the terminal 48 is formed, for example, by plastically deforming a metal plate material stamped into a specified shape. The terminal 48 has a pin portion 48A, a connection portion 48B, and a linking portion 48C.

[0055] The pin portion 48A is provided at the first end portion of the terminal 48. The pin portion 48A is in the shape of a rod. The pin portion 48A is formed, for example, by plastically deforming a part of the metal plate material corresponding to the pin portion 48A into the shape of a cylinder having a circular cross-sectional shape.

[0056] The connection portion 48B is provided at the second end portion of the terminal 48. The second end portion is the end portion of the terminal 48 on the side opposite to the first end portion. The connection portion 48B is the portion of the terminal 48 to which the second end portion of the wire 46 is connected. At the second end portion of the wire 46, the core wire is exposed from the covering layer. By riveting a part of the connection portion 48B so as to surround the exposed core wire, the connection portion 48B and the wire 46 are connected. The connection portion 48B has a flat portion. The flat portion is the portion of the connection portion 48B in the shape of a flat plate that extends along the core wire exposed from the riveted portion of the connection portion 48B.

[0057] The linking portion 48C is the middle portion of the terminal 48 that links the pin portion 48A and the connection portion 48B.

[0058] As Figure 6 shown, the linking portion 48C has a linking portion main body 81 and a protruding portion 82.

[0059] The connecting portion main body 81 is in the shape of a rectangular flat plate. The short side of the connecting portion main body 81 extends along the pin portion 48A. The long side of the connecting portion main body 81 extends in a direction orthogonal to the pin portion 48A. The first end portion of the connecting portion main body 81 in the long side direction is connected to the base end portion of the pin portion 48A. The first corner portion is formed by the pin portion 48A and the connecting portion main body 81. The second end portion of the connecting portion main 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 main body 81, the connecting portion main 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 portion is formed by the connecting portion main body 81 and the connecting portion 48B.

[0060] The protruding portion 82 protrudes to the side of the connecting portion main body 81. The protruding portion 82 has a cylindrical shape that extends in the long side direction of the connecting portion main body 81 and has a polygonal cross-sectional shape. The protruding portion 82 has a first protruding piece 83 and a second protruding piece 84.

[0061] The first protruding piece 83 is provided on the first long side of the connecting portion main body 81. The first protruding piece 83 has a first wall portion and a second wall portion. The first wall portion is in the shape of a rectangular plate. The first wall portion is orthogonal to the connecting portion main body 81. The second wall portion is in the shape of a rectangular plate. The second wall portion is connected to the end portion of the first wall portion on the side opposite to the connecting portion main body 81. The second wall portion is parallel to the connecting portion main body 81.

[0062] The first wall portion has a protruding portion 83A. The protruding portion 83A is in the shape of a rectangular plate. The protruding portion 83A is formed by cutting and bending. That is, by providing cuts corresponding to three sides of the protruding portion 83A in the first wall portion and bending the remaining portion after cutting, the protruding portion 83A is formed. The bending direction is the direction opposite to the second wall portion. The protruding portion 83A opens to the side opposite to the pin portion 48A.

[0063] The second protruding piece 84 is provided 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 protruding piece 83 in the long side direction. The second protruding 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 portion of the third wall portion on the side opposite to the connecting portion main body 81. The fourth wall portion is parallel to the connecting portion main body 81. The end portion of the fourth wall portion on the side opposite to the third wall portion is maintained in a state of being in contact with the end portion of the second wall portion on the side opposite to the first wall portion throughout its entire length.

[0064] As Figure 7As shown, when viewed in the direction from the connecting portion 48B toward the pin portion 48A, the protruding portion 82 has a closed loop shape. The shape of the loop is a quadrilateral. A cylinder is formed by the first protruding piece 83 and the second protruding piece 84. The cylinder has a polygonal cross-sectional shape. In addition, Figure 7 shows the connecting portion 48B before riveting.

[0065] As Figure 5 shown, when viewed in the direction orthogonal 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 in which two right-angled curves are alternately connected. The first corner portion formed by the pin portion 48A and the connecting portion main body 81, and the second corner portion formed by the connecting portion main body 81 and the connecting portion 48B are portions of the terminal 48 corresponding to the right-angled curves.

