Electrical equipment

Abstract

To provide an electrical device capable of improving electrical connectivity between a substrate and terminals.SOLUTION: An electrical device 1 is provided, comprising a substrate 2, terminals 3 joined with the substrate 2, a housing 5 configured to house the substrate 2 and the terminals 3 and provided with a window 512a for exposing joints between the substrate 2 and the terminals 3, a cover member 6 for closing the window 512a, and a mold resin 8 covering the housing 5 and the cover member 6.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to electrical devices. [Background technology]

[0002] Patent Document 1 discloses a torque detection device for detecting torque applied to a torsion bar of an electric power steering device. The torque detection device described in Patent Document 1 includes a magnetic detection element, a sensor housing that houses the magnetic detection element, a circuit board mounted in an accommodating recess provided in the sensor housing, terminals soldered to the circuit board, and a waterproof coating material made of epoxy resin that fills the accommodating recess of the sensor housing and covers the circuit board and terminals. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2020-134440 Summary of the Invention [Problem to be solved by the invention]

[0004] In the torque detection device described in Patent Document 1, the soldered portions between the circuit board and the terminals are directly covered with a coating material, which may cause stress at the joints between the circuit board and the terminals, reducing the electrical connectivity between the circuit board and the terminals.

[0005] The present invention has been made in view of the above circumstances, and has an object to provide an electric device that can improve the electrical connectivity between a substrate and a terminal. [Means for solving the problem]

[0006] In order to achieve the above-mentioned object, the present invention provides an electrical device comprising: a substrate; terminals joined to the substrate; a housing that accommodates the substrate and the terminals and has a window portion that exposes the joint between the substrate and the terminals; a cover member that closes the window portion; and a molded resin that covers the housing and the cover member. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide an electric device that can improve the electrical connectivity between the substrate and the terminals. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view of a magnetostrictive torque sensor according to an embodiment, viewed obliquely from above. [Figure 2] FIG. 1 is a perspective view of a magnetostrictive torque sensor according to an embodiment, viewed obliquely from below. [Figure 3] FIG. 2 is an enlarged cross-sectional view of a portion of the magnetostrictive torque sensor on the side opposite to the cable according to the embodiment. [Figure 4] FIG. 2 is an enlarged cross-sectional view of a cable side portion of the magnetostrictive torque sensor according to the embodiment. [Figure 5] FIG. 1 is a perspective view of a magnetostrictive torque sensor according to an embodiment, from which a molding resin and a heat-shrinkable tube are removed, as viewed obliquely from above. [Figure 6] FIG. 2 is a perspective view of the magnetostrictive torque sensor from which the molding resin has been removed, as viewed obliquely from below, according to the embodiment. [Figure 7] 2 is a perspective view of a board, a terminal, a cable, and a first housing member in the embodiment, as viewed obliquely from above. FIG. [Figure 8] 3 is a plan view of a substrate, a terminal, a cable, and a first housing member in the embodiment. FIG. [Figure 9] 4 is an enlarged bottom view of the substrate, terminals, cables, and the vicinity of the window of the first housing member in the embodiment. FIG. [Figure 10]2 is an exploded perspective view of the substrate, terminals, cables, and first housing member in the embodiment, seen obliquely from above. FIG. [Figure 11] 4 is a perspective view of a second housing member and a magnetic ring in the embodiment, seen obliquely from above. FIG. [Figure 12] 3 is a perspective view of a second housing member and a magnetic ring as viewed obliquely from a lower side L in the embodiment. FIG. [Figure 13] 5A and 5B are schematic diagrams illustrating the positional relationship between a fitting recess of a second housing member and an insertion hole of a circuit board in the embodiment. [Figure 14] FIG. 2 is a cross-sectional view of the periphery of a cover member of a magnetostrictive torque sensor, with a mold resin removed, viewed obliquely in accordance with an embodiment. [Figure 15] FIG. 2 is a cross-sectional view of the magnetostrictive torque sensor, with the mold resin removed, taken along a line passing through a joint between a terminal and a substrate, according to an embodiment. [Figure 16] FIG. 2 is a perspective view of the cover member as viewed from diagonally below in the embodiment. [Figure 17] FIG. 2 is a perspective view of the cover member as viewed from diagonally above in the embodiment. [Figure 18] FIG. 2 is a plan view of a cover member according to the embodiment. [Figure 19] FIG. 1 is a cross-sectional view showing a state in which a magnetostrictive torque sensor is placed in a mold for molding resin before molding resin and a heat-shrinkable tube are provided in the mold according to an embodiment. [Figure 20] 10 is a cross-sectional view showing a state after a resin constituting a molding resin is injected into a mold for the molding resin in the embodiment. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0009] [Embodiment Mode] Embodiments of the present invention will be described with reference to Figures 1 to 20. The embodiments described below are shown as preferred specific examples for carrying out the present invention, and although some of the embodiments specifically exemplify various technically preferable aspects, the technical scope of the present invention is not limited to these specific embodiments.

