Vacuum sensor and method for manufacturing vacuum sensor

Abstract

To provide a vacuum sensor capable of reducing defective connection between a first lead terminal and a connector terminal, and to provide a manufacturing method of the vacuum sensor.SOLUTION: The housing 4 includes a first mounting surface 412A on which the rear end of the connector terminal 3 is mounted, and a second mounting surface 412B that is spaced apart from and disposed below the second lead terminals 22B. The first mounting surface 412A and the second mounting surface 412B are provided such that a height Ha from the lower end of the connecting tube portion 42 to the upper side of the rear end of the connector terminal 3 is higher than a height Hb from the lower end of the connecting tube portion 42 to the second mounting surface 412B.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a vacuum sensor and a method for manufacturing a vacuum sensor. [Background technology]

[0002] Conventionally, a vacuum sensor that detects the intake pipe pressure of an engine has been known (Patent Document 1). The vacuum sensor has a sensor IC (sensor unit) and a connector terminal inside. The lead terminal (first lead terminal) of the sensor IC is connected to the connector terminal by welding. This allows power to be supplied to the sensor IC and signals to be extracted from the connector terminal. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2025-256781 Summary of the Invention [Problem to be solved by the invention]

[0004] Conventional vacuum sensors have had the problem of poor connection between the lead terminals of the sensor IC and the connector terminal due to variations in the mounting position of the sensor IC.

[0005] The present invention has been made in consideration of the above-mentioned circumstances, and its object is to provide a vacuum sensor and a method for manufacturing a vacuum sensor that can reduce connection defects between a first lead terminal and a connector terminal. [Means for solving the problem]

[0006] In order to achieve the above-mentioned object, the vacuum sensor according to the present invention has the following features. a sensor unit including a sensor body for detecting a pressure in an intake pipe, a first lead terminal protruding from the sensor body, and a second lead terminal protruding from the sensor body on the opposite side to the first lead terminal; a connector terminal on one end of which the tip of the first lead terminal is overlapped and welded; a housing having a housing portion that houses the connector terminal and the sensor portion, and a cylindrical connecting cylindrical portion that has one end in a cylinder length direction connected to the intake pipe and an opening provided at the other end in the cylinder length direction that is closed by the sensor main body, In the vacuum sensor, The housing includes: a first mounting surface on which the one end of the connector terminal is mounted, and a second mounting surface disposed on the one end side of the second lead terminal in the length direction of the tube and spaced apart from the first mounting surface; the first mounting surface and the second mounting surface are provided so that a height from one end of the connecting cylindrical portion in the cylindrical length direction to above the one end of the connector terminal is higher than a height from one end of the connecting cylindrical portion in the cylindrical length direction to the second mounting surface; It is a vacuum sensor.

[0007] In order to achieve the above-mentioned object, the manufacturing method of the vacuum sensor according to the present invention is characterized as follows. A method for manufacturing the vacuum sensor, a step of accommodating the connector terminal in the accommodating portion of the housing; a step of mounting a tip of the first lead terminal on one end of the connector terminal accommodated in the accommodation portion, and mounting the second lead terminal on the second mounting surface; and irradiating the first lead terminal with laser light from the second lead terminal side toward a side of the first lead terminal away from the second lead terminal to weld the first lead terminal and the connector terminal together. It is a manufacturing method for vacuum sensors. [Effects of the Invention]

[0008] The vacuum sensor and the method for manufacturing the vacuum sensor according to the present invention have the advantage of being able to reduce connection failures between the first lead terminal and the connector terminal.

[0009] The present invention has been briefly described above. The details of the present invention will become clearer by reading the following detailed description of the invention (hereinafter referred to as "embodiments") with reference to the accompanying drawings. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a perspective view showing an embodiment of a vacuum sensor of the present invention. [Figure 2] FIG. 2 is a cross-sectional view taken along line AA in FIG. [Figure 3] FIG. 3 is a partial top view of the vacuum sensor shown in FIG. 1 with the cover removed. [Figure 4] FIG. 4 is an explanatory diagram for explaining a method for manufacturing the vacuum sensor shown in FIG. [Figure 5] FIG. 5 is an explanatory diagram for explaining a method for manufacturing a vacuum sensor in a comparative example. DETAILED DESCRIPTION OF THE INVENTION

[0011] Specific embodiments of the present invention will be described below with reference to the accompanying drawings.