[0066] <Assembly Steps of the Board Mount Connector 45>

[0067] Next, the assembly steps of the board mount connector 45 will be described.

[0068] As Figure 4 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 movement of the pin portion 48A in the long side direction of the housing 60 is restricted by the contact of the pin portion 48A with the inner side surface of the positioning groove 63B. 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 side facing the opening portion 63A.

[0069] The claw portions of the first arm portion 71B, the second arm portion 71C, the third arm portion 72B, and the fourth arm portion 72C of the cover 70 are elastically engaged with a part of the housing 60 in the direction opposite to the mounting direction. Thereby, the detachment of the cover 70 from the housing 60 is suppressed. The cover 70 is maintained in a state mounted on the housing 60. Thus, the assembly operation of the board mount connector 45 is completed.

[0070] <Assembly State of the Board Mount Connector 45>

[0071] Next, the assembly state of the board mount connector 45 will be described.

[0072] As Figure 3As shown, in a state where 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 toward the side opposite to the mounting direction of the cover 70. The opening portion 63A and the terminal holding portion 62 of the housing 60 are covered by the covering portion 71. However, the opening portion 63A and the terminal insertion portion 62B are open to the outside through the resin inflow hole 71A of the cover 70.

[0073] In a state where 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 portion 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 portion of the wire 46 in the long side direction of the board-mounted connector 45 is restricted. The second end portion of the wire 46 is held at a determined position.

[0074] The housing 60 corresponds to the first holding member, and the cover 70 corresponds to the second holding member.

[0075] <Manufacturing Method of the First Sensor Housing 40>

[0076] Next, the manufacturing method of the first sensor housing 40 will be described.

[0077] First, the first magnetic focusing ring 44 and the board-mounted connector 45, which are inserts, are placed in an open mold. The board-mounted connector 45 is in a state of holding the wire 46. After that, the mold is closed and injection molding is performed. In a state where the mold is closed, a cavity is formed inside the mold. The cavity is a space corresponding to the outer shape of the first sensor housing 40.

[0078] Next, molten resin is injected into the cavity. The molten resin is a synthetic resin that is heated and melted. Inside the mold, the first magnetic focusing ring 44 is surrounded by the molten resin except for its inner peripheral surface. The board-mounted connector 45 is surrounded by the molten resin at least except for the first end portion. The molten resin also flows into the terminal insertion portion 62B and the opening portion 63A through the resin inflow hole 71A of the cover 70. That is, the resin inflow hole 71A is configured to introduce the molten resin into the inside of the terminal holding portion 62.

[0079] After filling the cavity with the molten resin, the filled molten resin is cooled and solidified. After that, the mold is opened, and the first sensor housing 40, which is a resin molded product, is taken out. Thus, Figure 2 the first sensor housing 40 shown, that is, the first sensor housing 40 in which the first magnetic focusing ring 44 and the board-mounted connector 45 are embedded, is obtained.

[0080] Above, the manufacturing of the first sensor housing 40 is completed.

[0081] As Figure 8As 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 joined to the substrate 47 by solder 47D. The pin portion 48A and the pattern wiring of the substrate 47 are electrically connected.

[0082] <State of the inside of the board-mounted connector 45>

[0083] The state of the inside of the board-mounted connector 45 is as described below.

[0084] As Figure 8 shown, inside the board-mounted connector 45, the periphery of the connecting portion 48C of the terminal 48 is covered with synthetic resin. That is, synthetic resin is filled in the opening 63A of the housing 61 and each terminal insertion portion 62B. Synthetic resin is also filled inside the protruding portion 82. In addition, the gap between the connecting portion 48C and the partition wall 62A (see Figure 4 ) is filled with synthetic resin. The gap 62C between two adjacent partition walls 62A in the longitudinal direction of the housing 61 is also filled with synthetic resin (see Figure 4 ). The protrusion 83A enters the synthetic resin. The entering direction is the direction opposite to the insertion direction of the terminal 48 with respect to the terminal insertion portion 62B. By filling the periphery of the connecting portion 48C with resin without gaps, the terminal 48 is held inside the terminal insertion portion 62B. Figure 8 The state where the board-mounted connector 45 and the synthetic resin filled inside the board-mounted connector 45 are assumed to be extracted is shown. At least the synthetic resin portion 40A that covers the periphery of the connecting portion 48C of the terminal 48 is a part of the first sensor housing 40.

