Hydraulic pressure control device and method for manufacturing the same.

Abstract

To reduce the cause of variation in a coil terminal position by holding a coil device with a case, facilitating assembly of the case and a circuit board, and provide a manufacturing method capable of directly holding the coil device with the case.SOLUTION: A liquid pressure controller comprises: a coil device comprising a bobbin made of a resin material, a pair of coil terminals made of a conductive material, a coil made of a conductive material, and a yoke made of a magnetic material; a case made of a resin material that holds the coil device; a circuit board assembled into the case; and a housing assembled into the case. The case has: an outer peripheral wall surface surrounding an outer periphery of the coil device; a coil device housing space that houses the coil device inside the outer peripheral wall surface; and a terminal holding part that embeds a holding part where the terminal part is continuous with an end part in a third direction of a bent part of the pair of coil terminals. Therefore, the cause of variation in tip positions of the coil terminals is reduced, and the assembly of the case and the circuit board is facilitated.SELECTED DRAWING: Figure 18

Description

[Technical Field]

[0001] The present disclosure relates to a hydraulic pressure control device and a method for manufacturing the hydraulic pressure control device, and the hydraulic pressure control device of the present disclosure is suitable for use in, for example, a vehicle brake system. [Background technology]

[0002] Patent Document 1 describes a technology for stabilizing the assembly of a circuit board by press-fitting a coil terminal into a case. However, Patent Document 1 requires a press-fitting process for press-fitting the coil terminal into the case, which increases the assembly man-hours. Furthermore, the height of the coil terminal must be controlled by the amount of press-fitting, making the assembly itself difficult. Furthermore, it is necessary to consider the reduction in holding force due to creep of the case caused by press-fitting the coil terminal, making it difficult to control the strength of the coil terminal retainer. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2018-131187 Summary of the Invention [Problem to be solved by the invention]

[0004] In view of the above, the present disclosure provides a hydraulic control device that holds a coil device directly in a case. Another object of the present disclosure is to reduce factors that cause variations in the tip position of the coil terminals by holding the coil device in a case, and to facilitate assembly of the case and the circuit board. Another object of the present disclosure is to provide a method for manufacturing a hydraulic control device that can hold a coil device directly in a case. [Means for solving the problem]

[0005] The first aspect of the present disclosure is a hydraulic control device having a coil device including a bobbin made of a resin material, a pair of coil terminals made of a conductive material, a coil made of a conductive material, and a yoke made of a magnetic material, a case made of a resin material that holds the coil device, a circuit board assembled to the case, and a housing assembled to the case.

[0006] The first bobbin of the present disclosure has a cylindrical portion, a first flange portion formed on a first axial side of the cylindrical portion, and a second flange portion formed on a second axial side of the cylindrical portion opposite the first axial direction. Each of the pair of coil terminals has a base portion fixed to the first flange portion, an extension portion extending from the base portion toward the first axial direction, a terminal portion formed at an end portion in the first axial direction, and a holding portion located between the terminal portion and the base portion.

[0007] The case also has an outer wall surface that surrounds the outer periphery of the coil device, a coil device accommodating space inside this outer wall surface that accommodates the coil device, and a terminal holding portion in which the holding portions of a pair of coil terminals are embedded.

[0008] In the first aspect of the present disclosure, the holding portions of the pair of coil terminals are embedded in the terminal holding portion of the case, so the coil device can be held directly by the case, which reduces the factors that cause variations in the tip positions of the coil terminals and makes it easier to assemble the case and the circuit board.

[0009] The present disclosure others Each of the pair of coil terminals further has a bent portion that bends from the end of the extension portion in the first direction in a third direction, which is the opposite direction to the cylindrical portion, and the terminal portion is formed by bending in the first direction from the end of this bent portion in the third direction. The holding portion is a portion where the bent portion and the terminal portion are continuous, and extends further in the third direction from the outer periphery of the coil. This allows the position of the terminal holding portion of the case to be outside the projected area of ​​the coil, increasing the degree of freedom in arranging the coil device within the case.

[0010] The present disclosure othersIn the present disclosure, the circuit board is disposed on the first direction side of the case and has a through hole through which the terminal portion of the coil terminal passes. According to the present disclosure, the terminal holding portion holds the coil terminal in the vicinity of the terminal portion. Therefore, even when the terminal is inserted into the through hole of the circuit board, the coil terminal You don't have to worry about your child buckling.

[0011] of the present disclosure others In the present disclosure, the housing is disposed on the second direction side of the case. The housing has a valve sleeve extending in the first direction side, and this valve sleeve is disposed on the inner periphery of the cylindrical portion of the bobbin. According to the present disclosure, the coil terminal is held by a terminal holding portion, and the case and the coil device are accurately aligned. Therefore, the valve sleeve of the housing can be accurately positioned on the inner periphery of the cylindrical portion of the bobbin.

[0012] of the present disclosure others In the present disclosure, a plurality of coil devices are arranged in a fourth direction perpendicular to the third direction, with respect to the first and second directions that are the axial directions of the cylindrical portion. The terminal holding portion of the case collectively embeds the coil terminals of the plurality of coil devices. others In the case, a plurality of coil devices can be arranged in an aligned manner within the case.

[0013] of the present disclosure others In the present disclosure, a pair of coil devices are arranged in the third direction so that their terminal portions face each other. The terminal holding portion of the case collectively embeds the coil terminals of the pair of coil devices. others This also makes it possible to arrange a pair of coil devices in alignment within the case.

[0014] The present disclosure 1is a manufacturing method for a hydraulic control device. The manufacturing method uses a fixed mold having an injection gate and a movable mold that abuts against the fixed mold to form a mold space. The movable mold has a movable mold insert pin that fits into the inner periphery of a cylindrical portion. The fixed mold and the movable mold sandwich the coil terminal at a portion of the bent portion of the coil terminal that is on the extension portion side, and abut against each other on the outer periphery of the coil device to form a coil device accommodating space in which the coil device is placed. The injection gate opens to a portion other than the coil device accommodating space.