[0012] For the sake of convenience, the following definitions are used for "front," "rear," "left," "right," "upper," and "lower" as shown in Figures 1 to 5. The "front-rear direction," "left-right direction," and "upper-lower direction" are perpendicular to one another. Note that the "cylinder length direction" of the present invention corresponds to the "upper-lower direction."

[0013] 1 to 3, the vacuum sensor 1 includes a sensor IC (Integrated Circuit) 2 (see FIG. 2) as a sensor unit, a connector terminal 3 (see FIG. 2) connected to the sensor IC 2, a housing 4 that houses the sensor IC 2 and the connector terminal 3, and a cover 5 that covers the housing 4.

[0014] As shown in FIGS. 2 and 3, the sensor IC 2 has a sensor main body 21, a first lead terminal 22A, and a second lead terminal 22B. The sensor main body 21 detects the pressure in the intake pipe. The first lead terminal 22A is a terminal connected to a connector terminal 3, which will be described later. The first lead terminal 22A protrudes forward from the sensor main body 21. In this embodiment, a total of four first lead terminals 22A are provided: two power supply terminals for supplying power to the sensor main body 21, and two signal terminals for extracting signals from the sensor main body. The four first lead terminals 22A are arranged side by side in the left-right direction.

[0015] The second lead terminals 22B are terminals used as test terminals. The second lead terminals 22B protrude rearward from the sensor body 21. In this embodiment, a total of three second lead terminals 22B are provided: two power supply terminals and one signal terminal. The three second lead terminals 22B are arranged side by side in the left-right direction. The length of the second lead terminals 22B in the front-rear direction is shorter than the length of the first lead terminal 22A in the front-rear direction.

[0016] The connector terminal 3 extends in the front-rear direction, and the front end of the first lead terminal 22A is placed on the rear end (one end) and laser-welded. In this embodiment, three connector terminals 3 are provided. The three connector terminals 3 are arranged side by side in the left-right direction, and are connected to the first lead terminal 22A arranged at both ends in the left-right direction and the second first lead terminal 22A from the right.

[0017] As shown in FIG. 2, the housing 4 is formed by integrally molding an accommodating portion 41 for accommodating the connector terminal 3 and the sensor IC 2, and a connecting cylindrical portion 42 for connecting to an intake pipe of the engine, using resin.

[0018] The accommodating portion 41 extends in the front-rear direction. The accommodating portion 41 has a connector housing 411 that accommodates the front ends of the connector terminals 3, and a mounting portion 412 that mounts the rear ends of the connector terminals 3 and the sensor IC 2. The connector housing 411 is shaped like a cylinder with a closed rear opening. A through-hole 411B that penetrates in the front-rear direction is provided in a bottom portion 411A that closes the rear opening of the connector housing 411. The front ends of the connector terminals 3 protrude from this through-hole 411B and are accommodated in the connector housing 411.

[0019] The mounting portion 412 is provided contiguous to the rear side of the connector housing 411, and has the rear ends of the connector terminals 3 and the sensor IC 2 mounted on its upper side. The mounting portion 412 has a first mounting surface 412A on which the rear ends of the connector terminals 3 are mounted on its upper side, and a second mounting surface 412B that is disposed below and spaced from the tips of the second lead terminals 22B of the sensor IC 2.

[0020] The connecting tube portion 42 is provided to protrude downward from the mounting portion 412. The connecting tube portion 42 is provided in a cylindrical shape, and its lower end (one end in the tube length direction) is connected to and communicates with the intake pipe. An opening 42A provided at the upper end of the connecting tube portion 42 is closed by the sensor main body 21. In this embodiment, the upper end of the connecting tube portion 42 is closed by an upper wall 42B, and the opening 42A is provided to penetrate the upper wall 42B. The sensor main body 21 is arranged to close this opening 42A.