[0085] The first sensor housing 40 corresponds to a resin member that covers the periphery of the connecting portion 48C of the terminal 48, as well as the peripheries of the housing 60 and the cover 70. The connecting portion 48C is the portion of the terminal 48 held inside the terminal holding portion 62.

[0086] <Supplementary explanation of the board-mounted connector 45>

[0087] There are concerns about the sensor device 10 as follows. That is, there is a concern that when the first sensor housing 40 is injection-molded, the molten resin protrudes to an unwanted part. For example, when the first sensor housing 40 is injection-molded, there is a concern that the molten resin flowing in through the resin inflow hole 71A of the cover 70 flows into the inside of the positioning groove 63B via the terminal insertion portion 62B and the opening 63A. In this case, there is a concern that the molten resin flowing into the positioning groove 63B overflows onto the surface of the exposed portion 63 on the side opposite to the mounting direction of the cover 70, that is, the side where the pin portion 48A protrudes.

[0088] Therefore, in the present embodiment, the following structure is adopted for the board-mounted connector 45.

[0089] As Figure 9 shown, the cover 70 has a plurality of blocking protrusions 73. The number of the blocking protrusions 73 is set to be the same as that of the terminal insertion portions 62B. The blocking protrusions 73 are provided on the inner surface of the covering portion 71. The blocking protrusions 73 are provided on the side edge of the covering portion 71 on the side opposite to the second wire clamping portion 72 in the short side direction. The blocking protrusions 73 are arranged in a row at intervals in the long side direction of the covering portion 71. The long side direction of the covering portion 71 is also the long side direction of the cover 70. The blocking protrusions 73 protrude from the inner surface of the covering portion 71 in the mounting direction of the cover 70. The protruding height of the blocking protrusions 73 from the inner surface of the covering portion 71 is the same as the depth of the opening portion 63A in the thickness direction of the housing 61.

[0090] The blocking protrusion 73 has a crank-shaped cross-sectional shape. The blocking protrusion 73 has a first fitting portion 73A and a second fitting portion 73B. The first fitting portion 73A and the second fitting portion 73B are respectively rectangular parallelepiped-shaped. The long sides of the first fitting portion 73A and the second fitting portion 73B respectively extend along the long side direction of the covering portion 71. The first fitting portion 73A and the second fitting portion 73B are connected with a stagger in the long side direction of the covering portion 71. The corner portion of the first fitting portion 73A on the side connected to the second fitting portion 73B is the first corner of the crank. The corner portion of the second fitting portion 73B on the side connected to the first fitting portion 73A is the second corner of the crank. The first fitting portions 73A are arranged in a row at intervals in the long side direction of the covering portion 71. The second fitting portions 73B are arranged in a row at intervals in the long side direction of the covering portion 71.

[0091] In the short side direction of the covering portion 71, the length of the connecting portion between the first fitting portion 73A and the second fitting portion 73B is, for example, the same as the length of the opening portion 63A in the short side direction of the housing 61. The plurality of blocking protrusions 73 can be inserted into the opening portion 63A. Among two adjacent blocking protrusions 73 in the long side direction of the covering portion 71, the first fitting portion 73A of one blocking protrusion 73 and the second fitting portion 73B of the other blocking protrusion 73 are separated from each other by a distance corresponding to the thickness of the connecting portion main body 81 of the terminal 48.

[0092] As Figure 10 shown, among two adjacent blocking protrusions 73 in the long side direction of the covering portion 71, the connecting portion main body 81 of the terminal 48 can be clamped between the first fitting portion 73A of one blocking protrusion 73 and the second fitting portion 73B of the other blocking protrusion 73. The length of the blocking protrusion 73 in the long side direction of the covering portion 71 is the same as the distance between two adjacent connecting portion main bodies 81. The blocking protrusion 73 can be clamped between two adjacent connecting portion main bodies 81. Figure 10Shows the state of observing the cover 70 from the inside and the state in which the terminal 48 is temporarily mounted on the cover 70.