[0015] The present disclosure 1 In this case, the fixed mold and the movable mold abut against each other to form a coil device accommodation space between the outer peripheral wall and the coil device, so the resin forming the case does not flow toward the coil device. In other words, the coil device is embedded in the case only at the portion where the bent portion of the coil terminal and the terminal portion are connected, so the operation of the coil device is not hindered at all. [Brief explanation of the drawings]

[0016] [Figure 1] 3 is a perspective view of the case holding the coil device, as viewed from a first direction. FIG. [Figure 2] FIG. 2 is a front view of the case shown in FIG. [Figure 3] FIG. 2 is a perspective view of the case shown in FIG. 1 as viewed from a second direction. [Figure 4] FIG. 2 is a side view of the bobbin and coil. [Figure 5] FIG. 2 is a perspective view of the bobbin and the coil as viewed from the first direction side. [Figure 6] 2 is a perspective view of the bobbin, the coil, and the yoke as viewed from the first direction side. FIG. [Figure 7] FIG. 10 is a side view of the bobbin, coil, and yoke after assembly. [Figure 8] FIG. 10 is a side view showing the bobbin, coil, and yoke being assembled. [Figure 9] 9 is a perspective view showing the arrangement of a mold and a coil device at part IX in FIG. 2. FIG. [Figure 10]FIG. 10 is a perspective view showing an installation state of the first mold and the coil device shown in FIG. 9. [Figure 11] FIG. 11 is a cross-sectional view of FIG. [Figure 12] 10 is a perspective view showing an installation state of the first and second types and the coil device shown in FIG. 9. FIG. [Figure 13] FIG. 13 is a cross-sectional view of FIG. 12. [Figure 14] 14 is a cross-sectional view showing the mold taken along the line XIV-XIV in FIG. 2. [Figure 15] FIG. 15 is a cross-sectional view showing a state in which resin has been injected into the mold shown in FIG. [Figure 16] 16 is a cross-sectional view showing the mold taken along the line XVI-XVI in FIG. 2. [Figure 17] FIG. 17 is a cross-sectional view showing a state in which resin has been injected into the mold shown in FIG. 16. [Figure 18] 1 is a cross-sectional view showing the state in which the coil device is assembled in the case, taken along line XVIII-XVIII in FIG. 2. [Figure 19] FIG. 2 is an exploded perspective view of a circuit board, a case, and a housing. [Figure 20] FIG. 2 is a perspective view showing a state in which the circuit board is assembled into the case. [Figure 21] 2. FIG. 2 is a cross-sectional view showing the state in which the circuit board is assembled into the case, taken along line XXI-XXI in FIG. [Figure 22] 22 is a half-sectional view showing the circuit board, case, and housing, taken along the same section line as FIG. 21. [Figure 23] FIG. 10 is a perspective view of another example of a bobbin and a coil as viewed from the second direction side. [Figure 24] FIG. 10 is a perspective view of yet another example of a bobbin and a coil as viewed from the second direction side. [Figure 25] FIG. 6 is a perspective view of the coil terminal as seen from the same direction as FIG. 5. DETAILED DESCRIPTION OF THE INVENTION

[0017] As shown in Figures 1, 2, and 3, a coil device 100 is disposed inside a case 200 of the present disclosure. In the example of Figure 1, ten coil devices 100 are disposed inside the case 200. Each coil device 100 has roughly the same shape. The case 200 is made of polybutylene terephthalate (PBT). The size of the case 200 is a rectangular parallelepiped surrounded by an outer peripheral wall surface 240 with long sides of approximately 150 mm, short sides of approximately 100 mm, and a height of approximately 30 to 50 mm.

[0018] A first coil device accommodating space 251 in which four coil devices 100 are arranged, and a second coil device accommodating space 252 in which four coil devices 100 are also arranged are formed inside an outer peripheral wall surface 240 of the case 200. The first coil device accommodating space 251 and the second coil device accommodating space 252 are separated by a first separation wall 221.

[0019] A third coil device accommodating space 253 and a fourth coil device accommodating space 254, each accommodating one coil device 100, are also formed inside the outer peripheral wall surface 240 of the case 200. The third coil device accommodating space 253 and the fourth coil device accommodating space 254 are separated by a motor terminal holder 255 interposed therebetween. The third coil device accommodating space 253 and the fourth coil device accommodating space 254 are also separated from the second coil device accommodating space 252 by a second separation wall 222.

[0020] One side (the right side in FIGS. 1 and 2) of the case 200 is formed with a case terminal section 230 for connecting various sensors and a power supply to a circuit board 300 (described later). The power supply is used to drive the coil device 100 and to supply power to a pump drive motor disposed within the housing 400 (described later). The various sensors are used to obtain information required when this example is used as a braking device for an automobile. For example, there are a brake hydraulic pressure sensor, a brake signal input sensor, a steering angle sensor, and an automobile yaw rate sensor.

[0021] 1 and 3, a connector 231 is formed on the back surface of the case terminal portion 230. The above-mentioned power is applied by connecting a power line to this connector 231. Similarly, signals from each of the above-mentioned sensors are also supplied by connecting a signal line to this connector 231.

[0022] As described above, the coil devices 100 arranged in the case 200 are basically of the same shape. Each coil device 100 includes a coil 120 wound many times around the cylindrical portion 111 (shown in FIG. 5) of a bobbin 110, and a coil terminal 130 that supplies power to the coil. Each coil device 100 also includes a yoke 140 arranged around the coil 120.

