Sensor with protector

Abstract

To take a countermeasure against mold falling by eliminating the accumulation of air during molding.SOLUTION: In a protector 30 with a sensor, one-end side of an insert 150 is press-fitted so as to close a space portion 33 provided in a hollow portion 12 attached to a slide door 1, and the other-end side is molded, thick portions 151A, 151B each of which has a cross-sectional shape to be press-fitted into the space portion 33 without a gap and thin portions 151C1, 151C2, 151C3 each of which has a cross-sectional shape to form a gap T1, T2, T3 between itself and the space portion 33, are provided from a terminal of an insertion portion 151 of the insert 150 to the other end. An elongated space KU communicating from a terminal of an extrusion molding portion to an end of the insertion portion 151 is formed by insertion of the insert 150. The thick portion and the thin portion are arranged such that sizes and cross-section setting positions of the gaps T1, T2, T3 in a cross-sectional direction constituting the elongated space KU change from the terminal of the extrusion molding portion to the end of the insertion portion 151.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a protector with a sensor that has a built-in sensor that detects the presence of a foreign object by outputting a corresponding signal when a foreign object such as a finger is caught between an opening and an opening that opens and closes an opening in a vehicle body, such as a sliding door, a back door, or a sunroof that moves forward and backward on the body of a wagon or a minivan. [Background technology]

[0002] Sensor-equipped protectors 10, 20 are installed in automobiles such as station wagons that have a sliding door 1 (or a back door) for opening and closing an opening in the body, as shown in FIG. 7, and in automobiles that have a sunroof 2 for opening and closing an opening in the body, as shown in FIG. 8.

[0003] For example, a protector 10 with a sensor is attached to the front end surface of the sliding door 1 so as to protrude toward the front side of the vehicle body and extend vertically, as shown in FIG. As shown in Figures 10 and 11, the protector with sensor 10 comprises a mounting base 11 having a concave cross-section and consisting of an inner side wall 11a, an outer side wall 11b and a connecting wall 11c, which is attached to a flange F formed on the front end surface of the sliding door 1, and a hollow portion 12 integrally molded therewith. A sensor (pressure-sensitive sensor) S is attached to the hollow portion 12, which detects the entrapment of a foreign object such as a part of the human body (a finger, a hand or a foot) between the sliding door 1 and a body side opening (which may be a front door (side door)) and outputs a corresponding electrical signal (see, for example, Patent Document 1). The outer peripheral surface of the hollow portion 12 is an outer shell 12a having a concave cross section, and both ends 12b, 12c of the outer shell 12a are connected to the left and right sides of the mounting base 11 with a gap between them. At the bottom of the sensor-equipped protector 10, a channel portion 13 having a C-shaped cross section is integrally formed on the vehicle interior side wall 11a of the mounting base 11, and holds a wire harness W connected to the pressure sensor S. A plurality of holding lips 14, 14 are provided on the inside of the mounting base 11, and a core material 15 having a concave cross section is embedded in the mounting base 11 to increase rigidity. Furthermore, a lip-shaped seal portion 16 is provided on the vehicle exterior side wall 11b of the mounting base 11.

[0004] The sensor (pressure sensor) S is configured such that two core wires (electrode wires) 31, 32 extending in the vehicle vertical direction (longitudinal direction) are embedded in conductive rubber-like elastic bodies (conductive parts) 34, 35 provided with a space 33 interposed therebetween and are fixed in the hollow part 12, and when the sliding door 1 is closed and a foreign object is caught between the sliding door 1 and the body side opening, the hollow part 12 is partially pressed and crushed, and the rubber-like elastic bodies 34, 35 come into contact with each other, shorting the two core wires 31, 32. Then, as shown in Figs. 9 and 15, this change in electrical signal is transmitted to the control device 40 connected to the lead wires 36, 36 connected to the two core wires 31, 32 at the lower terminal part L of the sensor-equipped protector 10, thereby detecting the presence of the foreign object. The lead wires 36, 36 are covered with an insulator and bundled together by the wire harness W, but the ends on the lower terminal portion L side are bare wires exposed from the covering portions 37, 37.

[0005] Also, as shown in Figures 10 and 11, the rubber-like elastic body (conductive portion) 34, 35 consists of a concave-shaped hollow upper conductive portion 34 and a convex-shaped hollow lower conductive portion 35, and in order to expand the detection range of the sensor (pressure sensor) S, the space portion 33 is shaped and arranged so that it has a "concave" cross section with the same cross section width and the opening of the "concave" shape faces the mounting base 11 side.

