Linear sensor
The linear sensor's innovative housing configuration with a welded cover member and recessed protrusion structure addresses the issue of foreign matter intrusion, enhancing sensor reliability and performance.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD
- Filing Date
- 2024-10-01
- Publication Date
- 2026-04-13
Smart Images

Figure 2026064113000001_ABST
Abstract
Description
Technical Field
[0001] The present disclosure relates to a linear sensor, and more particularly to a linear sensor including a substrate located inside a housing.
Background Art
[0002] Patent Document 1 discloses a rotation angle detection device. This rotation angle detection device includes a substrate on which an angle detection unit is mounted, a case, and a lid member.
[0003] The case has a case base and a case protrusion. The case protrusion projects axially from the case base. The case protrusion includes a case convex end face. The case convex end face is the end face of the case protrusion on the side opposite to the case base. In the rotation angle detection device, a substrate space defined by the case base and the case protrusion is formed. Further, in the rotation angle detection device, a substrate opening that is a space on the case convex end face of the case protrusion, is axially oriented and open, and communicates with the substrate space is formed. The substrate is inserted into the substrate space through this substrate opening.
[0004] The lid member is connected to the case convex end face. Further, the connection surface of this lid member and the case convex end face are welded by laser or the like, or adhered by an adhesive or the like.
Prior Art Documents
Patent Documents
[0005]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0006] In a sensor device such as the rotation angle detection device of Patent Document 1, when foreign matter enters the substrate space, the foreign matter may come into contact with the substrate, and the detection performance may deteriorate.
[0007] The objective of this disclosure is to provide a linear sensor capable of suppressing sensor malfunctions caused by the intrusion of foreign matter. [Means for solving the problem]
[0008] A linear sensor according to one aspect of the present disclosure comprises a housing and a substrate. The housing has an outer housing and a cover member. The outer housing has a first recess opening upward. The cover member is positioned to cover the first recess and is welded to the outer housing. The substrate is positioned inside the housing. The outer housing has a side wall portion that constitutes the side surface of the first recess and a bottom portion that constitutes the bottom surface of the first recess. The upper end of the side wall portion of the outer housing includes a recess portion provided so as to surround the outer circumference of the first recess when viewed from above, and an outer wall portion provided so as to surround the outer circumference of the recess portion when viewed from above and located above the bottom surface of the recess portion. The cover member has a covering portion that overlaps with the first recess when viewed from above, a side portion provided so as to surround the covering portion and overlaps with the recess portion when viewed from above, and a projection portion that protrudes downward from the side portion and whose lower surface is welded to the recess portion around its entire circumference. When viewed from above, the protruding portion is located inward from the outer circumference of the side portion. [Effects of the Invention]
[0009] According to this disclosure, there is an advantage in that it is possible to suppress the occurrence of sensor malfunctions caused by the intrusion of foreign objects. [Brief explanation of the drawing]
[0010] [Figure 1] Figure 1 is a perspective view of the linear sensor of the embodiment, seen from above. [Figure 2] Figure 2 is a perspective view of the linear sensor shown above, viewed from below. [Figure 3] Figure 3 is an exploded perspective view of the linear sensor shown above. [Figure 4] Figure 4 is a side view of the linear sensor shown above. [Figure 5]Figure 5 is a sectional view taken along the line V-V of Figure 4. [Figure 6] Figure 6 is an enlarged view of the main part A1 of Figure 5. [Figure 7] Figure 7 is a sectional view taken along the line VII-VII of Figure 4. [Figure 8] Figure 8 is an explanatory diagram for explaining the welding method of the housing of the linear sensor as described above. [Figure 9] Figure 9 is an explanatory diagram for explaining the welding method of the housing of the linear sensor as described above in the case of misalignment. [Figure 10] Figure 10 is an enlarged view of the main part of the linear sensor of Modification 1. [Figure 11] Figure 11 is a perspective view of the linear sensor of Modification 2 as seen from above. [Figure 12] Figure 12 is a sectional view of the linear sensor as described above. [Figure 13] Figure 13 is an enlarged view of the main part A2 of Figure 12. [Figure 14] Figure 14 is an enlarged view of the main part of the linear sensor of Modification 3. [Figure 15] Figure 15 is an enlarged view of the main part of the linear sensor of Modification 4. [Figure 16] Figure 16 is an explanatory diagram for explaining the welding method of the housing of the linear sensor of the comparative example in the case of misalignment.
Embodiments for Carrying Out the Invention
[0011] Hereinafter, a linear sensor according to an embodiment of the present disclosure will be described with reference to the accompanying drawings. However, the following embodiments are only a part of various embodiments of the present disclosure. The following embodiments can be variously modified according to design and the like as long as the object of the present disclosure can be achieved. In addition, each drawing described in the following embodiments is a schematic drawing, and the ratio of the size and thickness of each component in the drawing does not necessarily reflect the actual dimensional ratio.
[0012] (1) Embodiment Referring to FIGS. 1 to 7, the linear sensor 1 (sensor device) according to the embodiment will be described. FIG. 1 is a perspective view of the linear sensor 1 as viewed from above. FIG. 2 is a perspective view of the linear sensor 1 as viewed from below. FIG. 3 is an exploded perspective view of the linear sensor 1. FIG. 4 is a side view of the linear sensor 1 as viewed from the direction (right side) in which the through hole 19 can be seen. FIG. 5 is a cross-sectional view of the linear sensor 1 at a position passing through the center of the middle connection terminal 301 among the three connection terminals 301 to 303. FIG. 6 is an enlarged view of the main part A1 in FIG. 5. FIG. 7 is a cross-sectional view of the linear sensor 1 at a position where the through hole 19 can be seen.
[0013] The linear sensor 1 is mounted, for example, on a vehicle including an engine and a motor. The vehicle is, for example, a PHEV (Plug-in Hybrid Electric Vehicle) or an EV. The linear sensor 1 is used, for example, for detecting the position of a gear in an EV transmission from the movement (position) of a shift fork. The linear sensor 1 is, for example, an inductive sensor.