[0023] 4 is a side view showing the bobbin 110. The bobbin 110 is made of a resin material made of polyamide 66 (PA66). The bobbin 110 has a cylindrical portion 111 formed in the center, and a coil 120 made of copper wire coated with an enamel insulation is wound around this cylindrical portion 111 many times.

[0024] A first flange 112 is formed on the first direction side in the axial direction of the cylindrical portion 111 (upper side in FIG. 4). As shown in FIG. 5, first arms 113 extend from the first flange 112 on both the left and right sides. A locking portion 114 that serves as a retaining mechanism is formed to protrude from the first arm 113. In FIG. 3, if the left direction perpendicular to the axial direction of the cylindrical portion 111 is defined as a third direction, the locking portion 114 is formed to be inclined in the first direction toward the third direction. The end portion in the third direction forms a locking surface 1140.

[0025] The first flange portion 112 is formed with base holding portions 115 that hold the bases of the coil terminals 130 on the opposite side (third direction) from the first arm portion 113. The base holding portions 115 are formed in two locations corresponding to the pair of coil terminals 130, and the middle portions are connected to form a quadrangle.

[0026] A second flange 116 is formed on the second axial direction side of the cylindrical portion 111 (the lower side in FIG. 4). As shown in FIG. 5, second arm portions 117 extend from both the left and right sides of this second flange 116. The second arm portions 117 extend obliquely in the second direction from a main portion 118 of the second flange 116 toward the third direction. Therefore, the second arm portions 117 function as a resin spring by utilizing the elasticity of the resin.

[0027] The bobbin 110 is formed by integrally molding the above-described elements 111 to 118 with resin. During resin molding, a base portion 139 (shown in FIG. 25) of the coil terminal 130 is also insert-molded into the base holding portion 115. In addition to the base portion 139, the coil terminal 130 includes an extension portion 131, a bent portion 132, and a terminal portion 133. The extension portion 131 extends in a first direction from the base portion 139, which is insert-molded into the base holding portion 115. The bent portion 132 is bent from the end of the extension portion 131 in the first direction in a third direction (horizontal direction), which is the opposite direction from the cylindrical portion 111. The terminal portion 133 is formed by bending from the end of the bent portion 132 in the third direction in the first direction. The portion of the end of the bent portion 132 in the third direction, where the terminal portion 133 continues, becomes a holding portion 136, which will be described later. The terminal portion 133 has a tapered tip so as to be easily inserted into a through-hole 301 of the circuit board 300, which will be described later. The terminal portion 133 has a press-fit terminal structure and has a circular hole 1330 formed therein so as to be electrically connected to the circuit board 300.

[0028] The coil terminals 130 also have electrical connection portions 135 to which both ends of the copper wire forming the coil 120 are electrically connected. The electrical connection portions 135 extend horizontally from the extension portions 131 of the pair of coil terminals 130 and are bent into a U-shape at the midpoint (shown in FIG. 5 ). The base 139 of the coil terminal 130 has a copper wire holding portion 134 formed at a position closer to the first flange portion 112 than the electrical connection portions 135. The copper wire holding portion 134 also extends horizontally from the base holding portion 115.

[0029] The copper wire and coil terminal 130 are physically connected by winding the copper wire near its end around the copper wire holding portion 134. Next, the end of the copper wire is placed in the U-shaped portion of the electrical connection portion 135. In this state, the U-shaped portion is crushed and a high voltage current is applied at the same time to evaporate the enamel coating of the copper wire. This physically holds the end of the copper wire in the electrical connection portion 135 and also electrically connects it. The coil terminal 130 is made of a copper alloy, which is a conductive material.

[0030] Fig. 6 is a perspective view showing a state in which the yoke 140 is assembled to the bobbin 110 configured as described above. The yoke 140 is made of a magnetic material such as cold-rolled steel plate (SPCE). As shown in Fig. 6, the yoke 140 has an intermediate wall portion 141 disposed radially outward of the coil 120. A first wall portion 142 is bent and formed continuously from the intermediate wall portion 141 on the first direction side of the intermediate wall portion 141. The first flange portion 112 of the bobbin 110 abuts against the first wall portion 142.

[0031] A second wall portion 143 is also formed on the second direction side of the intermediate wall portion 141, bending the second wall portion 143 continuously from the intermediate wall portion 141. The first wall portion 142, the intermediate wall portion 141, and the second wall portion 143 are formed by bending a steel material having a thickness of about 2 mm into a U-shape.

[0032] The tip of a second arm portion 117 extends from a main portion 118 of a second flange portion 116 of the bobbin 110 at an angle in the second direction toward the third direction and abuts against the second wall portion 143 of the yoke 140. The elastic deformation of the second arm portion 117 allows the bobbin 110 to move in the first direction and the second direction within the yoke 140.

[0033] An engagement portion 144 is formed on the first wall portion 142 of the yoke 140, against which the locking surface of the locking portion 114 of the bobbin 110 abuts. Therefore, the movement of the bobbin 110 relative to the yoke 140 is restricted by the engagement between the locking portion 114 and the engagement portion 144. However, the bobbin 110 can move relative to the yoke 140 in the third direction.

[0034] To assemble the bobbin 110 and the yoke 140, the bobbin 110 is inserted into the yoke 140 in the third direction. During insertion, as shown in Fig. 8, the locking portion 114 abuts against the first wall portion 142, and the bobbin 110 is displaced in the second direction due to the elastic deformation of the second arm portion 117. When the bobbin 110 is inserted to a position where the locking portion 114 engages with the engaging portion 144, the bobbin 110 is displaced in the first direction due to the restoring force of the second arm portion 117, as shown in Fig. 7.