[0006] At the upper terminal U of the sensor-equipped protector 10, as shown in Fig. 9 and Fig. 12, two legs 39a, 39b of the resistor 39 are overlapped and connected by resistance welding or soldering to two core wires 31, 32 drawn out in the longitudinal direction (to the right in Fig. 12), and the space 33 shown in Fig. 10 is blocked by the insert 51 of the insert 50 consisting of the insert 51 on one end side and the insulating part 60 protruding from the other end side as shown in Fig. 13 and Fig. 14, and then the connection parts M1, M2 (painted black here), the insert 50 and the resistor 39 shown in Fig. 12 are covered with a molding material K by molding (for example, Patent Document 1). Note that the molding parts are shown by dotted lines in Fig. 12.

[0007] 15, the lower terminal L of the sensor-equipped protector 10 shown in Fig. 9 is made up of a support 82A having a small groove 83 formed on a front side 82Aa in which connection parts M3, M4 are accommodated, in which the lead wire 36 exposed from the wire harness W bundling the covering part 37 is overlapped with the two core wires 31, 32 drawn out in the longitudinal direction (downward in Fig. 15) and connected by resistance welding or soldering, and a cover 82B that covers the support 82A. The front side 82Aa of the insulating part 82 is substantially H-shaped. 15 and 16, the space 33 shown in FIG. 11 is closed with the insert 81 of the insert 80, which is made up of an insert 81 on one end side, a support 82A protruding on the other end side, and an insulating part 82 of a lid 82B covering it, and then molded as shown in FIG. 15, so that the connection parts M3 and M4 (painted black here), the insert 80, and a part of the wire harness W are covered with a molding material K (for example, Patent Document 2). The cross-sectional shape of the insert 81 is the same as that in FIG. 14, and corresponds to the shape of the space 33 formed in the hollow part 12 shown in FIG. 11. In FIG. 15, the molded part is indicated by a dotted line. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] JP 2023-8811 A [Patent Document 2] Patent Publication No. 2021-172165 Summary of the Invention [Problem to be solved by the invention]

[0009] However, in the upper terminal portion U of the sensor-equipped protector 10 shown in Figure 9, as shown in Figures 12 and 17, the insertion portion 51 of the insert 50 is pressed into the space 33 formed in the hollow portion 12 without any gaps, so when the connection portions M1, M2, the insert 50, and the resistor 39 are molded, the air has no place to escape near the end of the extrusion molded portion O and may end up accumulating inside the molded portion. If air accumulates inside, the molding material K will not reach the end of the extrusion molding part O, and voids will occur, making it impossible to ensure airtightness, resulting in a defective product and reduced productivity (commonly known as out-of-date).

[0010] This is not limited to the upper terminal part U of the sensor-equipped protector 10, but is also the same for the lower terminal part L shown in Figures 9 and 15, and since the insertion part 81 of the insert 80 is press-fitted into the space part 33 formed in the hollow part 12 without any gaps, when the connection parts M3, M4, the insert 80, and a part of the wire harness W are molded, there is a case where the air has no escape route near the end of the extrusion molded part O and accumulates inside the molded part. If air accumulates inside, the molding material K does not reach the end of the extrusion molded part O, and voids are generated, making it impossible to ensure airtightness, resulting in a problem of reduced productivity due to defective products (commonly known as "out-of-date").

[0011] SUMMARY OF THE PRESENT EMBODIMENT An object of the present invention is to provide a protector with a sensor which prevents air from collecting during molding, thereby preventing the mold from becoming out of date. [Means for solving the problem]

[0012] In order to achieve the above object, the protector with a sensor of the present invention comprises an attachment base (11) that is attached to the periphery of an opening / closing object (1, 2) that opens and closes an opening in a vehicle body or to the periphery of the opening, and a tubular hollow portion (12) that is integrally extrusion-molded with the attachment base (11) on an upper portion of the mounting base (11) and in which two conductive portions (34, 35) consisting of a hollow upper conductive portion (34) and a hollow lower conductive portion (35) in which two core wires (31, 32) are embedded are provided via a space (33), and when the opening / closing object (1, 2) is closed, a foreign object caught between the opening / closing object (1, 2) and the opening presses and crushes the hollow portion (12), thereby detecting the presence of the foreign object by a corresponding change in an electrical signal; a protector with a sensor (30) in which the core wires (31, 32) are pulled out in the longitudinal direction from an end portion of the extrusion-molded portion (O) and an insertion portion (151, 181) on one end side of an insert (150, 180) made of a non-conductive material is pressed in so as to close a space (33) at the end portion of the extrusion-molded portion (O), and the core wires (31, 32) pulled out in the longitudinal direction and the insert (50) are both covered with a molding material (K), a cross-sectional shape of the insertion portion (151, 181) of the insert (150, 180) from the very end toward the other end, in which a thick portion (151A, 151B) having a cross-sectional shape large enough to be pressed into the space portion (33) without a gap and a thin portion (151C1, 151C2, 151C3) having a cross-sectional shape large enough to form a gap (T1, T2, T3) between the insertion portion (151, 181) and the space portion (33) are provided, and an elongated space (KU) communicating from the terminal of the extrusion molding portion to the very end of the insertion portion (151, 181) is formed by inserting the insert (150, 180), The thick portions (151A, 151B) and the thin portions (151C1, 151C2, 151C3) are arranged so that the size and cross-sectional setting position of the gaps (T1, T2, T3) in the cross-sectional direction that constitute the elongated space (KU) change from the end of the extrusion molding portion to the very end of the insertion portion (151, 181). It should be noted that the "change in the electrical signal" here includes a change caused by a short circuit between two core wires and a change in capacitance.