[0021] The first mounting surface 412A and the second mounting surface 412B are provided so that the height Ha from the lower end of the connecting cylindrical portion 42 to the upper surface of the rear end of the connector terminal is higher than the height Hb from the lower end of the connecting cylindrical portion 42 to the second mounting surface 412B. More specifically, the first mounting surface 412A and the second mounting surface 412B are provided so that the height Ha>Hb within the tolerance of the height dimension. In other words, the minimum value of the dimensional tolerance of the height Ha of the first mounting surface 412A is provided so as to be higher than the maximum value of the dimensional tolerance of the height Hb of the second mounting surface 412B.

[0022] 3, the housing 4 has a pair of first positioning walls 412C, 412C, a pair of second positioning walls 412D, 412D, and a pair of third positioning walls 412E, 412E. The pair of first positioning walls 412C, 412C are provided to protrude from the first mounting surface 412A. The pair of first positioning walls 412C, 412C sandwich the multiple first lead terminals 22A between them in the left-right direction, and position the first lead terminals 22A in the left-right direction. The pair of second positioning walls 412D, 412D are provided to protrude from the second mounting surface 412B. The pair of second positioning walls 412D, 412D sandwich the multiple second lead terminals 22B between them in the left-right direction, and position the second lead terminals 22B in the left-right direction. The pair of third positioning walls 412E, 412E protrude from the first mounting surface 412A and abut against the tip of the second lead terminal 22B to position the second lead terminal 22B in the front-rear direction. In this embodiment, the pair of third positioning walls 412E, 412E are provided continuous with the pair of second positioning walls 412D, 412D.

[0023] The cover 5 covers the upper side of the mounting portion 412 .

[0024] Next, a manufacturing method of the above-mentioned vacuum sensor 1 will be described with reference to Fig. 4. First, the connector terminal 3 is housed in the housing 4, with the rear end of the connector terminal 3 mounted on the first mounting surface 412A and the front end housed in the connector housing 411. Next, the first lead terminal 22A of the sensor IC 2 is placed on the rear end of the connector terminal 3, and the second lead terminal 22B is mounted on the second mounting surface 412B.

[0025] Since Ha > Hb, the sensor IC2 is mounted with the front side (the side of the first lead terminal 22A) tilted upward and the rear side (the side of the second lead terminal 22B) tilted downward. That is, the rear side of the first lead terminal 22A contacts the connector terminal 3, and the front side of the first lead terminal 22A floats upward from the connector terminal 3.

[0026] Next, the laser beam LL is irradiated toward the upper surface of the first lead terminal 22A to weld and connect the first lead terminal 22A and the connector terminal 3. At this time, the laser beam LL is irradiated from the rear side of the first lead terminal 22A that contacts the connector terminal 3 toward the front side. As the laser beam LL moves toward the front side, the inclination of the sensor IC2 decreases. Finally, the inclination of the first lead terminal 22A disappears, and the second lead terminal 22B floats (is separated) from the second mounting surface 412B. As a result, the first lead terminal 22A and the connector terminal 3 are welded in a non-floating state from the rear side to the front side where the laser beam LL is irradiated. After that, the cover 5 is attached to the housing, and the vacuum sensor is completed.

[0027] Next, the effects of the present embodiment will be described in comparison with a comparative example shown in FIG. 5. In the comparative example shown in FIG. 5, Ha < Hb is provided. When the sensor IC2 is mounted, contrary to the present embodiment, the sensor IC2 is mounted with the front side tilted downward and the rear side tilted upward. Therefore, even if the laser beam LL is irradiated from the front side to the rear side of the first lead terminal 22A, the second lead terminal 22B contacts the second mounting surface 412B and is welded while tilted. That is, the first lead terminal 22A and the connector terminal 3 are welded in a floating state, resulting in a poor connection.

[0028] According to the above-described embodiment, Ha>Hb. Therefore, the first lead terminal 22A is mounted on the housing 4 with the first lead terminal 22A tilted upward and the second lead terminal 22B tilted downward. Thereafter, when the laser beam LL is irradiated onto the first lead terminal 22A from the rear side to the front side, welding can be performed without any floating between the first lead terminal 22A and the connector terminal 3. Therefore, poor connection between the first lead terminal 22A and the connector terminal 3 can be reduced.