[0035] The first wall portion 142 has a first round hole 148 formed in a portion facing the cylindrical portion 111 of the bobbin 110, through which a valve sleeve 410 (shown in FIG. 19) or a nesting pin 510 (shown in FIG. 9), which will be described later, passes. The first direction side of the first round hole 148 protrudes in the first direction to form a ring portion 145. However, the ring portion 145 is not essential for the coil device 100. In the example of FIG. 2, the six coil devices 100 arranged at the top of the figure have ring portions 145 formed in the first wall portion 142, but the four coil devices 100 arranged at the bottom of the figure do not have ring portions 145 formed in the first wall portion 142.

[0036] 3, the portion of the second wall portion 143 facing the cylindrical portion 111 of the bobbin 110 forms a second round hole 146 that corresponds to the outer diameter of the valve sleeve 410. Therefore, when the housing 400 is assembled to the case 200, the valve sleeve 410 passes through the cylindrical portion 111 of the bobbin 110 and the first round hole 148 and second round hole 146 of the yoke 140. Furthermore, even when the coil device 100 is placed in a mold, the insert pin 510 passes through the cylindrical portion 111 of the bobbin 110 and the first round hole 148 and second round hole 146 of the yoke 140.

[0037] As described above, the coil device 100 is fabricated by first forming the bobbin 110 with the coil terminal 130 insert-molded. Next, the coil 120 is wound multiple times around the cylindrical portion 111 of the bobbin 110. Then, the vicinity of both ends of the coil 120 is wound around the copper wire holding portions 134 of the coil terminal 130, and then both ends of the coil 120 are electrically connected to the electrical connection portions 135. Next, the bobbin 110 is inserted into the yoke 140, and the locking portions 114 of the bobbin 110 are engaged with the engaging portions 144 of the yoke 140, thereby completing the assembly.

[0038] 2, and is insert-molded into the case 200. The insert molding is performed such that the holding portion 136, which is the continuous portion between the bent portion 132 and the terminal portion 133 of the coil terminal 130 of the coil device 100, is inserted into the terminal holding portion 220 of the case 200.

[0039] 1 and 3, the first coil device accommodating space 251, the second coil device accommodating space 252, the third coil device accommodating space 253, and the fourth coil device accommodating space 254 are open in the first and second directions. The terminal holding portions 220 of the coil devices 100 arranged in the first coil device accommodating space 251 and the second coil device accommodating space 252 are formed on the first separation wall 221.

[0040] Here, four coil devices 100 are arranged in each of the first coil device accommodating space 251 and the second coil device accommodating space 252, and are arranged in parallel along the first separation wall 221. This parallel direction is a fourth direction that is orthogonal to the third direction and the first and second directions that are the axial directions of the cylindrical portion 111 described above. Therefore, by forming the terminal holding portion 220 on the first separation wall 221, the four coil devices 100 can be arranged in alignment in the fourth direction in each of the first coil device accommodating space 251 and the second coil device accommodating space 252.

[0041] Furthermore, the coil devices 100, four of which are arranged in each of the first coil device accommodating space 251 and the second coil device accommodating space 252, are arranged line-symmetrically with respect to each other with the first separation wall 221 in between. This line-symmetric arrangement is an arrangement facing each other in the third direction in the above-mentioned direction. Therefore, by forming the terminal holding portion 220 in the first separation wall 221, it is possible to collectively embed the coil terminals 130 of the four pairs of coil devices 100 arranged line-symmetrically with respect to each other with the first separation wall 221 in between. This makes it possible to simplify the arrangement of the terminal holding portion 220.

[0042] Since only one coil device 100 is disposed in each of the third coil device accommodating space 253 and the fourth coil device accommodating space 254 , the terminal holding portion 220 is formed integrally with the outer peripheral wall surface 240 .

[0043] Next, a manufacturing method for insert-molding these coil devices 100 into the case 200 will be described. As shown in FIG. 9, a first mold 500 is arranged in a first direction of the coil device 100, and a second mold is arranged in a second direction. Note that FIG. 9 shows only the rectangular portions of the first mold 500 and the second mold 600, indicated by IX in FIG. 2, cut out, in order to explain the structures of the first mold 500 and the second mold 600. The first mold 500 has an insertion hole 501 into which the terminal portion 133 of the coil terminal 130 is fitted. The first mold 500 also has a terminal holding groove 502 that holds the intermediate portion of the bent portion 132 of the coil terminal 130.

[0044] 10 shows a state in which the insert pin 510 of the first die 500 is inserted into the cylindrical portion 111 of the coil device 100. In FIG. 10, one of the pair of coil devices 100 is not shown so that the shape of the insert pin 510 can be clearly seen. As shown in FIG. 10, when the first die 500 is set in the coil device 100, the terminal portion 133 of the coil terminal 130 is inserted into the insertion hole 501. In addition, the bent portion 132 of the coil terminal 130 is held in the terminal holding groove 502.

[0045] 11 is a cross-sectional view of Fig. 10, and as shown in Fig. 11, the depth of the terminal holding groove 502 is equal to the thickness of the bent portion 132 of the coil terminal 130. Also, as shown in the figure, the first die 500 and the coil device 100 are positioned by fitting the insert pin 510 into the first round hole 148 of the yoke and the cylindrical portion 111 of the bobbin 110.

[0046] FIG. 12 shows a state in which the second die 600 is abutted against the first die 500. As is clear from comparison with FIG. 9, FIG. 12 shows a cutaway view of half of the second die 600. This makes it possible to clarify the shape of the second die 600 and the arrangement of the coil device 100 within the second die 600. A terminal holding space 610 is formed in the second die 600, which forms the terminal holding portion 220 and the first separation wall 221 of the case 200. In addition, the end of the terminal holding space 610 on the first die 500 side is also formed with a terminal pressing portion 601 that faces the terminal holding groove 502 of the first die 500 and presses the bent portion 132 of the coil terminal 130.