[0013] In addition, the present invention provides the elongated space (KU), a first gap (T1) formed only on both the left and right sides of the hollow lower conductive portion (35); A second gap (T2) formed only on the top side of the hollow lower conductive portion (35); The hollow lower conductive portion (35) is characterized in that the third gap (T3) formed from the top side thereof to both the left and right sides is configured by repeating the first gap (T1), the third gap (T3), the second gap (T2), and the third gap (T3) multiple times from the end of the extrusion molded portion to the very end of the insertion portion (151, 181) in that order.

[0014] The present invention is also characterized in that, when viewed from the end of the extrusion molding portion to the end side of the insertion portion (151, 181), the first gap (T1) has a portion which overlaps with the third gap (T3), and the second gap (T2) has a portion which overlaps with the third gap (T3).

[0015] In the present invention, the third gap (T3) is formed over the entire periphery of the upper side surface of the hollow lower conductive part (35).

[0016] In the present invention, the core wires (31, 32) are connected to two legs (39a, 39b) of a resistor (39), respectively, and an insulating portion (160) is provided on the other end side of the insert (150) for insulating connection portions (M1, M2) of the two legs (39a, 39b); the other end side of the insert (150) is covered with the molding material (K) together with the insulating portion (160), the core wires (31, 32), the resistor (39), the two legs (39a, 39b), and the connecting portion (M1, M2); The insulating portion (160) is characterized in that it has a flat plate shape.

[0017] In the present invention, the core wires (31, 32) are electrically connected to two lead wires (36, 36) protruding from a covering portion (37) bundled together by a wire harness (W), and an insulating portion (182) is provided on the other end side of the insert (180) for insulating connection portions (M3, M4) of the two lead wires, the other end side of the insert (180) is covered with the mold molding material (K) together with the insulating portion (182), the core wires (31, 32), the two lead wires (36, 36), the connecting portions (M3, M4), and the wire harness (W); The insulating portion (182) on the side of the insertion portion (181) is characterized in that it is formed into a substantially H-shape.

[0018] Note that symbols in parentheses indicate corresponding elements or matters described in the drawings and in the detailed description of the invention described below. Effect of the Invention

[0019] According to the present invention, from the very end of the insertion portion of the insert to the other end, the cross-sectional shape of the insertion portion is provided with a thick portion having a cross-sectional shape large enough to be pressed into the space portion without any gaps, and a thin portion having a cross-sectional shape large enough to form a gap between the space and the thick portion. In addition, by inserting the insert, a narrow space is formed that connects the end of the extrusion molded portion to the very end of the insertion portion, and the thick portion and the thin portion are arranged so that the size of the cross-sectional gap and the cross-sectional setting position that constitutes the narrow space change from the end of the extrusion molded portion to the very end of the insertion portion. Therefore, when the molding material is injected during molding, normally (in the conventional example), the air has no place to escape and accumulates inside the part being molded, but in the present invention, the air flows from the other end side of the insertion portion of the insert to the very end through the long and narrow space that is formed. This prevents air from accumulating inside, allowing the molding material to reach the ends of the extrusion molded part, suppressing the occurrence of voids and ensuring airtightness, thereby preventing the mold from becoming out of date. In addition, the mold molding material will also flow in through the gaps along with the air, but if the size of the gap in the cross-sectional direction that constitutes the elongated space and the cross-sectional setting position are adjusted, for example, by arranging the thick and thin portions so that the positions of the gaps do not overlap in the longitudinal direction from the end of the extrusion molding section to the very end of the insertion section, the mold molding material will be caught in the thick portion and will be prevented from flowing in further.

[0020] According to the present invention, the elongated space is configured such that the first gap formed only on both the left and right sides of the hollow lower conductive part, the second gap formed only on the top side of the hollow lower conductive part, and the third gap formed from the top side of the hollow lower conductive part to both the left and right sides are repeated multiple times in the order of the first gap, the third gap, the second gap, and the third gap from the end of the extrusion molding part to the very end of the insertion part, so that the air passes through the first gap, the third gap, the second gap, and the third gap in that order and flows toward the very end of the insertion part. At this time, the molding material flows from the first gap to the third gap, but is caught by the thick part at the second gap, making it difficult to flow further. Even if the molding material flows through the second gap T2 and flows toward the next stage, the third gap, it is caught by the thick part at the third gap, making it difficult to flow further. In this way, the amount of molding material flowing toward the very end of the insertion part can be gradually reduced.

