Sensor member and method for manufacturing sensor member

Abstract

To provide a sensor member which enables easy manufacture even if specifications are different.SOLUTION: A sensor member 11 includes a sensor 12, a wire member 13 connected to the sensor 12, a bracket 15 for fixation, and a resin molding member 16 which is integrally molded with the bracket 15 for fixation while covering parts of the sensor 12 and the wire member 13 drawn from the sensor 12. The resin molding member 16 has a primary molding part 31 covering the parts of the sensor 12 and the wire member 13 drawn from the sensor 12, and a secondary molding part 32 molded by using the primary molding part 31 and the bracket 15 for fixation as inserted articles.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a sensor member and a method for manufacturing the sensor member. [Background technology]

[0002] Conventionally, a sensor member such as a wheel speed sensor includes a sensor, an electric wire member connected to the sensor, a fixing bracket, and a resin molded member molded with these as insert parts (see, for example, Patent Document 1). The resin molded member is molded integrally with the fixing bracket while covering the sensor and a part of the electric wire member drawn out from the sensor. In such a sensor member, for example, the fixing bracket is fixed to a vehicle, and the sensor detects the rotation of the wheels. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2015-141129 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, the above-mentioned sensor member may have different specifications for the fixing bracket depending on, for example, the vehicle model to which it is fixed. Therefore, for example, a large mold for molding a large-sized resin molded member must be created for each specification. This, for example, causes an increase in manufacturing costs.

[0005] An object of the present disclosure is to provide a sensor member that can be easily manufactured even when specifications differ, and a method for manufacturing the sensor member. [Means for solving the problem]

[0006] The sensor member of the present disclosure includes a sensor, an electric wire member connected to the sensor, a fixing bracket, and a resin molded member that is integrally molded with the fixing bracket while covering the sensor and a portion of the electric wire member pulled out from the sensor, and the resin molded member has a primary molded portion that covers the sensor and a portion of the electric wire member pulled out from the sensor, and a secondary molded portion that is molded using the primary molded portion and the fixing bracket as insert parts. Effect of the Invention

[0007] According to the sensor member and the method for manufacturing the sensor member of the present disclosure, easy manufacturing is possible even when the specifications are different. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view of a sensor member according to an embodiment. [Diagram 2] FIG. 2 is a side view of a sensor member according to one embodiment. [Diagram 3] FIG. 3 is a partial side view of a primary molding part in one embodiment. [Figure 4] FIG. 4 is a partial perspective view of a primary molded part in one embodiment. [Diagram 5] FIG. 5 is a partially sectional perspective view of a primary molded part in one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] [Description of the embodiments of the present disclosure] First, the embodiments of the present disclosure will be listed and described. The sensor member of the present disclosure comprises: [1] A sensor member comprising: a sensor; an electric wire member connected to the sensor; a fixing bracket; and a resin molded member that is integrally molded with the fixing bracket while covering the sensor and a portion of the electric wire member pulled out from the sensor, wherein the resin molded member has a primary molded portion that covers the sensor and a portion of the electric wire member pulled out from the sensor, and a secondary molded portion that is molded using the primary molded portion and the fixing bracket as insert parts.

[0010] According to this configuration, the resin molded member has a primary molded portion that covers a part of the sensor and the electric wire member, and a secondary molded portion that is molded with the primary molded portion and the fixing bracket as insert parts, so that sensor members with different specifications can be easily obtained by using the primary molded portion as a common part. That is, the specifications of the fixing bracket of the sensor member may differ depending on, for example, the vehicle model to which it is fixed. And, for example, by producing the primary molded portion as a common part, the parts with different specifications can be handled with only a small change in the mold. Therefore, sensor members with different specifications can be easily manufactured. As a result, for example, manufacturing costs can be reduced.

[0011] [2] In the above [1], the fixing bracket may have a through hole through which the secondary molding portion passes, and the secondary molding portion may have a bent lead-out portion that bends outside the through hole and leads out the electric wire member.

[0012] According to this configuration, the secondary molding portion has a bent lead-out portion that leads out the electric wire member while being bent outside the through hole of the fixing bracket, so that the electric wire member can be stably led out in a direction intersecting the axis of the through hole, and the thickness of the through hole can be reduced in the direction in which the axis of the through hole extends. This makes it possible to stably prevent the electric wire member from coming into contact with other members, for example. That is, for example, when the space of the mounting object to which the sensor member is to be attached is small in the direction in which the axis of the through hole extends, it is possible to mount the sensor member without the electric wire member coming into contact with the mounting object.