[0047] 13 is a cross-sectional view of the state of FIG. 12, and as shown in FIG. 13, the terminal pressing portion 601 comes into contact with the terminal holding groove 502, thereby closing the terminal holding space 610. Furthermore, a first mold wall 602 in the lower left portion of the second mold 600 in FIG. 13 comes into contact with the first mold 500. The space between this first mold wall 602 and the terminal pressing portion 601 becomes the first coil device accommodating space 251. Similarly, a second mold wall 603 in the lower right portion of the second mold 600 in FIG. 13 also comes into contact with the first mold 500, and the space between this second mold wall 603 and the terminal pressing portion 601 becomes the second coil device accommodating space 252.

[0048] The first coil device accommodating space 251 and the second coil device accommodating space 252 are both surrounded on their outer peripheries by a first mold wall 602, a second mold wall 603, and a terminal pressing portion 601. A resin injection gate 630, which will be described later, does not open into the first coil device accommodating space 251 or the second coil device accommodating space 252. Therefore, resin does not flow into the first coil device accommodating space 251 or the second coil device accommodating space 252, and as described above, both the first direction and the second direction are open.

[0049] FIG. 14 is a cross-sectional view showing a portion of the first mold 500 and the second mold 600, taken along line XIV-XIV in FIG. 2. FIG. 14 shows the state in which the bent portion 132 of the coil terminal 130 is fitted into the terminal holding groove 502 of the first mold 500. A terminal holding space 610 is formed in the second mold 600. A resin injection gate 630 communicates with the terminal holding space 610. FIG. 15 shows the state in which resin has been injected into the terminal holding space 610. As shown in FIG. 15, the injected resin forms the terminal holding portion 220, including a portion of the coil terminal 130 (holding portion 136). It also forms the first separation wall 221.

[0050] 16 is a cross-sectional view showing the first mold 500 and the second mold 600 in a cross section different from that of FIG. 14, and shows the molds taken along line XVI-XVI in FIG. 2. The cross section shown in FIG. 16 shows the insertion hole 501 of the first mold 500, with the terminal portion 133 of the coil terminal 130 inserted into the insertion hole 501. As in FIG. 13, the first mold wall 602 and the terminal pressing portion 601 form the first coil device accommodating space 251, and the second mold wall 603 and the terminal pressing portion 601 form the second coil device accommodating space 252. As shown in FIG. 17, the resin injected from the injection gate 630 forms the outer peripheral wall surface 240, the first separation wall 221, and the second separation wall 222.

[0051] As described above, the coil device 100 is aligned by the insert pins 510 of the first die 500. In this state, the terminal portion 133 is inserted into the insertion hole 501 of the first die 500, and the bent portion 132 is held in the terminal holding groove 502. In this state, the first die 500 abuts against the second die 600. In this abutting state with the second die 600, the mold space that forms the outer peripheral wall surface 240, the first separation wall 221, the terminal holding portion 220, the second separation wall 222, the connector 231, etc. is closed. In this state, molten resin is injected from the injection gate 630 of the second die 600. The injected resin solidifies in the mold space and forms the outer peripheral wall surface 240, etc. In this example, the first die 500 is a movable die, and the second die 600 is a fixed die.

[0052] At the end of the insert molding, the coil device 100 is positioned accurately within the case 200 because it has been aligned with the insert pin 510. Furthermore, this state is maintained reliably in an accurate position because the holding portion 136 where the bent portion 132 and the terminal portion 133 of the coil terminal 130 are continuous is held by the terminal holding portion 220.

[0053] Fig. 18 shows the case 200 and the coil device 100 after the insert molding is completed. As shown in Fig. 18, the coil terminal 130 of the coil device 100 is insert-molded into the terminal holding portion 220 of the case 200 at the holding portion 136 where the bent portion 132 and the terminal portion 133 are continuous. Therefore, as described above, the relative positions between the coil terminal 130 and the case 200 are accurately determined.

[0054] 18 also shows that the first coil device accommodating space 251 to the fourth coil device accommodating space 254 of the case 200 are open in both the first and second directions. Therefore, when the coil device 100 is insert-molded into the case 200, the coil device 100 is held in the case 200 only by the coil terminals 130.

[0055] 19, a circuit board 300 is arranged in the first direction of the case 200 in which the coil device 100 is insert-molded. As described above, the circuit board 300 has through holes 301 opening at positions corresponding to the terminal portions 133. The circuit board 300 has a shape corresponding to the opening of the case 200, and is about 1 millimeter thick.

[0056] The circuit board 300 is made of epoxy resin reinforced with glass fiber, and wiring is printed on the circuit board 300. Therefore, when the terminal portion 133 of the coil terminal 130 is inserted into the through hole 301 and fixed by a press-fit terminal structure, the coil device 100 can be connected to a power source via the wiring of the circuit board 300.

[0057] Various electrical components such as a central processing unit (CPU), integrated circuits (ICs), diodes, etc. are also arranged on the circuit board 300. Based on signals from the various sensors described above, the central processing unit controls the operation of the coil device 100 and the pump drive motor.

[0058] Furthermore, the housing 400 is disposed in the second direction of the case 200 into which the coil device 100 is insert-molded. As described above, the valve sleeve 410 is disposed at a position corresponding to the cylindrical portion 111 of the bobbin 110. The outer diameter of the valve sleeve 410 is set to be slightly smaller than the inner diameters of the cylindrical portion 111 of the bobbin 110 and the ring portion 145 and second round hole 146 of the yoke 140. Furthermore, the tip 411 of the valve sleeve 410 in the first direction is spherical, and is formed to easily fit into the second round hole 146 of the yoke 140.

[0059] The housing 400 is made of an aluminum alloy and is formed by die-casting or cutting. The housing 400 is roughly shaped like a regular square prism with a side length of about 100 mm and a height of about 30 to 50 mm. The valve sleeve 410 is made of stainless steel and is fixed to the housing 400 by crimping while sealed with packing.