[0093] As Figure 11 shown, the opening 63A has a plurality of narrow-width portions 63C. The width of the narrow-width portion 63C is the same as the width of the second fitting portion 73B of the blocking projection portion 73. The width is the length in the insertion direction of the terminal 48. The second fitting portion 73B can be fitted with the narrow-width portion 63C. The width of the opening 63A other than the narrow-width portion 63C is the same as the width of the widest portion of the blocking projection portion 73, that is, the width of the connecting portion between the first fitting portion 73A and the second fitting portion 73B. Figure 11 Shows the state of observing the board-mounted connector 45 from the opposite side of the cover 70 and the state after cutting near the end wall inside the opening 63A.

[0094] The narrow-width portion 63C is formed on the end wall inside the opening 63A by providing a low-back projection portion 63D. The end wall is a plane extending in a direction orthogonal to the depth direction of the opening 63A. The height of the low-back projection portion 63D from the end wall is such that the low-back projection portion 63D does not protrude from the opening 63A. The protruding amount of the low-back projection portion 63D can also be very small. The narrow-width portions 63C are arranged at intervals in the arrangement direction of the terminals 48. The arrangement interval of the narrow-width portions 63C is also the arrangement interval of the low-back projection portions 63D. The interval is the same distance as the length obtained by adding the length of the first fitting portion 73A in the arrangement direction of the terminals 48 and the thickness of the connecting portion main body 81 of the terminals 48. The side surface of the connecting portion main body 81 of the terminal 48 contacts the first wall portion of the partition wall 62A. The first fitting portion 73A can be fitted between the low-back projection portion 73C and the connecting portion main body 81.

[0095] <Function of the Embodiment>

[0096] The present embodiment achieves the following functions.

[0097] As Figure 11 shown, after the installation operation of the terminal 48 relative to the housing 60 is completed, the cover 70 is mounted on the housing 60. When the cover 70 is mounted on the housing 60, the blocking projection portion 73 is inserted into the opening 63A of the housing 60. As a result, the first fitting portion 73A of the blocking projection portion 73 is fitted between the connecting portion main body 81 of the terminal 48 and the low-back projection portion 63D. In addition, the second fitting portion 73B of the blocking projection portion 73 is fitted with the narrow-width portion 63C.

[0098] When the front end of the blocking projection 73 abuts against the inner end wall of the opening 63A, the claw portions of the respective arm portions (71B, 71C, 72B, 72C) of the cover 70 elastically engage with a part of the housing 60 in a direction opposite to the mounting direction of the cover 70. Thereby, the cover 70 is fixed to the housing 60, and the assembly operation of the board-mounted connector 45 is completed.

[0099] In a state where the board-mounted connector 45 is assembled, the side surface of the first fitting portion 73A on the side opposite to the low-back projection 63D is maintained in contact with the side surface of the connection portion main body 81. The side surface of the second fitting portion 73B is maintained in contact with the side surface of the connection portion main body 81 of another terminal 48 adjacent to the terminal 48 in contact with the first fitting portion 73A. The blocking projection 73 is sandwiched between the connection portion main bodies 81 of two adjacent terminals 48. The connection portion main body 81 is clamped by two adjacent blocking projections 73. The connection portion main body 81 is clamped by the first fitting portion 73A of the blocking projection 73 and the second fitting portion 73B of another blocking projection 73.

[0100] In two adjacent blocking projections 73, the end portion of the first fitting portion 73A of one blocking projection 73 and the end portion of the second fitting portion 73B of the other blocking projection 73 sandwich the connection portion main body 81 of the terminal 48 at two positions different from each other in the insertion direction of the terminal 48 in the thickness direction. That is, in two adjacent blocking projections 73, the end portion of the first fitting portion 73A of one blocking projection 73 and the end portion of the second fitting portion 73B of the other blocking projection 73 are arranged so as not to face each other across the connection portion main body 81.