[0021] In addition, according to the present invention, when viewed from the end of the extrusion molding portion to the end of the insertion portion, the first gap has a portion that overlaps with the third gap, and the second gap is arranged so that it has a portion that overlaps with the third gap, so that air can be reliably and instantly released from the end of the extrusion molding portion to the end of the insertion portion.

[0022] In addition, according to the present invention, the third gap is formed around the entire upper side surface of the hollow lower conductive part, so that by releasing the mold molding material from the narrow space (first gap) to the wide space (third gap), the pressure of the mold molding material can be reduced, and the amount of mold molding material flowing into the next narrow space (second gap) can be reduced.

[0023] In addition, according to the present invention, the other end side of the insert is covered with molding material along with the insulating portion, the core wire, the resistor, the two legs, and the connecting portion, so that it can be applied to a terminal molded portion for a resistor. In addition, according to the present invention, the other end side of the insert is covered with a molded material together with the insulating portion, the core wire, the two lead wires, the connecting portion, and the wire harness, so that it can be applied to a terminal molded portion for a harness. [Brief description of the drawings]

[0024] [Figure 1] Fig. 2 is an enlarged perspective view showing an insert of the protector with a sensor according to the embodiment of the present invention; [Diagram 2] 2 is an enlarged cross-sectional view taken along lines C1-C1 and C2-C2 in FIG. 1. [Diagram 3] 2 are enlarged cross-sectional views taken along lines D1-D1, D2-D2, D3-D3, and D4-D4 in FIG. 1. [Figure 4] 2 is an enlarged cross-sectional view taken along lines E1-E1 and E2-E2 in FIG. 1. [Diagram 5] 5 is a schematic diagram showing the positional relationship of gaps T1, T2, and T3 shown in FIGS. 2 to 4. FIG. [Figure 6] 2 is a side end view showing a state in which an insert of the protector with sensor according to the embodiment of the present invention shown in FIG. 1 is inserted into a hollow portion. FIG. [Figure 7] FIG. 1 is a side view of an automobile that opens and closes with a sliding door. [Figure 8] FIG. 1 is a perspective view of an automobile equipped with a sunroof. [Figure 9] FIG. 8 is a side view showing the protector with the sensor shown in FIG. 7. [Figure 10] FIG. 10 is an enlarged cross-sectional view taken along line AA in FIG. [Figure 11] FIG. 10 is an enlarged cross-sectional view taken along line BB in FIG. [Figure 12] FIG. 13 is a perspective view showing an outline of the configuration of the upper terminal portion of the protector with the sensor after molding. [Figure 13]FIG. 13 is an enlarged perspective view showing an insert of a protector with a sensor according to a conventional example. [Figure 14] 14 is a cross-sectional view taken along line XX in FIG. 13. [Figure 15] FIG. 13 is a perspective view showing an outline of the configuration of the lower terminal portion of the protector with the sensor after molding. [Figure 16] 16 is a cross-sectional view taken along line YY in FIG. 15. [Figure 17] FIG. 14 is a side end view showing a state in which the insert of the protector with sensor according to the conventional example shown in FIG. 13 is inserted into a hollow portion. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] A protector with a sensor 30 according to an embodiment of the present invention will be described with reference to the drawings. The protector with sensor 30 according to the embodiment of the present invention is attached to the front end surface of the sliding door 1 of an automobile in which an opening of the vehicle body is opened and closed by the sliding door 1 as shown in FIG. 7 so as to protrude toward the front side of the vehicle body, and is equipped with a sensor (pressure sensor) S that detects a foreign object such as a part of the human body (a finger or a hand or foot) being caught between the sliding door 1 and the body side opening (which may be a front door (side door)) and outputs a corresponding electric signal. The extrusion molding part O shown in FIGS. 9 to 11 has the same configuration as that shown in the conventional example, but the configuration (shape) of the insert 150 is different from that of the insert 50 shown in the conventional example. The same parts as those in the conventional example are given the same reference numerals. Here, the "change in the electric signal" includes a change caused by a short circuit between the two core wires 31 and 32 and a change in capacitance.