[0060] A moving element made of a magnetic material is disposed inside the valve sleeve 410. The moving element moves in a first direction and a second direction inside the valve sleeve 410 due to the magnetic force generated when the coil 120 is energized. A fluid flow path (not shown) for operating the brake is formed inside the housing 400, and the movement of the moving element inside the valve sleeve 410 switches this fluid flow path and adjusts the pressure.

[0061] In this example, the hydraulic pressure control device 10 is constructed by assembling the circuit board 300 in a first direction of the case 200 into which the coil device 100 is insert-molded, and assembling the housing 400 in a second direction. As described above, the hydraulic pressure control device 10 is manufactured by insert-molding the coil device 100 into the case 200, and then assembling the circuit board 300 and the housing 400. The hydraulic pressure control device 10 of this example is used in a vehicle's antilock brake system (ABS), traction control system (TCS), electronic stability control (ESC), etc.

[0062] 20 is a perspective view showing a state in which the circuit board 300 is assembled to the case 200. As shown in FIG. 20, the tip of the terminal portion 133 of the coil terminal 130 protrudes from the through hole 301.

[0063] Fig. 21 is a cross-sectional view showing the state in which the circuit board 300 is assembled to the case 200. As can be seen from Figs. 18 and 21, the position of the coil terminal 130 is determined by the retaining portion 210 of the case 200 near the circuit board 300. Therefore, the circuit board 300 can be assembled to the case 200 with high precision. In other words, there is almost no chance of the coil terminal 130 being deformed due to misalignment between the case 200 and the circuit board 300. Therefore, excessive stress applied to the coil terminal 130 due to deformation caused by misalignment can be effectively prevented.

[0064] Furthermore, the coil terminal 130 is securely fixed by the terminal holding portion 220. Moreover, only a portion of the terminal portion 133 of the coil terminal 130 protrudes from the terminal holding portion 220. Therefore, even when the terminal portion 133 is inserted into the through hole 301 of the circuit board 300, the terminal portion 133 will not buckle due to the force applied during insertion. The above factors combine to make it easy to assemble the coil device 100 held in the case 200 and the circuit board 300.

[0065] As shown in FIGS. 18 and 21, when the coil device 100 is placed in the case 200, the lower end (second wall portion 143) of the coil device 100 protrudes slightly from the case 200 in the second direction. In the state shown in FIGS. 18 and 21, the housing 400 and the case 200 are fixed together with bolts. In the bolt-fixed state, the lower end (second wall portion 143) of the coil device 100 contacts the upper surface 401 (shown in FIG. 19) of the housing 400. Therefore, when the coil device 100 is assembled with the housing 400, the coil device 100 moves slightly in the first direction (shown in FIG. 22). This movement in the first direction during assembly can be absorbed by the elastic deformation of the second arm portion 117 described above.

[0066] When assembling the case 200 and the housing 400, first, the tip 411 of the valve sleeve 410 is fitted into the second round hole 146 of the yoke 140, and then into the cylindrical portion 111 of the bobbin 110. At this time, since the tip 411 of the valve sleeve 410 is spherical, it is guided into the second round hole 146 and the cylindrical portion 111 by the shape of the tip 411. The valve sleeve 410 aligns the case 200 and the housing 400 in the horizontal direction.

[0067] When the valve sleeve 410 is assembled to the cylindrical portion 111 of the bobbin 110, the bobbin 110 can move slightly horizontally relative to the yoke 140. That is, the pressing force caused by the elastic deformation of the second arm portion 117 is large enough to allow horizontal movement during assembly. Furthermore, the engagement between the locking portion 114 of the bobbin 110 and the engaging portion 144 of the yoke 140 is also large enough to allow horizontal movement during assembly.

[0068] Therefore, even if the yoke 140 is slightly misaligned horizontally as a result of being guided by the spherical shape of the tip 411 of the valve sleeve 410, the misalignment can be absorbed by the coil device 100 itself. In particular, when the tip 411 of the valve sleeve 410 is fitted into the cylindrical portion 111 of the bobbin 110, the lower end (second wall portion 143) of the coil device 100 is free. In other words, the lower end (second wall portion 143) of the coil device 100 is not in contact with the upper surface 401 of the housing 400. Therefore, even if the bobbin 110 and the yoke 140 are slightly misaligned in the coil device 100 itself, the misalignment will not be applied as excessive stress to the coil terminal 130 and the holding portion 210 of the case 200.

[0069] The upper surface 401 of the housing 400 comes into contact with the lower end (second wall portion 143) of the coil device 100 when horizontal alignment is complete, as described above. Therefore, even if the yoke 140 moves as the housing 400 is assembled, the movement is entirely in the first direction, and no force is applied in the horizontal direction. Any displacement in the first direction can be reliably absorbed by the elastic deformation of the second arm portion 117.

[0070] 18, 21, and 22, the circuit board 300 is first assembled to the case 200 holding the coil device 100, and then the housing 400 is fixed. However, it is also possible to fix the housing 400 first. In that case, the housing 400 is bolted to the second direction side of the case 200 without the circuit board 300 being present. In the fixed state, the alignment of the case 200 and the housing 400 is completed by the valve sleeve 410, the cylindrical portion 111 of the bobbin 110, and the second round hole 146 of the yoke 140.

[0071] As in the above-described assembling process, the horizontal misalignment that occurs when aligning the case 200 and the housing 400 can be absorbed by the coil device 100 itself. Similarly, as in the above-described assembling process, the misalignment in the first direction that occurs when aligning the case 200 and the housing 400 has also been absorbed by the coil device 100 itself.