[0101] The end portion of the first fitting portion 73A corresponds to the end portion of the blocking projection 73 on the side opposite to the second fitting portion 73B in the arrangement direction of the terminals 48, that is, the first contact end. The end portion of the second fitting portion 73B corresponds to the end portion of the blocking projection 73 on the side opposite to the first fitting portion 73A in the arrangement direction of the terminals 48, that is, the second contact end.

[0102] As Figure 12 shown, in a state where the board-mounted connector 45 is assembled, the path between the terminal holding portion 62 and the pin portion 48A is blocked by the blocking projection 73 and the connection portion main body 81 of the terminal 48. The path is the part in the internal space of the board-mounted connector 45 from the terminal insertion portion 62B to the positioning groove 63B (refer to Figure 4 ). The connection portion main body 81 is a part of the terminal 48.

[0103] When the first sensor housing 40 is injection-molded, the molten resin flows into the inside of the terminal insertion portion 62B through the resin inflow hole 71A of the cover 70. However, the molten resin flowing in the direction from the terminal insertion portion 62B toward the opening portion 63A is blocked by the first fitting portion 73A of the blocking protrusion 73. Therefore, the situation where the molten resin flows into the inside of the positioning groove 63B through the opening portion 63A is suppressed.

[0104] In addition, terminals 48 can also not be sandwiched at several positions between two adjacent blocking protrusions 73. Since the terminal insertion portion 62B is not formed at this position, the molten resin does not initially flow toward the positioning groove 63B.

[0105] Due to the dimensional tolerance of the cover 70 or the dimensional tolerance of the housing 60, a minute gap is sometimes formed between the outer side surface of the second fitting portion 73B on the side away from the terminal insertion portion 62B and the inner side surface of the opening portion 63A on the side away from the terminal insertion portion 62B.

[0106] Regarding this point, when the first sensor housing 40 is injection-molded, the pressure of the molten resin acts on the blocking protrusion 73. The direction of the pressure is the same as the flow direction FD of the molten resin, for example, the direction from the terminal insertion portion 62B toward the opening portion 63A. The blocking protrusion 73 is pressed in the flow direction FD of the molten resin due to the pressure of the molten resin. Therefore, in the flow direction FD of the molten resin, the second fitting portion 73B of the blocking protrusion 73 is pressed against the inner side surface of the opening portion 63A on the side away from the terminal insertion portion 62B.

[0107] As a result, in the flow direction FD of the molten resin, the outer side surface of the second fitting portion 73B on the side away from the terminal insertion portion 62B and the inner side surface of the opening portion 63A on the side away from the terminal insertion portion 62B are in close contact with each other. Therefore, the situation where the molten resin flows into the inside of the positioning groove 63B through the opening portion 63A is suppressed.

[0108] In addition, the inner side surface of the opening portion 63A on the side away from the terminal insertion portion 62B is a part of the insertion direction of the terminal 48 of the housing 60.

[0109] <Effect of the Embodiment>

[0110] The present embodiment achieves the following effects.

[0111] (1) The blocking protrusion 73 is disposed at a position close to the pin portion 48A with respect to the resin inflow hole 71A. In other words, the blocking protrusion 73 is disposed between the resin inflow hole 71A and the pin portion 48A. The terminal holding portion 62 and the pin portion 48A are mutually blocked by the blocking protrusion 73 and the connecting portion main body 81 of the terminal 48. During the injection molding of the first sensor housing 40, the molten resin flowing in the direction from the terminal insertion portion 62B toward the opening portion 63A is blocked by the blocking protrusion 73. Therefore, the situation where the molten resin flows into the positioning groove 63B through the opening portion 63A is suppressed. Accordingly, the situation where the molten resin protrudes to an undesired portion can be suppressed.

[0112] (2) The blocking member 73 is clamped between two adjacent terminals 48 without a gap. Therefore, during the injection molding of the first sensor housing 40, the molten resin flowing in the direction from the terminal insertion portion 62B toward the opening portion 63A can be appropriately blocked by the blocking protrusion 73.