[0014] Hereinafter, for convenience, a three-axis (X-axis, Y-axis, and Z-axis) of a right-handed three-dimensional orthogonal coordinate system will be defined for the linear sensor 1 as follows and described. That is, the direction along the axis of the cylindrical housing 10 included in the linear sensor 1 is taken as the Z-axis direction. Also, the direction orthogonal to the Z-axis direction and in which the connecting member 13 connected to the housing 10 extends is taken as the X-axis direction. Also, the direction orthogonal to both the X-axis direction and the Z-axis direction is taken as the Y-axis direction. Also, for convenience of explanation, the Z-axis direction is taken as the vertical direction, the side (positive direction of the Z-axis) where the cover member 12 is located with respect to the outer housing 11 in the housing 10 is “up”, and the opposite is “down”. Also, the X-axis direction is taken as the left-right direction, the positive direction of the X-axis is “right”, and the opposite is “left”. Also, the Y-axis direction is taken as the front-back direction, the positive direction of the Y-axis is “front”, and the opposite is “back”. However, the definition of the axis and direction in the present disclosure only shows the relative positional relationship between the members of the linear sensor 1 and does not limit the orientation during the use of the linear sensor 1 or the like.
[0015] As shown in Figures 1 to 4, the linear sensor 1 comprises a housing 10 and a circuit board 20.
[0016] The housing 10 is made of resin. As shown in Figures 1 to 4, the housing 10 has an outer housing 11 and a cover member 12.
[0017] The outer casing 11 is made of resin. As shown in Figure 3, the outer casing 11 is cylindrical with a bottom, and more specifically, it is roughly cylindrical with a bottom. As shown in Figures 2, 4, and 5, the outer casing 11 has a side wall portion 111 and a bottom portion 112 integrally.
[0018] As shown in Figures 3 and 5, the side wall portion 111 of the outer casing 11 is cylindrical. More specifically, the side wall portion 111 is cylindrical with a flat plate-like shape in part (the right side portion).
[0019] The bottom portion 112 of the outer casing 11 is plate-shaped. The bottom portion 112 is connected to the lower end of the side wall portion 111 and closes the lower opening of the side wall portion 111.
[0020] As shown in Figure 3, the outer casing 11 has a first recess 110 that opens upward. The first recess 110 is formed by being surrounded by the inner surface of the side wall portion 111 and the upper surface of the bottom portion 112. That is, the side wall portion 111 (more specifically, the inner surface of the side wall portion 111) constitutes the side surface of the first recess 110. The bottom portion 112 (more specifically, the upper surface of the bottom portion 112) constitutes the bottom surface of the first recess 110.
[0021] As shown in Figures 3 and 6, the upper end of the side wall portion 111 of the outer casing 11 includes a recessed portion 118 and an outer wall portion 119.
[0022] As shown in Figure 3, the recessed portion 118 is provided so as to surround the outer circumference of the first recess 110 when viewed from above. The recessed portion 118 is provided around the entire circumference of the first recess 110.
[0023] Of the outer casing 11, at least the upper surface of the recessed portion 118 has the characteristic of absorbing the laser light L1 described later (light absorption). The outer casing 11 is, for example, made of a black material.
[0024] As shown in Figure 3, the outer wall portion 119 is provided so as to surround the outer periphery of the recess portion 118 when viewed from above. The outer wall portion 119 is provided around the entire circumference of the first recess 110. As shown in Figures 5 to 7, the outer wall portion 119 is located above the bottom surface (top surface) of the recess portion 118. A step is formed between the top surface of the outer wall portion 119 and the bottom surface of the recess portion 118.
[0025] As shown in Figure 3, a groove 113 is formed along the circumferential direction of the side wall portion 111 on the lower part of the outer surface of the side wall portion 111. In addition, a plurality (for example, three) of convex ribs 114 are formed on the inner surface of the side wall portion 111 to facilitate insertion of the substrate 20 into the outer housing 11. The three convex ribs 114 are arranged asymmetrically, with two on the left and one on the right.
[0026] The cover member 12 is made of resin. The cover member 12 has properties that allow it to transmit, for example, the laser light L1 described later (translucency). The cover member 12 is bonded to the outer housing 11 so as to cover the first recess 110 of the outer housing 11.
[0027] As shown in Figures 3, 5 to 7, the cover member 12 has a covering portion 128 and a side portion 129. The covering portion 128 is the part of the cover member 12 that overlaps with the first recess 110 of the outer housing 11 when viewed from above. The side portion 129 is the part of the cover member 12 that overlaps with the recess 118 of the outer housing 11 when viewed from above.
[0028] As shown in Figure 3, the covering portion 128 is a bottomed cylindrical shape, or more specifically, a bottomed, substantially cylindrical shape. The covering portion 128 integrally comprises a side wall portion 121 and a bottom portion 122.
[0029] The side wall portion 121 of the covering portion 128 is cylindrical. More specifically, the side wall portion 121 is a flat cylindrical shape in part (the right side portion). As shown in Figures 5 and 7, the side wall portion 121 is a tapered cylindrical shape in which the diameter decreases towards the bottom (away from the open top surface).
[0030] As shown in Figure 3, the side wall portion 121 of the covering portion 128 has multiple (in this case, three) recesses 123 that are recessed inward to avoid the multiple protruding ribs 114 of the outer housing 11.
[0031] Furthermore, the inner surface of the side wall portion 121 of the covering portion 128 is provided with a plurality (eight in this case) of protrusions 124 that project toward the center of the covering portion 128. This improves the strength of the covering portion 128. In addition, when manufacturing the cover member 12 by resin molding, it is possible to create or adjust a difference between the area of the portion that contacts the upper mold (for example, the inner surface of the cover member 12) and the area of the portion that contacts the lower mold (for example, the outer surface of the cover member 12). This adjustment makes it easier for the upper and lower molds to be removed from the cover member 12 simultaneously, thus simplifying the manufacturing of the cover member 12.
[0032] The projection 124 is rectangular in side view. Furthermore, the projection 124 is a ridge-like projection extending in the vertical direction. Multiple projections 124 are arranged at equal angular intervals on the inner surface of the cylindrical side wall 121, with the center of the side wall 121 as the reference point.
[0033] The bottom portion 122 of the covering portion 128 is plate-shaped. The bottom portion 122 is connected to the lower end of the side wall portion 121 and closes the lower opening of the side wall portion 121.
[0034] Furthermore, a convex portion 125 (a concave portion on the lower side of the bottom portion 122) that protrudes upward is formed at the center of the upper surface of the bottom portion 122 of the covering portion 128.