[0072] The state shown in FIG. 22 also occurs when the housing 400 is fixed first and then the circuit board 300 is fixed. Even when the housing 400 is fixed in this manner, the fixation of the case 200 and the circuit board 300 is similar to the fixation shown in FIGS. 18 to 21 described above. That is, the coil terminals 130 are accurately positioned near the circuit board 300 by the terminal holding portions 220 of the case 200. Furthermore, the amount of protrusion of the coil terminals 130 from the terminal holding portions 220 is small, so there is no risk of buckling. Therefore, even if the housing 400 is fixed first, it does not hinder the fixation of the circuit board 300.

[0073] As described above, in the present disclosure, the assembly of the case 200 and the housing 400 does not affect the assembly of the case 200 and the circuit board 300. Similarly, the assembly of the case 200 and the circuit board 300 does not affect the assembly of the case 200 and the housing 400. The process of insert-molding the coil device 100 into the case 200 precedes, but thereafter, the circuit board 300 or the housing 400 may be assembled first. Moreover, it is also possible to fix the circuit board 300 and the housing 400 to the case 200 at the same time.

[0074] Note that the above is a preferred example of the present disclosure, but the present disclosure can be modified in various ways. In the above example, the base 139 of the coil terminal 130 is insert-molded, but it may also be fixed by press-fitting into the terminal holding portion 220. Alternatively, it may be fixed by adhesive or a clip. In the above example, two second arm portions 117 are formed in parallel, but three or more second arm portions 117 may also be formed. Even in the case of three or more second arm portions, each second arm portion 117 has the same shape. Furthermore, each second arm portion 117 is disposed symmetrically around the central axis. Here, the central axis refers to the central axis of the cylindrical portion 111 of the bobbin 110.

[0075] Furthermore, the second arm b117 may be replaced with a disk-shaped portion 119 as shown in FIG. 23. The disk-shaped portion 119 is also connected to the second flange portion 116 at a main portion 118. It extends obliquely from the main portion 118 in the second direction so as to widen outward toward the outer periphery. The disk-shaped portion 119 is also molded integrally with the bobbin 110 using the same resin. The disk-shaped portion 119 is also capable of elastic deformation in the first and second directions.

[0076] 24, a semicircular arc portion 1190 may be formed. This semicircular arc portion 1190 also extends obliquely in the second direction from the main portion 118 of the second flange portion 116. The semicircular arc portion 1190 also enables the bobbin 110 to move relative to the yoke 140 in the first and second directions.

[0077] However, relative movement of the bobbin 110 with respect to the yoke 140 in the first and second directions is not essential. In the above example, the lower end of the coil device 100 (second wall portion 143 of the yoke 140) protrudes from the case 200 in the second direction as shown in Figures 18 and 21, but it is sufficient if the lower end of the coil device 100 and the lower end of the case 200 are aligned. Slight misalignment in the first and second directions between the lower end of the coil device 100 and the lower end of the case 200 can be absorbed by the bent portion 132 of the coil terminal 130.

[0078] 23 and 24, the first arm portion 113 is not formed on the first flange portion 112. Therefore, the locking portion 114 provided on the first arm portion 113 is also not provided. This makes it easy to move the bobbin 110 horizontally relative to the yoke 140. As shown in FIGS. 4 and 5, it is possible to eliminate the locking portion 114 even when the first arm portion 113 is formed.

[0079] In the above example, yoke 140 is U-shaped and made up of first wall portion 142, intermediate wall portion 141, and second wall portion 143, but yoke 140 may have other shapes. Yoke 140 may have any structure as long as it is disposed around coil 120 and forms a magnetic circuit when coil 120 is energized. For example, it may be cylindrical. Furthermore, yoke 140 may be formed of two members: a member including first wall portion 142 and a member including second wall portion 143.

[0080] In the above example, the coil terminal 130 and the circuit board 300 are joined using a press-fit terminal structure. This is easy to do as the joining can be done simply by inserting the coil terminal 130 into the through-hole 301. However, the electrical connection between the coil terminal 130 and the circuit board 300 can also be made by soldering.

[0081] In the above example, four coil devices 100 are arranged in each of the first coil device accommodating space 251 and the second coil device accommodating space 252, but the number of coil devices 100 can be changed depending on the functions required of the hydraulic control device 10. Also, arranging multiple coil devices 100 in parallel in the fourth direction is desirable in terms of accommodating the coil devices 100 in the case 200. However, individual coil devices 100 may be accommodated in spaces such as the third coil device accommodating space 253 and the fourth coil device accommodating space 254, as necessary.

[0082] Similarly, in the above example, the coil device 100 accommodated in the first coil device accommodating space 251 and the coil device 100 accommodated in the second coil device accommodating space 252 are arranged in the third direction with their terminal portions 133 facing each other. This is a desirable arrangement for compactly accommodating multiple coil devices 100. However, this arrangement is not essential. If necessary, the coil device 100 accommodated in the first coil device accommodating space 251 and the coil device 100 accommodated in the second coil device accommodating space 252 may be arranged with an offset. Also, all of the coil devices 100 may be arranged so that they face the same direction.

[0083] Furthermore, in the above example, the coil device 100 placed in the first coil device accommodating space 251 and the coil device 100 placed in the second coil device accommodating space 252 have approximately the same shape, but they do not necessarily have to be the same shape. The coil device 100 placed in the first coil device accommodating space 251 may be larger than the coil device 100 placed in the second coil device accommodating space 252, or vice versa. Not only the size of the coils but also the shapes themselves may be different.

[0084] Furthermore, in the above example, the holding portion 136 of the coil terminal 130 is formed between the bent portion 132 and the terminal portion 133, but the holding portion 136 may be any portion of the coil terminal 130. In order to arrange the coil devices 100 in parallel or facing each other like the coil devices 100 housed in the first coil device accommodating space 251 and the second coil device accommodating space 252, it is desirable to make the holding portion 136 the bent portion 132.