[0029] According to the embodiment described above, the first positioning walls 412C, 412C and the second positioning walls 412D, 412D are provided. This allows the first lead terminal 22A and the second lead terminal 22B to be positioned in the left-right direction. This prevents a reduction in the overlapping area between the first lead terminal 22A and the connector terminal 3 due to misalignment in the left-right direction, further reducing poor connection between the first lead terminal 22A and the connector terminal 3.

[0030] According to the embodiment described above, the pair of first positioning walls 412C, 412C sandwich the multiple first lead terminals 22A therebetween, and the pair of second positioning walls 412D, 412D sandwich the multiple second lead terminals 22B therebetween. This makes it possible to position the first lead terminals 22A and the second lead terminals 22B in the left-right direction even if the distance between the first lead terminals 22A and the second lead terminals 22B is narrow.

[0031] The present invention is not limited to the above-described embodiments, and can be appropriately modified, improved, etc. Furthermore, the material, shape, size, number, location, etc. of each component in the above-described embodiments are arbitrary and not limited as long as they can achieve the present invention.

[0032] According to the embodiment described above, the first positioning wall 412C, the second positioning wall 412D, and the third positioning wall 412E are provided, but this is not limitative. The first positioning wall 412C, the second positioning wall 412D, and the third positioning wall 412E are not essential and may be omitted.

[0033] According to the embodiment described above, the first positioning wall 412C and the second positioning wall 412D sandwich the plurality of first lead terminals 22A and the plurality of second lead terminals 22B together, but this is not limited to this. The first positioning wall 412C and the second positioning wall 412D may be provided so as to sandwich one of the plurality of first lead terminals 22A and the plurality of second lead terminals 22B.

[0034] Here, the features of the embodiments of the vacuum sensor and the method for manufacturing the vacuum sensor according to the present invention described above will be briefly summarized and listed below in [1] to [4].

[0035] [1] a sensor unit (2) having a sensor body (21) for detecting pressure in an intake pipe, a first lead terminal (22A) protruding from the sensor body (21), and a second lead terminal (22B) protruding from the sensor body (21) on the opposite side to the first lead terminal (22A); a connector terminal (3) on one end of which the tip of the first lead terminal (22A) is overlapped and welded; and a housing (4) having an accommodating section (41) for accommodating the connector terminal (3) and the sensor section (2), and a cylindrical connecting section (42) having one end (lower end) in the cylinder length direction connected to the intake pipe and an opening (42A) provided at the other end (upper end) in the cylinder length direction that is closed by the sensor main body (21). In the vacuum sensor (1), The housing (4) is a first mounting surface (412A) on which the one end of the connector terminal (3) is mounted, and a second mounting surface (412B) arranged at a distance from one end (lower side) of the second lead terminal (22B) in the tube length direction, The first mounting surface (412A) and the second mounting surface (412B) are provided so that the height from one end (lower end) of the connecting cylindrical portion (42) in the cylindrical length direction to above the one end of the connector terminal (3) is higher than the height from one end (lower end) of the connecting cylindrical portion (42) in the cylindrical length direction to the second mounting surface (412B). Vacuum sensor (1).

[0036] According to the vacuum sensor (1) having the configuration [1] above, the first lead terminal (22A) is mounted on the housing (4) with the first lead terminal (22A) tilted toward the other end (upper side) of the tube length direction and the second lead terminal (22B) tilted toward one end (lower side) of the tube length direction. Then, when a laser beam (LL) is irradiated onto the first lead terminal (22A) from the second lead terminal side (rear side) toward the side away from the second lead terminal (front side), welding can be performed without any floating between the first lead terminal (22A) and the connector terminal (3). This reduces poor connection between the first lead terminal (22A) and the connector terminal (3).

[0037] [2] In the vacuum sensor (1) described in [1], The housing (4) is a pair of first positioning walls (412C, 412C) protruding from the first mounting surface (412A) and sandwiching the first lead terminal (22A) therebetween; a pair of second positioning walls (412D, 412D) protruding from the second mounting surface (412B) and sandwiching the second lead terminal (22B) therebetween; Vacuum sensor (1).