[0035] As shown in Figures 1 and 3, the covering portion 128 has a second recess 120 that opens upward. The second recess 120 is formed by being surrounded by the inner surface of the side wall portion 121 and the upper surface of the bottom portion 122. That is, the side wall portion 121 (more specifically, the inner surface of the side wall portion 121) constitutes the side surface of the second recess 120. Also, the bottom portion 122 (more specifically, the upper surface of the bottom portion 122) constitutes the bottom surface of the second recess 120.
[0036] The side portion 129 is provided so as to surround the covering portion 128. The side portion 129 is provided around the entire circumference of the covering portion 128. The side portion 129 protrudes outward from the upper end of the covering portion 128. When viewed from above, the side portion 129 is approximately annular in shape.
[0037] As shown in Figure 6, a projection 127 is provided on the lower surface of the side portion 129 of the cover member 12. The projection 127 protrudes downward from the side portion 129. The projection 127 protrudes from the lower surface of the side portion 129 in a manner that surrounds the covering portion 128 (in a roughly annular shape). Thus, the cover member 12 has a projection 127 that protrudes downward from the side portion 129.
[0038] As shown in Figure 5, when viewed from above, the protrusion 127 is located inward from the outer circumference of the side portion 129. There is a step between the outer surface of the side portion 129 and the outer surface of the protrusion 127.
[0039] Furthermore, when viewed from above, the protruding portion 127 is positioned away from the covering portion 128.
[0040] As shown in Figures 5 and 7, the second recess 120 of the covering portion 128 of the cover member 12 is located inside the first recess 110 of the outer housing 11. In the housing 10, a space 100 is formed between the covering portion 128 of the cover member 12 and the outer housing 11.
[0041] As shown in Figures 5 and 7, the housing 10 has a first space 101 between the bottom 112 of the outer housing 11 and the bottom 122 of the cover member 12. The first space 101 is the space within the housing 100 that is enclosed by the bottom 112 of the outer housing 11, the bottom 122 of the covering portion 128 of the cover member 12, and the side wall portion 111 of the outer housing 11.
[0042] Furthermore, the housing 10 has a second space 102. The second space 102 is the space within the housing 100 between the side wall portion 111 of the outer housing 11 and the side wall portion 121 of the covering portion 128 of the cover member 12.
[0043] As shown in Figures 5 and 7, the circuit board 20 is located inside the housing 10. That is, the circuit board 20 is located within the space 100 of the housing 10. The circuit board 20 is located between the bottom 112 of the outer housing 11 and the bottom 122 of the cover member 12. That is, the circuit board 20 is located in the first space 101 of the space 100 inside the housing 10.
[0044] The substrate 20 has a sensor section 21. The sensor section 21 includes, for example, a coil patterned on the substrate 20. The sensor section 21 is located near the center of the substrate 20. That is, the sensor section 21 is located on the substrate 20 in a region of the first space 101 within the housing 10 that is away from the second space 102.
[0045] In addition to the sensor unit 21, one or more electronic components 22 are mounted on the circuit board 20. These electronic components 22 may include, for example, an IC, memory, resistor, or capacitor.
[0046] In the linear sensor 1, the cover member 12 is fixed to the outer housing 11 by welding (resin welding). More specifically, the cover member 12 is fixed to the outer housing 11 by welding the lower surface of the protruding portion 127 to the recessed portion 118 (more specifically, the bottom surface of the recessed portion 118) of the side wall portion 111 of the outer housing 11. Because the protruding portion 127 is located inside the outer circumference of the side portion 129, the laser beam L1 is more likely to hit the lower surface of the protruding portion 127 when welding, as described later, thus reducing the likelihood of welding defects.
[0047] Here, the method for fixing the cover member 12 to the outer casing 11 will be explained with reference to Figure 8.
[0048] First, the covering portion 128 of the cover member 12 is fitted into the first recess 110 of the outer housing 11 so that the lower surface of the protruding portion 127 contacts the bottom (upper) surface of the recessed portion 118. Next, a retaining glass plate 90 is placed on the upper surface of the cover member 12. Then, a laser beam L1 is irradiated from the upper side of the glass plate 90 so as to reach the lower surface of the protruding portion 127. At this time, the glass plate 90 may be pressed down from above while the laser beam L1 is irradiated. When the laser beam L1 is irradiated, the portion of the upper surface of the recessed portion 118 that is in contact with the protruding portion 127 absorbs the laser beam L1, and the interface between the protruding portion 127 and the recessed portion 118 melts. Then, as this molten portion cools and solidifies, the lower surface of the protruding portion 127 and the bottom surface of the recessed portion 118 are welded together, and the cover member 12 is fixed to the outer housing 11.
[0049] By irradiating the protrusion 127 with the laser beam L1 over its entire circumference, the lower surface of the protrusion 127 is welded to the recess 118 over its entire circumference. Since the lower surface of the protrusion 127 is welded to the recess 118 surrounding the outer circumference of the first recess 110 over its entire circumference, the possibility of foreign matter entering the housing 10 through the recess 118 can be reduced. As a result, the occurrence of sensor malfunctions due to the intrusion of foreign matter can be suppressed.
[0050] As shown in Figures 5 to 7, the lower surface of the covering portion 128 (the lower surface of the bottom portion 122) is located below the bottom surface (top surface) of the recessed portion 118 of the outer housing 11. This further reduces the possibility of foreign matter entering the housing 10 through the recessed portion 118. Furthermore, even if foreign matter does enter the housing 10 through the recessed portion 118, it will pass through the space between the side surface of the covering portion 128 and the inner surface of the outer housing 11 (second space 102). This reduces the possibility of foreign matter reaching the substrate 20, further suppressing sensor malfunctions caused by foreign matter intrusion.
[0051] Furthermore, in the linear sensor 1 of this embodiment, as described above, the covering portion 128 has a second recess 120. The bottom surface of the second recess 120 (the top surface of the bottom portion 122 of the covering portion 128) is located below the bottom surface (top surface) of the recessed portion 118 of the outer housing 11. In this way, because the second recess 120 has a certain depth or greater (here, a depth such that the bottom surface of the second recess 120 is located below the bottom surface of the recessed portion 118), foreign objects that reach the linear sensor 1 from above will be trapped in the second recess 120. This makes it difficult for foreign objects to reach the recessed portion 118, further reducing the possibility of foreign objects entering the housing 10.