[0013] [3] In the above [2], the fixing bracket is formed in a plate shape and has a fixing hole that penetrates parallel to the through hole, and may further have a guide recess that is recessed so that at least a portion of the bent guide portion is buried.

[0014] According to this configuration, the fixing bracket is formed in a plate shape and has a fixing hole that penetrates parallel to the through hole, and further has an outlet recess that is recessed so that at least a portion of the bent outlet portion is buried, thereby making it possible to achieve further thinning in the direction in which the axis of the through hole extends.

[0015] [4] In any one of [1] to [3] above, the primary molded portion may have a connecting portion with the secondary molded portion, and the connecting portion may have a rotation prevention portion in a part of the circumferential direction.

[0016] According to this configuration, the primary molded portion has a connecting portion with the secondary molded portion, and the connecting portion has a rotation prevention portion in part of the circumferential direction, thereby preventing the primary molded portion from rotating relative to the secondary molded portion.

[0017] The method for producing a sensor member according to the present disclosure includes the steps of: [5] A manufacturing method for a sensor member comprising a sensor, an electric wire member connected to the sensor, a fixing bracket, and a resin molded member that covers the sensor and a portion of the electric wire member pulled out from the sensor and is integrally molded with the fixing bracket, the method comprising: a first molding process for molding a primary molded portion that is a part of the resin molded member that covers the sensor and the portion of the electric wire member pulled out from the sensor; and a second molding process for molding a secondary molded portion that is a part of the resin molded member using the primary molded portion and the fixing bracket as insert parts.

[0018] According to this method, the resin molded member has a primary molded portion that covers a part of the sensor and the electric wire member, and a secondary molded portion that is molded with the primary molded portion and the fixing bracket as insert parts, so that sensor members with different specifications can be easily obtained by using the primary molded portion as a common part. That is, the specifications of the fixing bracket of the sensor member may differ depending on, for example, the vehicle model to which it is fixed. And, for example, by producing the primary molded portion as a common part in the first molding process, the parts with different specifications can be handled by only making a small change to the mold in the second molding process. Therefore, sensor members with different specifications can be easily manufactured. As a result, for example, it is possible to reduce manufacturing costs.

[0019] [6] In the above [5], the primary molded portion may have a connecting portion with the secondary molded portion, and in the first molding process, a molten rib that will melt in the second molding process may be molded around the connecting portion.

[0020] According to this method, the primary molded part has a connecting part with the secondary molded part, and in the first molding step, a melting rib that will melt in the second molding step is molded around the connecting part, so that the primary molded part and the secondary molded part can be firmly connected. Also, high waterproofness can be ensured at the boundary between the primary molded part and the secondary molded part.

[0021] [Details of the embodiment of the present disclosure] Specific examples of the sensor member of the present disclosure will be described below with reference to the drawings. In each drawing, for convenience of explanation, some of the configuration may be exaggerated or simplified. In addition, the dimensional ratio of each part may differ in each drawing. In this specification, "parallel," "orthogonal," and "perfect circle" do not only mean strictly parallel, orthogonal, or perfect circle, but also include approximately parallel, orthogonal, or perfect circle within the range of the action and effect of this embodiment. Note that the present invention is not limited to these examples, but is indicated by the claims, and is intended to include all modifications within the meaning and scope equivalent to the claims.

[0022] (Configuration of sensor member 11) 1 and 2, the sensor member 11 includes a sensor 12, an electric wire member 13, a sensor holder 14, a fixing bracket 15, and a resin molded member 16. The sensor member 11 of this embodiment is, for example, a wheel speed sensor in which the fixing bracket 15 is fixed to a vehicle and the sensor 12 detects the rotation of the wheel.

[0023] (Configuration of sensor 12) The sensor 12 is a rotation detection sensor capable of detecting a change in a magnetic field based on the rotation of the wheel, and employs, for example, a square plate-shaped Hall IC.

[0024] (Configuration of electric wire member 13) The electric wire member 13 has two electric wires 21 and an exterior material 22. The electric wire 21 has a conductive core wire 21a and an insulating coating 21b that surrounds the outer periphery of the core wire 21a and has insulating properties. The exterior material 22 is made of a flexible material such as urethane, and covers the two electric wires 21 while bundling them together. The electric wire member 13 is connected to the sensor 12. More specifically, the ends of the two electric wires 21 are provided so as to be exposed to the outside of the exterior material 22, and the core wires 21a of each of the two electric wires 21 are connected to the sensor 12.