[0026] 10 and 11, the protector with sensor 30 includes a mounting base 11 that is directly attached to a flange F formed on the sliding door 1, a hollow portion 12 that is integrally molded with the mounting base 11 and elastically contacts a foreign object such as a finger between the front end surface of the sliding door 1 and the body side opening that the front end surface faces when the sliding door 1 is closed, and a sensor (pressure sensor) S that is incorporated in the hollow portion 12 and detects the foreign object and outputs a corresponding electric signal, and the sensor (pressure sensor) S is fixed in the hollow portion 12 such that two core wires (electrode wires (including twisted wires)) 31, 32 extending in the vertical direction (longitudinal direction) are embedded in conductive rubber-like elastic bodies 34, 35 provided with a space 33 between them. A plurality of holding lips 14, 14 are provided on the inside of the mounting base 11, and a core material 15 having a substantially U-shaped cross section is embedded in the mounting base 11 to increase rigidity. Furthermore, a lip-shaped (or hollow) seal portion 16 is provided on the vehicle exterior side wall 11b of the mounting base 11.

[0027] In the upper terminal portion U of the protector with sensor 30 shown in Fig. 9, the space 33 of the hollow portion 12 opened at the upper terminal portion U is blocked by an insert 150 as shown in Fig. 12. Fig. 12 shows the upper terminal portion U of the protector with sensor 30 attached to the front end surface of the right sliding door 1 of the sliding doors 1 provided on both the left and right sides of the vehicle body. Note that in Fig. 12, the molded portions are indicated by dotted lines.

[0028] As shown in FIG. 1, the insert 150 is made of a non-conductive material such as polypropylene, polyethylene, polyethylene terephthalate, nylon, nylon 6, nylon 6-6, TPO, or TPS, and is composed of an insertion portion 151 with a concave cross-sectional shape provided at one end, and an insulating portion 160 provided at the other end.

[0029] The insulating part 160 has a flat plate shape (diamond-shaped in this embodiment) and is integrated with the top of the end face of the insertion part 151. Furthermore, since the plate surface of the diamond-shaped plate of the insulating part 160 is arranged parallel to a plane passing through the bottom parts on both sides of the insertion part 151, when the insertion part 151 of the insert 150 is press-fitted into the space part 33 of the hollow part 12, as shown in Figs. 1 and 12, the plate surface of the diamond-shaped plate extends in the left-right direction (diamond-shaped in this embodiment) perpendicular to the plane T passing through the centers of the two core wires 31, 32 drawn out at the extrusion-molded terminal part, and is arranged so that both left and right ends 161, 162 protrude, but the present invention is not limited to this. In this embodiment, the plane T extends in the front-rear direction of the vehicle, the plate surface of the rhombus-shaped flat plate extending perpendicularly thereto extends in the interior-exterior direction of the vehicle, and the plate thickness is in the up-down direction. Here, the inner end portion (left end portion) 161 and the outer end portion (right end portion) 162 are shown.

[0030] Of the outer and inner surfaces of the insulating part 160, a recess 163 for accommodating the resistor 39 is formed on the inner surface side (vehicle rear side) that faces the mounting base 11, as shown in Fig. 1. By forming the recess 163, the resistor 39 can be easily positioned. That is, as shown in Fig. 12, the resistor 39 is disposed on the inner surface side (rear side of the vehicle) of the insulating section 60, and one of the two legs 39a, 39b extending from the resistor 39 is connected to one of the core wires 31 drawn out in the longitudinal direction from the terminal portion where the mounting base 11 and the hollow portion 12 are integrally extruded on the outer surface side (front side of the vehicle) of the insulating section 160 to form a connection portion M1. The other of the two legs 39a, 39b extending from the resistor 39 is connected to the other of the core wires 32 drawn out in the longitudinal direction from the terminal portion where the mounting base 11 and the hollow portion 12 are integrally extruded on the inner surface side (rear side of the vehicle) of the insulating section 160 to form a connection portion M2. The two core wires 31, 32 and the legs 39a, 39b of the resistor 39 are overlapped and connected by resistance welding or soldering.

[0031] As shown in FIG. 12, the insertion portion 151 is press-fitted into the space 33 of the hollow portion 12, but has a cross-sectional shape different from that of the insertion portion 51 of the insert 50 shown in the conventional example. That is, the cross-sectional shape of the insertion part 51 of the insert 50 shown in Fig. 13, which is a conventional example, is matched to the cross-sectional shape of the space 33 as shown in Fig. 14, and is almost the same as or slightly larger than the space 33, so as to close the space 33 without any gaps as shown in Fig. 17, thereby preventing the molding material K from flowing into the space 33 of the extrusion molding part O during subsequent molding, thereby preventing the sensor function from being impaired, but the cross-sectional shape of the insertion part 151 of the insert 150 shown in this embodiment is provided with a thin part as shown in Figs. 2 to 4. When the insertion part 151 having the thin part is inserted into the space 33 of the extrusion molding part O, three types of first gap T1, second gap T2, and third gap T3 are formed between the space 33 and the insertion part 151 in the cross-sectional direction, forming an elongated space KU for flowing air from the other end side (insulating part 160 side) of the insertion part 151 of the insert 150 to the very end side (from the lower right side to the upper left side in Fig. 1) in the longitudinal direction.