[0052] As shown in Figures 5 to 7, the covering portion 128 of the cover member 12 is in contact with the inner surface of the side wall portion 111 of the outer housing 11. In other words, the covering portion 128 of the cover member 12 is in contact with the side surface of the first recess 110 in the outer housing 11. Here, the outer surface of the upper end portion of the side wall portion 121 of the covering portion 128 is in contact with the inner surface of the upper end portion of the side wall portion 111 of the outer housing 11. Because the covering portion 128 is in contact with the inner surface of the side wall portion 111, even if foreign matter enters the housing 10, the possibility of the foreign matter coming into contact with the substrate 20 can be further reduced.
[0053] Furthermore, in the linear sensor 1 of this embodiment, the covering portion 128 of the cover member 12 is in contact with the inner surface of the side wall portion 111 of the outer housing 11 around its entire circumference. This further reduces the possibility of foreign matter entering the housing 10 and coming into contact with the substrate 20.
[0054] As shown in Figure 5, the vertical depth D2 of the second recess 120 is smaller than the vertical depth D1 of the first recess 110. Also, the vertical depth D2 of the second recess 120 is greater than half the vertical depth D1 of the first recess 110. In this disclosure, "vertical depth D1 of the first recess 110" means the vertical distance from the upper end surface of the side wall portion 111 of the outer housing 11 to the upper surface of the bottom portion 112 of the outer housing 11 (the lowest part of the upper surface of the bottom portion 112). Also, in this disclosure, "vertical depth D2 of the second recess 120" means the vertical distance from the upper end surface of the side wall portion 121 of the cover member 12 to the upper surface of the bottom portion 122 of the cover member 12 (the lowest part of the upper surface of the bottom portion 122).
[0055] In the linear sensor 1, the vertical depth D2 of the second recess 120 is greater than half the vertical depth D1 of the first recess 110, which increases the vertical dimension of the second space 102. Therefore, even if a foreign object enters the housing 10 from the upper end of the second space 102, the foreign object will move downward through the second space 102 and will have difficulty moving horizontally (forward, backward, left, or right). This reduces the possibility of the foreign object reaching the substrate 20.
[0056] Furthermore, when viewed from above, the area of the bottom surface of the second recess 120 is smaller than the area of the bottom surface of the first recess 110. Also, when viewed from above, the area of the bottom surface of the second recess 120 is larger than half the area of the bottom surface of the first recess 110. In this disclosure, "the area of the bottom surface of the first recess 110 when viewed from above" means the area of the upper surface of the bottom 112 of the outer housing 11 when viewed from above (the area of the region enclosed by the contour of the bottom 112 on the projection plane when the bottom 112 is projected onto a horizontal projection plane). Also, in this disclosure, "the area of the bottom surface of the second recess 120 when viewed from above" means the area of the upper surface of the bottom 122 of the cover member 12 when viewed from above (the area of the region enclosed by the contour of the bottom 122 on the projection plane when the bottom 122 is projected onto a horizontal projection plane).
[0057] Furthermore, when viewed from above, the area of the bottom surface of the second recess 120 is larger than the area of the substrate 20.
[0058] In the linear sensor 1, the area of the bottom surface of the second recess 120 is larger than the area of the substrate 20, which reduces the horizontal dimensions (front, back, left, and right) of the second space 102. Therefore, even if a foreign object enters the housing 10 from the upper end of the second space 102, it is difficult for that foreign object to move horizontally (front, back, left, and right). This reduces the possibility of the foreign object reaching the substrate 20.
[0059] As shown in Figures 2, 5, and 7, the bottom 112 of the outer casing 11 has a third recess 115 that opens downward. The substrate 20 is positioned above the third recess 115 and on the upper surface of the bottom 112 of the outer casing 11. More specifically, the sensor portion 21 provided on the substrate 20 is located within the projection area of the third recess 115 when the linear sensor 1 is viewed from above.
[0060] Furthermore, as shown in Figures 5 and 7, the bottom portion 112 of the outer casing 11 has a thin-walled portion 116. In the linear sensor 1, the thin-walled portion 116 includes the bottom of the third recess 115. The thin-walled portion 116 is thinner than the substrate 20. Also, the thin-walled portion 116 is thinner than the bottom portion 122 of the covering portion 128 of the cover member 12. The sensor portion 21 of the substrate 20 is positioned on the upper surface of the thin-walled portion 116.
[0061] The linear sensor 1 detects the position of an object by detecting changes in magnetic flux caused by the object approaching or moving away from the high-frequency magnetic field generated by the pattern coil (sensor section 21). The object is located, for example, below the linear sensor 1. The detection accuracy of the linear sensor 1 depends on the gap (distance) between the sensor section 21 and the object, and it is desirable that the gap between the sensor section 21 and the object be as small as possible. Therefore, from the viewpoint of improving the detection accuracy of the sensor section 21, it is desirable that the part of the housing 10 in which the substrate 20 (sensor section 21) is placed be thin. For this reason, in the linear sensor 1 of this embodiment, the housing 10 has a thin-walled section 116, and the substrate 20 is placed so that the sensor section 21 overlaps with the thin-walled section 116.
[0062] As shown in Figures 3 to 5 and Figure 7, the outer casing 11 has a through hole 19 that connects to the outside. The through hole 19 penetrates the side wall portion 111 of the outer casing 11 in the left-right direction. As shown in Figure 7, the through hole 19 connects to the second space 102 of the space 100 inside the casing 10. In the linear sensor 1 of this embodiment, the space 100 inside the casing 10 is connected to the outside only by the through hole 19.
[0063] In the linear sensor 1, the outer housing 11 has through holes 19, so that the gas inside the housing 10 that has expanded due to heat can be released to the outside through the through holes 19. As a result, even if the linear sensor 1 is placed in a high-temperature environment, the pressure in the space 100 inside the housing 10 is less likely to increase. This makes deformation of the housing 10, especially deformation of the thin-walled portion 116, less likely.
[0064] Furthermore, since the through-hole 19 is connected to the second space 102, even if foreign matter enters the second space 102 through the through-hole 19, it is difficult for that foreign matter to reach the substrate 20.
[0065] As shown in Figures 1 to 7, the linear sensor 1 further comprises a connecting member 13 and three connecting terminals 301 to 303.