[0025] (Configuration of sensor holder 14) The sensor holder 14 is made of a resin material. The sensor holder 14 holds the sensor 12. The sensor holder 14 also maintains the connection between the core wires 21a of the two electric wires 21 and the sensor 12.

[0026] (Configuration of the fixing bracket 15) Fixing bracket 15 is made of a resin material. Fixing bracket 15 is formed in a plate shape. Fixing bracket 15 has a disk-shaped sensor fixing portion 15a and an external fixing portion 15b that protrudes outward from a part of the outer periphery of sensor fixing portion 15a.

[0027] 2, the sensor fixing portion 15a has a through hole 15c. The through hole 15c passes through the sensor fixing portion 15a along the axis of the plate thickness of the fixing bracket 15. The through hole 15c is formed in the center of the sensor fixing portion 15a. The external fixing portion 15b has a fixing hole 15d that passes through in parallel with the through hole 15c. A cylindrical metal collar 23 is provided on the inner surface of the fixing hole 15d.

[0028] The sensor fixing portion 15a also has a lead-out recess 15e extending from the open end of the through hole 15c to the outer edge of the sensor fixing portion 15a. The lead-out recess 15e is recessed into one main surface 15f of the plate-shaped fixing bracket 15. In other words, the plate-shaped fixing bracket 15 is formed so that the portion where the lead-out recess 15e is formed is thinner than the other portions. The lead-out recess 15e has a cross section orthogonal to the direction in which the lead-out recess 15e extends, which is formed in an arc shape.

[0029] (Configuration of resin molded member 16) The resin molded member 16 is made of a resin material. The resin molded member 16 is molded integrally with the fixing bracket 15 while covering the sensor 12, the sensor holder 14, and a part of the electric wire member 13 drawn out from the sensor 12. That is, in the completed product of the sensor member 11, the fixing bracket 15 and the resin molded member 16 are an integrally molded product.

[0030] The resin molded member 16 has a primary molded portion 31 that covers the sensor 12, the sensor holder 14, and a portion of the wire member 13 pulled out from the sensor 12, and a secondary molded portion 32 that is molded using the primary molded portion 31 and the fixing bracket 15 as insert parts.

[0031] In detail, as shown in FIG. 3, the primary molding portion 31 is composed of a rectangular prism-shaped tip portion 31a, a cylindrical middle portion 31b, and a cylindrical connecting portion 31c having a smaller diameter than the middle portion 31b, which are continuously arranged in this order in a straight line.

[0032] The tip portion 31a covers the sensor holder 14 including the sensor 12. The middle portion 31b and the connecting portion 31c cover a part of the electric wire member 13 drawn out from the sensor 12. The electric wire member 13 extends while protruding outward from the end of the connecting portion 31c.

[0033] As shown in Figs. 3 to 5, the connecting portion 31c has a rotation prevention portion 31d at a part in the circumferential direction. More specifically, the connecting portion 31c is a portion that is connected to the secondary molded portion 32 (see Fig. 3) when the secondary molded portion 32 is molded. The rotation prevention portion 31d is shaped so that it can be engaged in the circumferential direction so that the primary molded portion 31 does not rotate relative to the secondary molded portion 32. In this embodiment, two rotation prevention portions 31d are provided at equal intervals on the outer periphery of the connecting portion 31c. The rotation prevention portion 31d is a flat surface shaped by removing a part of the outer periphery of the cylindrical connecting portion 31c. The two rotation prevention portions 31d are formed parallel to each other.

[0034] 3 and 4, before the secondary molded portion 32 is molded, the connecting portion 31c has a melt rib 31e on its periphery. The melt rib 31e is provided on the entire outer periphery of the connecting portion 31c. In other words, the melt rib 31e is provided in an annular shape. The melt rib 31e protrudes thinly so as to melt when the secondary molded portion 32 is molded. Three melt ribs 31e are provided on the connecting portion 31c with a gap therebetween. The two melt ribs 31e are provided at positions sandwiching the anti-rotation portion 31d.

[0035] As shown in Figures 1 and 2, the secondary molding portion 32 has a cylindrical secondary connecting portion 32a, a cylindrical through portion 32b extending continuously from the secondary connecting portion 32a and having a smaller diameter than the secondary connecting portion 32a, and a bent derived portion 32c extending from the through portion 32b in a bent manner.

[0036] The secondary connecting portion 32a is molded using the primary molded portion 31 as an insert product, and is connected to the connecting portion 31c while covering the connecting portion 31c of the primary molded portion 31 and a portion of the electric wire member 13 protruding from the connecting portion 31c.