[0038] According to the vacuum sensor (1) having the configuration [2] above, the first positioning walls (412C, 412C) and the second positioning walls (412D, 412D) can position the first lead terminal (22A) and the second lead terminal (22B) in the sandwiching direction (left-right direction). This makes it possible to prevent a reduction in the overlapping area between the first lead terminal (22A) and the connector terminal (3) due to misalignment in the sandwiching direction (left-right direction), thereby further reducing poor connection between the first lead terminal (22A) and the connector terminal (3).

[0039] [3] [2] The vacuum sensor (1) according to The first lead terminal (22A) and the second lead terminal (22B) are provided in plural, The pair of first positioning walls (412C, 412C) sandwich the plurality of first lead terminals (22A) therebetween, The pair of second positioning walls (412D, 412D) sandwich the plurality of second lead terminals (22B) therebetween. Vacuum sensor (1).

[0040] According to the vacuum sensor (1) having the configuration (3) above, even if the distance between the first lead terminal (22A) and the second lead terminal (22B) is narrow, the first lead terminal (22A) and the second lead terminal (22B) can be positioned in the sandwiching direction (left and right direction).

[0041] [4] A method for manufacturing the vacuum sensor according to [1], a step of accommodating the connector terminal (3) in the accommodating portion (41) of the housing (4); a step of mounting a tip of the first lead terminal (22A) on one end of the connector terminal (3) accommodated in the accommodation portion (41) and mounting the second lead terminal (22B) on the second mounting surface (412B); and a step of irradiating a laser beam (LL) from a side (rear side) of the first lead terminal (22A) toward a side (front side) away from the second lead terminal (22B) to weld the first lead terminal (22A) and the connector terminal (3). A method for manufacturing a vacuum sensor.

[0042] According to the manufacturing method of the vacuum sensor having the above configuration [4], it is possible to reduce poor connection between the first lead terminal (22A) and the connector terminal (3). [Explanation of symbols]

[0043] 1 Vacuum Sensor 2 Sensor section 3 Connector Terminals 4. Cabinet 21 Sensor body 22A First lead terminal 22B Second lead terminal 41 Storage unit 42 Connecting tube 42A opening 412A 1st mounting surface 412B Second mounting surface 412C First positioning wall 412D Second positioning wall Ha Height Hb height

Claims

1. a sensor unit including a sensor body for detecting a pressure in an intake pipe, a first lead terminal protruding from the sensor body, and a second lead terminal protruding from the sensor body on a side opposite to the first lead terminal; a connector terminal on one end of which the tip of the first lead terminal is overlapped and welded; a housing having a housing portion that houses the connector terminal and the sensor portion, and a cylindrical connecting cylindrical portion that has one end in a cylinder length direction connected to the intake pipe and an opening provided at the other end in the cylinder length direction that is closed by the sensor main body, In the vacuum sensor, The housing includes: a first mounting surface on which the one end of the connector terminal is mounted, and a second mounting surface disposed on the one end side of the second lead terminal in the length direction of the cylinder and spaced apart from the first mounting surface; the first mounting surface and the second mounting surface are provided so that a height from one end of the connecting cylindrical portion in the cylindrical length direction to above the one end of the connector terminal is higher than a height from one end of the connecting cylindrical portion in the cylindrical length direction to the second mounting surface; Vacuum sensor.

2. 2. The vacuum sensor according to claim 1, The housing includes: a pair of first positioning walls protruding from the first mounting surface and sandwiching the first lead terminal therebetween; a pair of second positioning walls protruding from the second mounting surface and sandwiching the second lead terminal therebetween; Vacuum sensor.

3. 3. The vacuum sensor according to claim 2, a plurality of the first lead terminals and a plurality of the second lead terminals are provided; the pair of first positioning walls sandwich the first lead terminals therebetween, the pair of second positioning walls sandwich the second lead terminals therebetween; Vacuum sensor.

4. 2. A method for manufacturing the vacuum sensor according to claim 1, comprising: a step of accommodating the connector terminal in the accommodating portion of the housing; a step of mounting a tip of the first lead terminal on one end of the connector terminal accommodated in the accommodation portion, and mounting the second lead terminal on the second mounting surface; and irradiating the first lead terminal with laser light from the second lead terminal side toward a side of the first lead terminal away from the second lead terminal to weld the first lead terminal and the connector terminal together. A method for manufacturing a vacuum sensor.

Images