[0066] The connecting member 13 is made of, for example, resin. The connecting member 13 is connected to the outer casing 11. The connecting member 13 extends to the right from the upper end of the flat plate portion of the side wall portion 111 of the outer casing 11. The connecting member 13 is a component for connecting the linear sensor 1 to an external device, such as a vehicle's ECU (Electronic Control Unit).
[0067] The connecting member 13 is cylindrical. As shown in Figure 4, the cross-sectional shape of the inner surface of the connecting member 13 is a rectangle with rounded corners. In the extending direction (left-right direction) of the connecting member 13, the width of the cross-section of the inner surface of the connecting member 13 is constant. In other words, there are no protrusions or indentations on the inner surface of the connecting member 13. The connecting member 13 has an internal space (third space 103) inside.
[0068] Each of the three connection terminals 301 to 303 integrally includes a board connection portion 31 and an external connection portion 32. Of each of the connection terminals 301 to 303, the portion located within the first space 101 and the portion held by the outer housing 11 (the J-shaped portion in Figure 5 and the portion extending diagonally upward to the right from the upper end of the J) is the board connection portion 31. Also, of each of the connection terminals 301 to 303, the portion located within the internal space (third space 103) of the connection member 13 (the portion extending in the left-right direction) is the external connection portion 32.
[0069] The first end 311 of the board connection portion 31 is located in the first space 101 and is electrically connected to the board 20. The three connection terminals 301 to 303 are electrically connected to the sensor portion 21 and the electronic component 22 (IC) via conductive patterns formed on the board 20.
[0070] The second end 312 of the board connection portion 31 is located inside the through hole 19. The external connection portion 32 is connected to the second end 312 of the board connection portion 31.
[0071] The external connection portion 32 is located in the internal space (third space 103) of the connecting member 13. The external connection portion 32 is located above the through hole 19.
[0072] The external connection section 32 is electrically connected, for example, to an external device (such as an ECU) to which the linear sensor 1 is coupled via the connecting member 13. The sensor signal obtained by processing the data acquired by the sensor section 21 of the circuit board 20 is transmitted to the external device via the three connection terminals 301 to 303.
[0073] As shown in Figures 4 and 7, in the linear sensor 1, the through-hole 19 is connected to the internal space (third space 103) of the connecting member 13. This suppresses the entry of foreign matter into the housing 10 through the through-hole 19, compared to the comparative example structure in which the through-hole is connected to the outside in a part other than the part connected to the connecting member in the outer housing. In addition, in the comparative example structure, there is a possibility that an external device such as a thermometer is located beyond the through-hole, but it is unlikely that such a device is located at the connection point of the connecting member 13. Therefore, the possibility that gas released to the outside of the housing 10 through the through-hole 19 may affect an external device such as a thermometer is reduced. Furthermore, by forming the through-hole 19 so that the second space 102 is connected to the internal space (third space 103) of the cylindrical connecting member 13, the height of the linear sensor 1 can be reduced.
[0074] In the linear sensor 1, the connecting member 13 is integrally formed with the outer housing 11. For example, the outer housing 11 and the connecting member 13 are integrally formed by resin molding. This makes it even more difficult for foreign matter to enter the inside of the housing 10 compared to the case where the connecting member and the outer housing are separate and joined to each other by adhesive or the like. Also, when joining the connecting member and the outer housing, it is not necessary to align the position of the through holes and assemble them in a way that prevents foreign matter from entering.
[0075] As shown in Figures 5 and 7, the linear sensor 1 further includes a wall portion 14. The wall portion 14 is located inside the through hole 19. The wall portion 14 is formed integrally with the outer housing 11. The wall portion 14 covers the portion of the connection terminals 301 to 303 that is exposed to the through hole 19. More specifically, as shown in Figures 4, 5, and 7, the wall portion 14 covers the front side (right side in Figure 4), rear side (left side in Figure 4), and left side (left side in Figure 5) of the second end 312 of the substrate connection portion 31. Although the wall portion 14 does not cover the right side (right side in Figure 5) of the second end 312 of the substrate connection portion 31 as shown in Figure 4, it may also cover the right side (right side in Figure 5).
[0076] In this way, since the wall portion 14 covers the portion of the connection terminals 301 to 303 that is located inside the through hole 19, the possibility of foreign objects coming into contact with the connection terminals 301 to 303 and damaging them is reduced. In addition, the possibility of metal foreign objects getting mixed in and causing a short circuit between the connection terminals 301 to 303 is reduced.
[0077] As shown in Figures 3 and 5, the wall portion 14 is flush with the side surface of the first recess 110 (the side of the side wall portion 111 of the outer housing 11 that faces the first recess 110). Also, the length of the wall portion 14 (dimension in the left-right direction) is shorter than the length of the through hole 19 (dimension in the left-right direction). In this disclosure, "flush" does not necessarily mean that the wall portion 14 and the inner surface of the first recess 110 are on the same plane and connected; the wall portion 14 may slightly protrude or recess from the inner surface of the first recess 110.
[0078] As shown in Figures 1 to 7, the linear sensor 1 further comprises a pair of fixed arms 15. The fixed arms 15 are for fixing the linear sensor 1 to an external member.
[0079] The fixed arms 15 are made of, for example, resin. The pair of fixed arms 15 are connected to the outer housing 11. The pair of fixed arms 15 are integrally formed with the outer housing 11. For example, the outer housing 11 and the pair of fixed arms 15 are integrally formed by resin molding. The pair of fixed arms 15 protrude from the outer surface of the side wall portion 111 of the outer housing 11 in opposite directions. The fixed arms 15 are flat. A through hole 150 is formed at the tip of the fixed arms 15, penetrating vertically.
[0080] A cylindrical metal collar 151 is provided in the through hole 150 of the fixed arm portion 15. The collar 151 is integrally formed with the fixed arm portion 15 by insert molding, in which the collar 151 is used as an insert part.
[0081] As shown in Figures 1 to 5 and Figure 7, the linear sensor 1 further includes an O-ring 40. The O-ring 40 is positioned in a groove 113 formed in the side wall portion 111 of the outer housing 11. The O-ring 40 ensures airtightness of the mounting portion when the linear sensor 1 is attached to an external member.