[0037] The through portion 32b is filled inside the through hole 15c of the fixing bracket 15, so as to penetrate the through hole 15c while covering a part of the electric wire member 13. The bent leading-out portion 32c is bent and extends outside the through hole 15c while covering a part of the electric wire member 13. The electric wire member 13 is led out from the tip of the bent leading-out portion 32c. The bent leading-out portion 32c is disposed so as to be partially embedded in the leading-out recess 15e.

[0038] The sensor member 11 configured as described above is attached to a vehicle by the fixing bracket 15. The sensor member 11 of this embodiment is attached to a position near a wheel of the vehicle by a bolt (not shown) or the like that penetrates the fixing hole 15d, more specifically, the metal collar 23.

[0039] Next, a method for manufacturing the sensor member 11 configured as above will be described. The manufacturing method of the sensor member 11 includes a pre-process, a first molding process, and a second molding process. In the pre-process, a member in which the sensor 12, the electric wire member 13, and the sensor holder 14 are assembled, and a fixing bracket 15 are prepared.

[0040] Then, in the first molding step, a primary molded portion 31 is molded to cover the sensor 12, the sensor holder 14, and a part of the electric wire member 13 drawn out from the sensor 12. That is, in the first molding step, a member assembled with the sensor 12, the electric wire member 13, and the sensor holder 14 is placed in a mold (not shown) as an insert product, and molten resin is filled in the mold to mold the primary molded portion 31. In this first molding step, a molten rib 31e (see FIGS. 3 and 4) that will melt in the second molding step is molded around the connecting portion 31c.

[0041] Then, in the second molding step, the secondary molded portion 32 is molded using the primary molded portion 31 and the fixing bracket 15 as insert parts. That is, in the second molding step, the secondary molded portion 32 is molded by filling a mold (not shown) with molten resin while the primary molded portion 31 and the fixing bracket 15 are placed in the mold as insert parts. In this manner, the manufacture of the sensor member 11 is completed.

[0042] Next, the effects of the above embodiment will be described below. (1) The resin molded member 16 has a primary molded portion 31 that covers the sensor 12, the sensor holder 14, and a part of the electric wire member 13 drawn out from the sensor 12, and a secondary molded portion 32 that is molded with the primary molded portion 31 and the fixing bracket 15 as insert parts. Therefore, it is possible to easily obtain sensor members 11 with different specifications by using the primary molded portion 31 as a common part. That is, the specifications of the fixing bracket 15 of the sensor member 11 may differ depending on, for example, the vehicle model to which the sensor member 11 is fixed. And, for example, by producing the primary molded portion 31 as a common part, it is possible to deal with parts with different specifications by only making small changes to the mold. Therefore, it is possible to easily manufacture sensor members 11 with different specifications. As a result, for example, it is possible to reduce manufacturing costs.

[0043] (2) The secondary molding portion 32 has a bent guide portion 32c that guides the electric wire member 13 while bending outside the through hole 15c of the fixing bracket 15. Therefore, the electric wire member 13 can be stably drawn out in a direction intersecting the axis of the through hole 15c, and the thickness can be reduced in the direction in which the axis of the through hole 15c extends. This makes it possible to stably prevent the electric wire member 13 from coming into contact with other members, for example. That is, for example, when the space of the mounting object to which the sensor member 11 is to be mounted is small in the direction in which the axis of the through hole 15c extends, the sensor member 11 can be mounted without the electric wire member 13 coming into contact with the mounting object.

[0044] (3) The fixing bracket 15 is formed in a plate shape, has a fixing hole 15d penetrating parallel to the through hole 15c, and further has a lead-out recess 15e recessed so that at least a part of the bent lead-out portion 32c is embedded in the lead-out recess 15e. This makes it possible to further reduce the thickness in the direction in which the axis of the through hole 15c extends.

[0045] (4) The primary molding portion 31 has a connecting portion 31c with the secondary molding portion 32, and the connecting portion 31c has an anti-rotation portion 31d in a portion of the circumferential direction, thereby preventing the primary molding portion 31 from rotating relative to the secondary molding portion 32.

[0046] (5) The primary molded portion 31 has a connecting portion 31c with the secondary molded portion 32, and in the first molding step, a melting rib 31e that will melt in the second molding step is formed around the connecting portion 31c. This allows the primary molded portion 31 and the secondary molded portion 32 to be firmly connected. In addition, high waterproofness of the boundary between the primary molded portion 31 and the secondary molded portion 32 can be ensured.