[0085] However, for individually arranged coil devices 100, such as the coil devices 100 arranged in the third coil device accommodating space 253 and the fourth coil device accommodating space 254, it is possible to hold the coil terminals 130 by devising the shape of the case 200 side. In such a case, it is not necessary to provide the bent portion 132 in the coil terminal 130, and it is not necessary for the holding portion 136 to be located in the bent portion 132. The first mold 500 can form the terminal holding portion 220 by providing the terminal holding groove 502 in a position closer to the base 139 than the holding portion 136.

[0086] Furthermore, in the present disclosure, it is sufficient that the terminal holding portion 220 of the case 200 holds the coil terminal 130. Therefore, not only the coil terminal 130 but also the entire coil device 100 may be insert-molded into the case 200.

[0087] Furthermore, the materials and sizes described above are merely examples and can be selected appropriately depending on the required performance. The disclosure in this specification and drawings is not limited to the exemplified embodiments. The disclosure encompasses the exemplified embodiments and modifications thereto by those skilled in the art. [Explanation of symbols]

[0088] 10. Hydraulic pressure control device 100 Coil device 110 Bobbin 111 Cylindrical part 112 First flange 120 coils 130 Coil terminal 131 Extension part 133 Terminal section 140 York 200 cases 300 Circuit Boards 400 Housing 500 Type 1 (movable type) 510 Nested Pin 600 Type 2 (fixed type) 630 Injection Gate

Claims

1. a coil device including a bobbin made of a resin material, a pair of coil terminals made of a conductive material, a coil made of a conductive material, and a yoke made of a magnetic material; a case made of a resin material that holds the coil device; a circuit board to be assembled in the case; A hydraulic pressure control device having a housing assembled to the case, the bobbin has a cylindrical portion, a first flange portion formed on a first direction side in the axial direction of the cylindrical portion, and a second flange portion formed on a second direction side in the axial direction of the cylindrical portion that is opposite to the first direction, Each of the pair of coil terminals has a base portion fixed to the first flange portion, an extension portion extending from the base portion toward the first direction, a terminal portion formed at an end portion in the first direction, and a holding portion located between the terminal portion and the base portion, The case has an outer peripheral wall surface surrounding the outer periphery of the case, a coil device accommodating space inside the outer peripheral wall surface for accommodating the coil device, and a terminal holding portion in which the holding portions of the pair of coil terminals are embedded.

1. A method of manufacturing a hydraulic control device, comprising: A fixed mold having an injection gate and a movable mold that abuts against the fixed mold to form a mold space, the movable die has a movable die insert pin that fits into the inner periphery of the cylindrical portion, the fixed mold and the movable mold sandwich the coil terminal at a portion of the coil terminal closer to the base portion than the holding portion, and abut against each other on the outer periphery of the coil device to form a coil device accommodating space in which the coil device is disposed, The injection gate opens to a location other than the coil device housing space. A method for manufacturing a hydraulic control device.

2. a coil device including a bobbin made of a resin material, a pair of coil terminals made of a conductive material, a coil made of a conductive material, and a yoke made of a magnetic material; a case made of a resin material that holds the coil device; a circuit board to be assembled in the case; A hydraulic pressure control device having a housing assembled to the case, the bobbin has a cylindrical portion, a first flange portion formed on a first direction side in the axial direction of the cylindrical portion, and a second flange portion formed on a second direction side in the axial direction of the cylindrical portion that is opposite to the first direction, Each of the pair of coil terminals has a base portion fixed to the first flange portion, an extension portion extending from the base portion toward the first direction, a terminal portion formed at an end portion in the first direction, and a holding portion located between the terminal portion and the base portion, The case has an outer peripheral wall surface surrounding the outer periphery of the case, a coil device accommodating space inside the outer peripheral wall surface for accommodating the coil device, and a terminal holding portion in which the holding portions of the pair of coil terminals are embedded.

1. A method of manufacturing a hydraulic control device, comprising: A fixed mold having an injection gate and a movable mold that abuts against the fixed mold to form a mold space, the fixed die and the movable die sandwich the coil terminal at a portion of the coil terminal closer to the base than the holding portion, and abut against each other on an outer periphery of the coil device to form the terminal holding portion; The holding portions of the pair of coil terminals are embedded in the terminal holding portion by the resin injected from the injection gate. A method for manufacturing a hydraulic control device.

3. Each of the pair of coil terminals further has a bent portion that is bent from an end of the extension portion in the first direction in a third direction that is the opposite direction to the cylindrical portion, and the terminal portion is The end portion in the third direction is bent in the first direction, The holding portion is a portion where the bent portion and the terminal portion are continuous, and is located from the outer periphery of the coil. Further extending in the third direction 3. A hydraulic pressure control device manufactured by the manufacturing method of claim 1 or 2.

4. The circuit board is disposed on the first direction side of the case and has a through hole through which the terminal portion of the coil terminal passes. A hydraulic control device manufactured by the manufacturing method of claim 1 or 2, or a hydraulic control device according to claim 3.

5. the housing is disposed on the second direction side of the case, The housing has a valve sleeve extending in the first direction, and the valve sleeve is disposed on the inner periphery of the cylindrical portion of the bobbin. A hydraulic pressure control device manufactured by the manufacturing method of claim 1 or 2, or a hydraulic pressure control device according to claim 3 or 4.

6. the coil device is arranged in a fourth direction perpendicular to the third direction with respect to the first direction and the second direction, which are axial directions of the cylindrical portion, and The terminal holding portion of the case collectively embeds the coil terminals of the plurality of coil devices.

6. A hydraulic pressure control device according to claim 3, or claim 4 or 5 depending on claim 3.

7. The coil device is a pair of the coil devices arranged in the third direction such that the terminal portions of the coil devices face each other, The terminal holding portion of the case collectively embeds the coil terminals of the pair of coil devices.

7. A hydraulic pressure control device according to claim 3 or any one of claims 4 to 6 dependent on claim 3.

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