[0082] (2) Advantages The advantages of the linear sensor 1 of this embodiment will be explained, including a comparison with the linear sensor of the comparative example.
[0083] The comparative example linear sensor has basically the same configuration as the linear sensor 1 of the embodiment, but differs in that, as shown in Figure 16, the cover member 12 does not have a protrusion 127, and a protrusion 1181 with a shape corresponding to the protrusion 127 is formed on the bottom surface (top surface) of the recess 118 of the outer housing 11.
[0084] In the comparative example linear sensor, when fixing the cover member 12 to the outer housing 11, as shown in Figure 16, the covering portion 128 of the cover member 12 is fitted into the outer housing 11, a retaining glass plate 90 is placed, and the cover member 12 is fixed to the outer housing 11 by welding when the laser beam L1 is irradiated. In the comparative example linear sensor, the upper surface of the protruding portion 1181 of the outer housing 11 absorbs the laser beam L1, so the upper surface of the protruding portion 1181 of the outer housing 11 and the lower surface of the side portion 129 of the cover member 12 are welded together.
[0085] In the linear sensor, for example, due to manufacturing errors in the outer housing 11 and the cover member 12, the outer circumference of the covering portion 128 of the cover member 12 may be (partially) smaller than the diameter of the first recess 110 of the outer housing 11, as shown in Figure 16. Also, in the linear sensor, due to manufacturing errors in the cover member 12, the protruding length of the side portion 129 of the cover member 12 may be (partially) shorter. In such cases, in the linear sensor of the comparative example, as shown in Figure 16, a part of the upper surface of the protruding portion 1181 may be exposed without being covered by the side portion 129 of the cover member 12 (occurrence of misalignment). When laser light L1 is irradiated in this misaligned state, the energy of the laser light L1 may not be sufficiently transmitted to the upper surface of the protruding portion 1181, and the interface between the protruding portion 1181 and the side portion 129 may not melt sufficiently, potentially reducing the fixing strength between the outer housing 11 and the cover member 12. When external force is applied to the part with reduced fixing strength, the cover member 12 may (partially) detach from the outer housing 11. This could lead to foreign matter entering the space 100 inside the enclosure 10.
[0086] On the other hand, in the linear sensor 1 of this embodiment, as shown in Figures 6 and 8, the protrusion 127 is provided on the lower surface of the side portion 129 of the cover member 12. Therefore, for example, if the outer circumference of the covering portion 128 of the cover member 12 becomes smaller than the diameter of the first recess 110 of the outer housing 11, even if the protrusion 127 is positioned relatively inward (misaligned) as shown in Figure 9, the entire lower surface of the protrusion 127 is easily welded to the bottom surface of the recess 118. Therefore, the linear sensor 1 of this embodiment can reduce the possibility of a decrease in the fixing strength between the outer housing 11 and the cover member 12 compared to the linear sensor of the comparative example.
[0087] Furthermore, as described above, in the linear sensor 1 of this embodiment, the covering portion 128 (side surface of the covering portion 128) of the cover member 12 faces and contacts the side surface of the first recess 110 in the outer housing 11. Therefore, misalignment between the outer housing 11 and the cover member 12 is unlikely to occur in the first place. This makes it easier to align the laser beam L1 with respect to the protrusion 127, and improves the fixing strength between the outer housing 11 and the cover member 12.
[0088] (3) Variant The embodiments described above are merely one of many embodiments of this disclosure. These embodiments can be modified in various ways depending on the design, etc., as long as the objectives of this disclosure are achieved. The following lists some modifications of the embodiments. The embodiments described above and the modifications described below can be combined and applied as appropriate.
[0089] (3.1) Variation 1 The linear sensor 1 of this modified example will be described with reference to Figure 10. In the linear sensor 1 of this modified example, components similar to those in the linear sensor 1 of the embodiment are denoted by the same reference numerals and their descriptions are omitted as appropriate.
[0090] In this modified linear sensor 1, as shown in Figure 10, the side wall portion 111 of the outer housing 11 further has a projection 117. The projection 117 is provided inside the recess portion 118 and along the edge of the first recess 110. In addition, the protruding portion 127 of the cover member 12 is positioned inside the recess portion 118 (between the projection 117 and the outer wall portion 119). In this way, because the side wall portion 111 has the projection 117, the distance required for foreign matter to enter the space 100 is increased, further reducing the intrusion of foreign matter into the housing 10.
[0091] Furthermore, as shown in Figure 10, the vertical height L10 of the projection 117 is less than the vertical height L20 of the protruding portion 127. This reduces the intrusion of foreign matter while improving the manufacturing stability of the welding process. To explain in more detail, for example, if the height L10 of the projection 117 is greater than the height L20 of the protruding portion 127, the lower surface of the protruding portion 127 will be lifted away from the bottom surface of the recessed portion 118, and welding between the lower surface of the protruding portion 127 and the recessed portion 118 may be insufficient. In contrast, by making the height L10 of the projection 117 less than the height L20 of the protruding portion 127, it becomes possible to sufficiently adhere and weld the lower surface of the protruding portion 127 to the recessed portion 118. As a result, the possibility of foreign matter entering the housing 10 can be further reduced, and the occurrence of sensor malfunctions due to the intrusion of foreign matter can be suppressed.
[0092] When welding is performed using laser light L1, the lower end of the protrusion 127 may melt, causing the vertical height L20 of the protrusion 127 to shrink. Therefore, the vertical height L20 of the protrusion 127 after welding may be approximately the same as the vertical height L10 of the projection 117, but it is sufficient that the distance from the lowest point of the molten surface of the protrusion 127 to the boundary between the protrusion 127 and the side portion 129 is greater than the vertical height L10 of the projection 117.
[0093] In this modified example, the projection 117 is provided around the entire circumference along the edge of the first recess 110. However, the projection 117 is not limited to this, and it is sufficient if it is provided on at least a portion of the edge of the first recess 110.
[0094] (3.2) Variation 2 The linear sensor 1 of this modified example will be described with reference to Figures 11 to 13. In the linear sensor 1 of this modified example, components similar to those in the linear sensor 1 of the embodiment are denoted by the same reference numerals and their descriptions are omitted as appropriate.
[0095] In this modified linear sensor 1, as shown in Figures 11 to 13, the covering portion 128 of the cover member 12 does not have a second recess 120. Specifically, the covering portion 128 is plate-shaped and covers the first recess 110 of the outer housing 11.