[0032] More specifically, the first gap T1 is formed by forming thin portions 151C1 that are thinner than the thick portion 151A at the apex only on (the portions corresponding to the lower portions of) both the left and right sides of the hollow lower conductive portion 35, as in the cross-sectional shape shown in Fig. 2. The thick portions 151A are formed by providing ribs RA on the thin portions 151C1. 4, the second gap T2 is formed by forming a thin portion 151C2 that is thinner than the thick portions 151B on both the left and right sides only on the vertex side (the portion corresponding to the vertex side) of the hollow lower conductive part 35. The thick portion 151B is formed by providing a rib RB on the thin portion 151C2. The third gap T3 is formed by forming the entire upper surface (the portion corresponding to the upper surface) of the hollow lower conductive portion 35 into a thin portion 151C3, as shown in the cross-sectional shape of FIG.

[0033] As shown in Fig. 5, when viewed from the end of the extrusion molding part toward the very end of the insertion part 151, the positional relationship of the first gap T1, the second gap T2, and the third gap T3 is such that the first gap T1 has a portion overlapping the third gap T3 and the second gap T2 has a portion overlapping the third gap T3, and at the end of the extrusion molding part, the first gap T1 appears on the surface as shown in Fig. 6. In Fig. 5, the portion where the first gap T1 and the second gap T2 do not overlap is shown painted black.

[0034] As shown in Figure 1, when the insert 150 is inserted from the other end side (insulating portion 160 side) of the insertion portion 151 of the insert 150, i.e., when the insert 150 is inserted into the space portion 33 of the hollow portion 12, the cross-sectional shape in which the first gap T1 is formed (state in Figure 2), the cross-sectional shape in which the third gap T3 is formed (state in Figure 3), and the cross-sectional shape in which the second gap T2 is formed (state in Figure 4) are repeated multiple times from the end of the extrusion molded portion to the very end of the insertion portion 151. In this embodiment, the thick portions 151A, 151B and the thin portions 151C1, 151C2, 151C3 are arranged so that the size and cross-sectional setting position of the gaps T1, T2, T3 in the cross-sectional direction constituting the elongated space KU change (in the longitudinal direction) from the end of the extrusion molding portion to the very end of the insertion portion 151 so that the cross-sectional shape from the other end side (insulating portion 160 side) of the insertion portion 151 of the insert 150 becomes a cross-sectional shape in which the first gap T1 is formed (state in FIG. 2), a cross-sectional shape in which the third gap T3 is formed (state in FIG. 3), a cross-sectional shape in which the second gap T2 is formed (state in FIG. 4), a cross-sectional shape in which the third gap T3 is formed (state in FIG. 3), a cross-sectional shape in which the first gap T1 is formed (state in FIG. 2), a cross-sectional shape in which the third gap T3 is formed (state in FIG. 3), a cross-sectional shape in which the second gap T2 is formed (state in FIG. 4), or a cross-sectional shape in which the third gap T3 is formed (state in FIG. 3).

[0035] Then, as shown in FIG. 12, the other end side of the insert 150, in which the insertion portion 151 on one end side is pressed into the hollow portion 12, is covered with mold molding material K together with the insulating portion 160, the core wires 31, 32, the resistor 39, the two legs 39a, 39b, and the connection portions M1, M2.

[0036] During this molding process, when the molding material K is injected, normally (in the conventional example), the air has no place to escape and accumulates inside the part being molded. However, since an elongated space KU is formed in the insertion portion 151 of the insert 150, the air is able to flow from the other end side (insulating portion 160 side) of the insertion portion 151 of the insert 150 to the near end side through that elongated space KU. This prevents air from accumulating inside, so that the molded material K reaches the end of the extrusion molded portion O, suppresses the occurrence of voids, ensures airtightness, and prevents the mold from becoming out of date. In addition, the mold molding material K also flows from the first gap T1 (FIG. 2) to the third gap T3 (FIG. 3) together with the air, but is caught by the rib RB (FIG. 4) and is difficult to flow further. Even if the mold molding material K flows from the rib RB shown in FIG. 4 to the second gap T2 and then to the third gap T3 (FIG. 3), it is caught by the rib RA (FIG. 2) in the next stage and is difficult to flow further. In addition, the third gap T3 is formed from the top side of the hollow lower conductive part 35 to both the left and right sides, and is a wider space than the first gap T1 and the second gap T2. Therefore, when the mold molding material K flows from the narrow space of the first gap T1 or the second gap T2 to the wide space of the third gap T3, the pressure of the mold molding material K decreases, so that the amount of the mold molding material K gradually decreases.