[0047] This embodiment can be modified as follows: This embodiment and the following modifications can be combined with each other to the extent that there is no technical contradiction. In the above embodiment, the secondary molding portion 32 has the bent lead-out portion 32c that leads out the electric wire member 13 while being bent outside the through hole 15c of the fixing bracket 15, but is not limited thereto, and may have a lead-out portion that leads out the electric wire member 13 without being bent. That is, the bent lead-out portion 32c may be changed to a lead-out portion that extends in the direction of the axis of the through hole 15c and leads out the electric wire member 13 in that direction, and the sensor member 11 may be embodied with different specifications that have such a lead-out portion.

[0048] In the above embodiment, the fixing bracket 15 has the lead-out recess 15e recessed so that at least a portion of the bent lead-out portion 32c is embedded therein. However, this is not limited to this and the fixing bracket 15 may have a configuration that does not have the lead-out recess 15e.

[0049] In the above embodiment, the connecting portion 31c of the primary molded portion 31 has the anti-rotation portion 31d at a part in the circumferential direction, but this is not limited to this and may be modified to a configuration that does not have the anti-rotation portion 31d. Also, the number of the anti-rotation portions 31d may be modified to a different number. Also, the shape of the anti-rotation portion 31d may be modified to a different shape.

[0050] In the above embodiment, the melt rib 31e, which will melt in the second molding process, is molded around the connecting portion 31c in the first molding process. However, this is not limited to this, and the melt rib 31e does not have to be molded.

[0051] In the above embodiment, the electric wire member 13 has two electric wires 21 and an outer casing 22, but is not limited thereto and may be changed to an electric wire member having another configuration. For example, an electric wire member may have three or more electric wires 21. Also, for example, an electric wire member without an outer casing 22 may be used.

[0052] In the above embodiment, the sensor member 11 is a wheel speed sensor equipped with the sensor 12 capable of detecting a change in a magnetic field based on the rotation of the wheel. However, the present invention is not limited to this and may be embodied as a sensor member 11 for other purposes. [Explanation of symbols]

[0053] 11 Sensor components 12 Sensors 13 Electrical wiring materials 14 Sensor holder 15 Fixing bracket 15a Sensor fixing part 15b External fixing part 15c through hole 15d fixing hole 15e Lead-out recess 15f main surface 16 Plastic molding parts 21 Electric wire 21a core wire 21b Insulation coating 22 Exterior materials 23 Metal Color 31 Primary forming part 31a Tip 31b Middle part 31c connection part 31d Anti-rotation part 31e Melting Rib 32 Secondary molding section 32a Secondary connection 32b Penetration 32c Bend lead-out part

Claims

1. A sensor; An electric wire member connected to the sensor; A fixing bracket; a resin molded member that is molded integrally with the fixing bracket and covers the sensor and a portion of the electric wire member that is drawn out from the sensor; A sensor member comprising: The resin molded member has a primary molded portion that covers the sensor and a part of the electric wire member drawn out from the sensor, and a secondary molded portion that is molded using the primary molded portion and the fixing bracket as an insert product. Sensor component.

2. the fixing bracket has a through hole through which the secondary molded portion passes, The secondary molding portion has a bent guide portion that guides the electric wire member while being bent outside the through hole. The sensor member according to claim 1 .

3. The fixing bracket is formed in a plate shape and has a fixing hole penetrating parallel to the through hole, and further has a lead-out recess recessed so that at least a part of the bent lead-out portion is embedded therein. The sensor member according to claim 2 .

4. The primary molded portion has a connecting portion with the secondary molded portion, The connecting portion has a rotation preventing portion at a part in a circumferential direction. The sensor member according to claim 1 .

5. A sensor; An electric wire member connected to the sensor; A fixing bracket; a resin molded member that is molded integrally with the fixing bracket and covers the sensor and a portion of the electric wire member that is drawn out from the sensor; A method for manufacturing a sensor member comprising: a first molding step of molding a primary molding portion that is a part of the resin molded member and covers the sensor and a part of the electric wire member drawn out from the sensor; and a second molding step of molding a secondary molded portion that is a part of the resin molded member using the primary molded portion and the fixing bracket as insert parts. A method for manufacturing a sensor member.

6. The primary molded portion has a connecting portion with the secondary molded portion, In the first molding step, a melt rib is molded around the connecting portion, the melt rib being to be melted in the second molding step. A method for manufacturing the sensor member according to claim 5.

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