[0113] (3) Two adjacent blocking protrusions 73 hold the connecting portion main body 81 of one terminal 48 at two positions different from each other in the insertion direction of the terminal 48. That is, among the two adjacent blocking protrusions 73, the first fitting portion 73A of one blocking protrusion 73 and the second fitting portion 73B of the other blocking protrusion 73 do not face each other across the connecting portion main body 81. Since the cover 70 does not have a gap portion corresponding to the thickness of the connecting portion main body 81, the production of the mold is easy. Therefore, the cover 70 as a resin molded product can be easily molded.

[0114] In addition, a structure is considered in which the blocking protrusion 73 is provided as a single rectangular parallelepiped shape, and two adjacent blocking protrusions 73 in the arrangement direction of the terminals 48 face each other across the connecting portion main body 81. In this case, between the two adjacent blocking protrusions 73, a minute gap corresponding to the thickness of the connecting portion main body 81 needs to be provided between one blocking protrusion 73 and the other blocking protrusion 73. It is time-consuming to provide a minute shape portion corresponding to the minute gap in the mold.

[0115] (4) During the injection molding of the first sensor housing 40, the second fitting portion 73B of the blocking protrusion 73 is pressed against the inner surface of the opening portion 63A on the side away from the terminal insertion portion 62B due to the pressure of the molten resin. Therefore, the outer surface of the second fitting portion 73B on the side away from the terminal insertion portion 62B and the inner surface of the opening portion 63A on the side away from the terminal insertion portion 62B are in close contact. Accordingly, the situation where the molten resin flows into the positioning groove 63B through the opening portion 63A can be suppressed.

[0116] (5) The synthetic resin is filled into each terminal insertion portion 62B of the housing 61 without any gap. Therefore, dust and the like are prevented from entering the interior of the on-board connector 45. The dustproof property of the on-board connector 45 can be improved.

[0117] <Other embodiments>

[0118] This embodiment can also be implemented by changing as follows.

[0119] The blocking protrusion 73 may also be provided in a single rectangular parallelepiped shape. In this case, for example, two adjacent blocking protrusions 73 are arranged so as not to be mutually opposed in the arrangement direction of the terminals 48. That is, the positions of the plurality of blocking protrusions 73 in the insertion direction of the terminals 48 are different from each other. In this way, the cover 70 does not have a gap portion corresponding to the thickness of the connecting portion body 81, so the mold is easy to make.

[0120] The sensor device 10 may also be a rotation angle sensor for detecting 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 substrate storage portion 42A of the first sensor housing 40 supports the two driven gears so that they can rotate. 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 the opening of the 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 are different relative to the rotation angle of the driving gear. 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.

Claims

1. An insert-molded product, comprising: A terminal having a first end provided with a pin portion and a second end on the side opposite to the first end; A first holding member having a terminal holding portion for holding the terminal in a state where the terminal is inserted; A second holding member combined with the first holding member and having a covering portion for covering the terminal holding portion; and A resin member covering the periphery of a part of the terminal located inside the terminal holding portion and the peripheries of the first holding member and the second holding member, The covering portion has: A resin inlet hole configured to introduce molten resin into the inside of the terminal holding portion during molding of the resin member; and A protrusion provided at a position close to the pin portion with respect to the resin inlet hole and combined with the first holding member, The terminal holding portion and the pin portion are mutually blocked by the protrusion and a part of the terminal.

2. The insert-molded product according to claim 1, wherein The terminals are plural and arranged in a direction orthogonal to the insertion direction of the terminals into the terminal holding portion, The protrusions are plural and arranged in the arrangement direction of the terminals, Each of the protrusions is sandwiched between two adjacent terminals.

3. The insert-molded product according to claim 2, wherein Each of the protrusions has a first contact end and a second contact end located on opposite sides in the arrangement direction of the terminals, The first contact end and the second contact end are located at different positions in the insertion direction of the terminals, In two adjacent protrusions in the arrangement direction of the terminals, a part of the terminal is clamped by the first contact end of one protrusion and the second contact end of the other protrusion.

4. The insert-molded product according to claim 2, wherein The protrusion is in close contact with a part of the first holding member in the insertion direction of the terminals.

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

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