[0037] 15, the space 33 of the hollow section 12 opened at the lower terminal section L of the sensor-equipped protector 30 is blocked by the insertion section 181 of the insert 180. The insert 180 is formed in a substantially J-shape, with the end side of the insulating section (projection section) 182 formed in a curved shape relative to the linear insertion section 181 side. In FIG. 15, the area of ​​the lower terminal section L is indicated by a dotted line.

[0038] Although not shown, the insertion portion 181 of the insert 180 has the same configuration as the insertion portion 151 of the insert 150. In other words, in the same manner as the cross-sectional shape of the insertion portion 151, the insertion portion 181 is provided with a first gap T1, a second gap T2, and a third gap T3 of three patterns in the cross-sectional direction between the space portion 33 as shown in Figures 2 to 4, forming an elongated space KU for allowing air to flow from the other end side (insulating portion 182 side) of the insertion portion 181 of the insert 180 to the very end side in the longitudinal direction.

[0039] 15 and 16, the insulating part 182 is made up of a support 182A having a small groove 183 formed on a front side 182Aa in which connection parts M3, M4 are placed, in which the ends of the core wires 31, 32 and the ends of the lead wires 36, 36 are overlapped and connected by resistance welding or soldering, and a lid 182B that covers the support 182A. The front side 182Aa of the insulating part 182 is substantially H-shaped.

[0040] Then, at the other end side of the insert 180 with the insertion portion 181 on one end side pressed into the hollow portion 12, the protrusion 182, the core wires 31, 32, the two lead wires 36, 36, the connection portions M3, M4 and a part of the wire harness W are covered with the molding material K.

[0041] In the lower terminal portion L of the sensor-equipped protector 30, as in the upper terminal portion U, when molding material K is injected during molding, air flows from the other end side (the protruding portion 182 side) of the insertion portion 181 of the insert 180 to the very end side through the elongated space formed in the insertion portion 181 (the same as the elongated space KU formed in the insertion portion 151 of the insert 150). This prevents air from accumulating inside, so that the molded material K reaches the end of the extrusion molded portion O, suppresses the occurrence of voids, ensures airtightness, and prevents the mold from becoming out of date. As with the upper terminal portion U of the sensor-equipped protector 30, the molding material K also flows into the insertion portion 181 along with the air at the lower terminal portion L, but is caught by the provided ribs RB and RA, making it difficult for the molding material K to flow any further. The third gap T3 is formed from the top side of the hollow lower conductive portion 35 to both the left and right sides, and is a larger space than the first gap T1 and the second gap T2. Therefore, when the mold molding material K flows from the narrow spaces of the first gap T1 and the second gap T2 to the wide space of the third gap T3, the pressure of the mold molding material K decreases, so that the inflow amount of the mold molding material K gradually decreases.

[0042] In this embodiment, from the other end side (insulating portion 160 side) of the insertion portion 151 of the insert 150, a cross-sectional shape in which the first gap T1 is formed (state in FIG. 2), a cross-sectional shape in which the third gap T3 is formed (state in FIG. 3), a cross-sectional shape in which the second gap T2 is formed (state in FIG. 4), a cross-sectional shape in which the third gap T3 is formed (state in FIG. 3), a cross-sectional shape in which the first gap T1 is formed (state in FIG. 2), a cross-sectional shape in which the third gap T3 is formed (state in FIG. 3), and a cross-sectional shape in which the second gap T2 is formed (state in FIG. 4) The thick portions 151A, 151B and the thin portions 151C1, 151C2, 151C3 are arranged so that the cross-sectional shape in which the third gap T3 is formed (as shown in Figure 3) is formed, and the size and cross-sectional setting position of the cross-sectional gaps T1, T2, T3 that constitute the elongated space KU change (in the longitudinal direction) from the end of the extrusion molding portion to the very end of the insertion portion 151. However, any cross-sectional shape and cross-sectional setting position may be used as long as the configuration allows air to escape during molding but traps the molding material K. Further, the cross-sectional shape is changed by providing the ribs RA and RB, but the present invention is not limited to this. For example, the cross-sectional shape of the insertion portion 151 side of the insert 150 may be changed by integral molding.

[0043] In addition, the shape of insulating portion 160 of insert 150 is rhombus, and the shape of insulating portion 182 of insert 180 is approximately J-shaped, but the shape of insulating portions 160, 182 is not particularly limited as long as the insertion portions 151, 181 are configured such that air escapes during molding but molding material K is trapped.