[0096] In this modified linear sensor 1, as shown in Figures 12 and 13, the upper end of the side wall portion 111 of the outer housing 11 includes a recessed portion 118 and an outer wall portion 119. The recessed portion 118 is provided so as to surround the outer circumference of the first recess 110 when viewed from above. The outer wall portion 119 is provided so as to surround the outer circumference of the recessed portion 118 when viewed from above and is located above the bottom surface of the recessed portion 118. The cover member 12 also has a covering portion 128, a side portion 129, and a protruding portion 127. The covering portion 128 overlaps with the first recess 110 when viewed from above. The side portion 129 is provided so as to surround the covering portion 128 and overlaps with the recessed portion 118 when viewed from above. The protruding portion 127 protrudes downward from the side portion 129 and its lower surface is welded to the recessed portion 118 around its entire circumference. Furthermore, when viewed from above, the protruding portion 127 is located inward from the outer circumference of the side portion 129. This reduces the intrusion of foreign matter into the housing 10 and suppresses sensor malfunctions caused by the intrusion of foreign matter.
[0097] Furthermore, in this modified linear sensor 1, the thickness (vertical dimension) of the covering portion 128 is greater than the thickness (vertical dimension) of the side portion 129. And, as shown in Figures 12 and 13, the lower surface of the covering portion 128 is located below the bottom surface of the recessed portion 118. This reduces the possibility of foreign matter entering the housing 10 through the recessed portion 118.
[0098] (3.3) Modification example 3 The linear sensor 1 of this modified example will be described with reference to Figure 14. In the linear sensor 1 of this modified example, components similar to those in the linear sensor 1 of modified example 2 are denoted by the same reference numerals and their descriptions are omitted as appropriate.
[0099] In this modified linear sensor 1, as shown in Figure 14, the cover member 12 further has a flange portion 126. The flange portion 126 is the part of the cover member 12 that overlaps with the outer wall portion 119 of the outer housing 11. The flange portion 126 protrudes outward from at least a part of the side portion 129. Here, the flange portion 126 protrudes outward from the entire circumference of the side portion 129.
[0100] Furthermore, in this modified linear sensor 1, as shown in Figure 14, the lower surface of the flange portion 126 is separated from the upper surface of the outer wall portion 119. That is, the lower surface of the flange portion 126 and the upper surface of the outer wall portion 119 are not in contact, and there is a gap between them. The thickness (vertical dimension) of the flange portion 126 is smaller than the thickness (vertical dimension) of the side portion 129.
[0101] In this modified linear sensor 1, the cover member 12 has a flange portion 126, which further reduces the possibility of foreign matter entering the housing 10.
[0102] (3.4) Modification 4 The linear sensor 1 of this modified example will be described with reference to Figure 15. In the linear sensor 1 of this modified example, components similar to those in the linear sensor 1 of modified example 2 are denoted by the same reference numerals and their descriptions are omitted as appropriate.
[0103] In this modified linear sensor 1, as shown in Figure 15, the cover member 12 further has a flange portion 126. The flange portion 126 is the part of the cover member 12 that overlaps with the outer wall portion 119 of the outer housing 11. The flange portion 126 protrudes outward from at least a part of the side portion 129. Here, the flange portion 126 protrudes outward from the entire circumference of the side portion 129.
[0104] Furthermore, in this modified linear sensor 1, as shown in Figure 15, at least a portion of the lower surface of the flange portion 126 contacts the outer wall portion 119. Here, the flange portion 126 is curved relative to the side portion 129, and a portion of the lower surface of the flange portion 126 contacts the outer wall portion 119. More specifically, the connection portion of the flange portion 126 with the side portion 129 contacts the upper surface of the outer wall portion 119 and bends (curves) upward. The flange portion 126 can bend in this way and contact the upper surface of the outer wall portion 119 by pressing the cover member 12 from above via the glass plate during welding of the lower surface of the protruding portion 127 and the recessed portion 118. In this case, the portion of the glass plate corresponding to the flange portion 126 on its lower surface may be recessed upward.
[0105] In this way, the lower surface of the flange portion 126 comes into contact with the outer wall portion 119, further reducing the possibility of foreign matter entering the housing 10.
[0106] The flange portion 126 and the outer wall portion 119 may be welded together, for example, by irradiating the interface with laser light L1. This further reduces the possibility of foreign matter entering the housing 10.
[0107] (3.5) Other variations In one modified example, the covering portion 128 of the cover member 12 may have a projection at its lower end, which may contact the side surface of the first recess 110 in the outer housing 11. Even in this case, the misalignment of the cover member 12 relative to the outer housing 11 can be reduced.
[0108] In one modified example, the housing 10 does not need to have a through hole 19 and may be airtightly sealed.
[0109] (4) Aspect As can be seen from the above embodiments and modifications, the following embodiments are disclosed herein.
[0110] A linear sensor (1) in the first embodiment comprises a housing (10) and a substrate (20). The housing (10) has an outer housing (11) and a cover member (12). The outer housing (11) has a first recess (110) that opens upward. The cover member (12) is positioned to cover the first recess (110) and is welded to the outer housing (11). The substrate (20) is positioned inside the housing (10). The outer housing (11) has a side wall portion (111) that forms the side surface of the first recess (110) and a bottom portion (112) that forms the bottom surface of the first recess (110). The upper end of the side wall portion (111) of the outer housing (11) includes a recessed portion (118) provided so as to surround the outer circumference of the first recess (110) when viewed from above, and an outer wall portion (119) provided so as to surround the outer circumference of the recessed portion (118) when viewed from above, and located above the bottom surface of the recessed portion (118). The cover member (12) has a covering portion (128) that overlaps with the first recess (110) when viewed from above, a side portion (129) provided so as to surround the covering portion (128) and overlaps with the recessed portion (118) when viewed from above, and a projection portion (127) that protrudes downward from the side portion (129) and whose lower surface is welded to the recessed portion (118) around its entire circumference. When viewed from above, the projection portion (127) is located inside the outer circumference of the side portion (129).
[0111] According to this embodiment, it is possible to reduce the intrusion of foreign matter into the housing (10), and to suppress the occurrence of sensor malfunctions due to the intrusion of foreign matter.