[0044] In the embodiment of the present invention, an example has been described in which the sensor-equipped protector 30 is attached to the sliding door 1 side of a vehicle in which the sliding door 1 moves in the forward and backward directions. However, the sensor-equipped protector 30 may also be attached to an opening on the body side to detect foreign objects between the sliding door 1 and the door. The protector 30 with the sensor can also be applied to a back door (not shown) or a sunroof 2 (FIG. 8). [Explanation of symbols]

[0045] 1. Sliding door 2. Sunroof 10 Sensored Protector 11 Mounting base 11a Car interior wall 11b Vehicle outside wall 11c Connecting wall 12 Hollow part 12a Outer shell 12b End 12c end 13 Channel section 14 Retaining Lip 15 Core material 16 Seal part 20 Sensored Protector 30 Sensored Protector 31,32 Core wire 33 Space section 34 Conductive rubber-like elastic body (hollow upper conductive part) 35 Conductive rubber-like elastic body (hollow lower conductive part) 36 Lead Wire 37 Covering section 39 Resistor 39a, 39b Resistor legs 40 Control device 50 Inserts 51 Insertion section 60 Insulation 61 Inside end (left end) 62 Outer side edge (right side edge) 63 Recess 80 Insert 81 Insertion section 82 Insulation 82A Support 82Aa Front side of support 82B Lid body 83 Small groove 150 Insert 151 Insertion part 151A Thick part 151B Thick part 151C1 Meat detail part 151C2 Meat detail 151C3 Meat detail 160 Insulation 161 Inner end of the car (left end) 162 Outer side edge (right side edge) 163 Recess 180 Insert 181 Insertion part 182 Insulating part (protruding part) 182A Support 182Aa Front side of support 182B Lid body 183 Small groove F flange K type molding material KU elongated space M1,M2 connection section M3, M4 connection part RA Lib RB Rib S sensor (pressure sensor) T plane T1 First gap T2 Second gap T3 Third gap W Wire Harness

Claims

1. The device comprises an attachment base that is attached to the periphery of an opening / closing object for opening and closing an opening in a vehicle body or to the periphery of the opening, and a tubular hollow portion that is integrally extruded with the attachment base on an upper portion of the mounting base and has two conductive portions, each consisting of a hollow upper conductive portion and a hollow lower conductive portion, each having two core wires embedded therein, and is provided with a space between them, and when the opening / closing object is closed, a foreign object caught between the opening / closing object and the opening presses and collapses the hollow portion, thereby detecting the presence of the foreign object by a corresponding change in an electrical signal, A protector with a sensor, in which a core wire is pulled out in a longitudinal direction from an end portion of the extrusion molded part, and an insert portion on one end side of an insert made of a non-conductive material is pressed in so as to close a space in the end portion of the extrusion molded part, and both the core wire pulled out in the longitudinal direction and the insert are covered with a molding material, a thick portion having a cross-sectional shape sized to be press-fitted into the space with no gap and a thin portion having a cross-sectional shape sized to form a gap between the space and the thick portion is provided from the very end of the insertion portion of the insert toward the other end, and an elongated space is formed that communicates from the end of the extrusion molded portion to the very end of the insertion portion by inserting the insert, The thick portion and the thin portion are arranged so that the size of the gap in the cross-sectional direction constituting the elongated space and the cross-sectional setting position change from the end of the extrusion molding portion to the very end of the insertion portion. A protector with a sensor.

2. The elongated space is a first gap formed only on both sides of the hollow lower conductive portion; a second gap formed only on a top side of the hollow lower conductive portion; The protector with sensor as described in claim 1, characterized in that the third gap formed from the top side of the hollow lower conductive portion to both the left and right sides is configured by repeating the first gap, the third gap, the second gap, and the third gap multiple times in that order from the end of the extrusion molded portion to the end of the insertion portion.

3. The protector with sensor as described in claim 2, characterized in that, when viewed from the end of the extrusion molding portion to the end side of the insertion portion, the first gap has a portion overlapping the third gap, and the second gap has a portion overlapping the third gap.

4. The protector with the sensor according to claim 3 , wherein the third gap is formed around the entire periphery of the upper side surface of the hollow lower conductive portion.

5. The core wire is connected to two legs of a resistor, and an insulating portion is provided on the other end side of the insert to insulate the connection portions of the two legs, the other end side of the insert is covered with the molding material together with the insulating portion, the core wire, the resistor, the two legs, and the connecting portion, 2. The protector with a sensor according to claim 1, wherein the insulating portion is in a flat plate shape.

6. The core wire is electrically connected to two lead wires protruding from a covering portion bundled in a wire harness, and an insulating portion is provided on the other end side of the insert to insulate the connection portions of the two lead wires, the other end side of the insert is covered with the molding material together with the insulating portion, the core wire, the two lead wires, the connecting portion, and the wire harness, 2. The protector with a sensor according to claim 1, wherein the insulating portion has a substantially H-shape on the side of the insertion portion.

Images