[0112] In the second embodiment of the linear sensor (1), in the first embodiment, the lower surface of the covering portion (128) is located below the bottom surface of the recessed portion (118).
[0113] According to this embodiment, the possibility of foreign matter entering the housing (10) through the recessed portion (118) can be reduced.
[0114] In the third embodiment of the linear sensor (1), in the first or second embodiment, the upper end of the side wall portion (111) of the outer housing (11) further has a projection (117) provided inside the recess (118) and along the edge of the first recess (110). The projection (127) is located inside the recess (118).
[0115] According to this embodiment, the intrusion of foreign matter into the housing (10) can be further reduced.
[0116] In the linear sensor (1) of the fourth embodiment, the vertical height (L10) of the projection (117) is less than the vertical height (L20) of the protruding portion (127).
[0117] According to this embodiment, it is possible to improve the manufacturing stability of the welding process on the lower surface of the protrusion (127) while reducing the intrusion of foreign matter.
[0118] In the linear sensor (1) of the fifth embodiment, in any one of the first to fourth embodiments, the covering portion (128) of the cover member (12) has a second recess (120) that opens upward. The second recess (120) is located inside the first recess (110). The bottom surface of the second recess (120) is located below the bottom surface of the recess (118).
[0119] According to this embodiment, the intrusion of foreign matter into the housing (10) can be reduced.
[0120] In the linear sensor (1) of the sixth embodiment, as in the fifth embodiment, when viewed from above, the area of the bottom surface of the second recess (120) is larger than the area of the substrate (20).
[0121] According to this embodiment, even if a foreign object enters the housing (10), the possibility of that foreign object reaching the circuit board (20) can be reduced.
[0122] In the seventh embodiment of the linear sensor (1), in any one of the first to sixth embodiments, the cover member (12) further has a flange portion (126) that protrudes outward from at least a portion of the side portion (129). The lower surface of the flange portion (126) is separated from the upper surface of the outer wall portion (119). Viewed from above, the flange portion (126) overlaps with the outer wall portion (119) of the outer housing (11).
[0123] According to this embodiment, the possibility of foreign matter entering the housing (10) can be further reduced.
[0124] In the linear sensor (1) of the eighth embodiment, in any one of the first to sixth embodiments, the cover member (12) further has a flange portion (126) that protrudes outward from at least a portion of the side portion (129). At least a portion of the lower surface of the flange portion (126) is in contact with the outer wall portion (119).
[0125] According to this embodiment, the possibility of foreign matter entering the housing (10) can be further reduced.
[0126] In the linear sensor (1) of the ninth embodiment, the flange portion (126) is curved relative to the side portion (129) as in the eighth embodiment. A portion of the lower surface of the flange portion (126) is in contact with the outer wall portion (119).
[0127] According to this embodiment, the possibility of foreign matter entering the housing (10) can be further reduced.
[0128] In the linear sensor (1) of the tenth embodiment, the flange portion (126) and the outer wall portion (119) are welded together in the eighth or ninth embodiment.
[0129] According to this embodiment, the possibility of foreign matter entering the housing (10) can be further reduced.
[0130] In the linear sensor (1) of the 11th embodiment, in any one of the first to tenth embodiments, the covering portion (128) of the cover member (12) is in contact with the side surface of the first recess (110) in the outer housing (11).
[0131] According to this embodiment, the misalignment of the cover member (12) with respect to the outer casing (11) is reduced. [Explanation of symbols]
[0132] 1 Linear Sensor 10 cabinets 11 Outer casing 110 First recess 111 Side wall section 112 Bottom 117 Protrusion 118 Recessed area 119 Exterior wall 12 Cover component 120 Second recess 126 Flange section 127 Protrusion 128 Covering part 129 Side 20 circuit boards
Claims
1. A resin housing having an outer housing having a first recess opening upward, and a cover member disposed to cover the first recess and welded to the outer housing, The enclosure comprises a circuit board disposed inside the enclosure, The aforementioned external enclosure is The side wall portion that constitutes the side surface of the first recess, The bottom portion of the first recess has a bottom portion that constitutes the bottom surface, The upper end of the side wall portion of the outer housing is A recessed portion is provided so as to surround the outer circumference of the first recess when viewed from above, It includes an outer wall portion that surrounds the outer periphery of the recess when viewed from above and is located above the bottom surface of the recess, The cover member is A covering portion that overlaps with the first recess when viewed from above, It is provided so as to surround the covering portion, and has a side portion that overlaps with the recessed portion when viewed from above, It has a projection that protrudes downward from the side portion, and whose lower surface is welded to the recessed portion around its entire circumference, When viewed from above, the protruding portion is located inward from the outer circumference of the side portion. Linear sensor.
2. The lower surface of the covering portion is located below the bottom surface of the recessed portion. The linear sensor according to claim 1.
3. The upper end of the side wall portion of the outer housing further has a projection provided inside the recess portion and along the edge of the first recess, The protruding portion is positioned inside the recessed portion. The linear sensor according to claim 1 or 2.
4. The vertical height of the projection is less than the vertical height of the protruding portion. The linear sensor according to claim 3.
5. The covering portion of the cover member has a second recess that opens upward, The second recess is located inside the first recess. The bottom surface of the second recess is located below the bottom surface of the recess. A linear sensor according to any one of claims 1 to 4.
6. Viewed from above, the area of the bottom surface of the second recess is larger than the area of the substrate. The linear sensor according to claim 5.
7. The cover member further has a flange portion that protrudes outward from at least a part of the side portion, The lower surface of the flange portion is separated from the upper surface of the outer wall portion. Viewed from above, the flange portion overlaps with the outer wall portion of the outer housing. A linear sensor according to any one of claims 1 to 6.
8. The cover member further has a flange portion that protrudes outward from at least a part of the side portion, At least a portion of the lower surface of the flange portion is in contact with the outer wall portion. A linear sensor according to any one of claims 1 to 6.
9. The flange portion is curved relative to the side portion. A portion of the lower surface of the flange portion is in contact with the outer wall portion. The linear sensor according to claim 8.
10. The flange portion and the outer wall portion are welded together. The linear sensor according to claim 8 or 9.
11. The covering portion of the cover member is in contact with the side surface of the first recess in the outer housing. A linear sensor according to any one of claims 1 to 10.
Citation Information
Patent Citations
Rotation angle detection device
JP2023022767A