[0010] (Magnetostrictive torque sensor 10) Fig. 1 is a perspective view of the magnetostrictive torque sensor 10 as seen from diagonally above U. Fig. 2 is a perspective view of the magnetostrictive torque sensor 10 as seen from diagonally below L. Fig. 3 is an enlarged cross-sectional view of a portion of the magnetostrictive torque sensor 10 on the side opposite the cable 4. Fig. 4 is an enlarged cross-sectional view of a portion of the magnetostrictive torque sensor 10 on the cable 4 side.

[0011] In this embodiment, the electric device 1 is a magnetostrictive torque sensor 10. Note that the electric device 1 can be a device other than the magnetostrictive torque sensor 10, as long as it has a configuration in which a substrate 2 and terminals 3 are joined together and covered with a housing 5, a cover member 6, and a molded resin 8. For example, the electric device 1 can be a sensor device other than the magnetostrictive torque sensor 10, or a relay device that relays electrical connections between multiple cables.

[0012] The magnetostrictive torque sensor 10 of this embodiment is used to measure the rotational torque applied to a magnetostrictive material 100 (see FIG. 3) having magnetostrictive properties. Magnetostriction is a phenomenon in which distortion appears in a ferromagnetic material when a magnetic field is applied to the ferromagnetic material to magnetize it. The magnetostrictive torque sensor 10 uses this phenomenon in reverse, detecting the magnetic field generated by the distortion of the magnetostrictive material 100 with a detection coil, thereby detecting the torque acting on the magnetostrictive material 100. The magnetostrictive torque sensor 10 can be mounted on, for example, a vehicle, and the magnetostrictive material 100, the rotational torque of which is to be measured, can be, for example, a predetermined rotating shaft used in the vehicle.

[0013] The magnetostrictive torque sensor 10 includes a substrate 2, terminals 3, a cable 4, a housing 5, a cover member 6, a magnetic ring 7, a molded resin 8, and a heat-shrinkable tube 9. The substrate 2 has a detection coil (not shown) for detecting an electrical signal corresponding to the magnitude of torque applied to the magnetostrictive material 100. As shown in FIG. 4 , one end of the terminal 3 is connected to the substrate 2 and the other end is connected to a cable 4. The cable 4 transmits the output of the detection coil to an external control device (not shown). The housing 5 is formed by combining a first housing member 51 and a second housing member 52 and accommodates the substrate 2, terminals 3, and cable 4. The cover member 6 closes a window 512a formed in the first housing member 51. As shown in FIG. 3 , the magnetic ring 7 is disposed to surround the outer periphery of the substrate 2 and serves to prevent magnetic flux generated by the detection coil of the substrate 2 from leaking to the outside, thereby reducing the accuracy of torque measurement by the magnetostrictive torque sensor 10. 1 to 4, the molded resin 8 is molded to cover the housing 5 and the cover member 6. A heat-shrinkable tube 9 seals the gap between the cable 4 and the housing 5 and the molded resin 8. Each part of the magnetostrictive torque sensor 10 will now be described in detail.

[0014] Hereinafter, the axial direction of the magnetostrictive material 100 will be referred to as the rotation axis direction Z, the longitudinal direction of the cable 4 will be referred to as the cable longitudinal direction X, and the direction perpendicular to both the rotation axis direction Z and the cable longitudinal direction X will be referred to as the width direction Y.

[0015] FIG. 5 is a perspective view of the magnetostrictive torque sensor 10, with the molded resin 8 and heat-shrinkable tube 9 removed, as viewed from the diagonally upper side U. FIG. 6 is a perspective view of the magnetostrictive torque sensor 10, with the molded resin 8 removed, as viewed from the diagonally lower side L. FIG. 7 is a perspective view of the board 2, terminals 3, cables 4, and first housing member 51, as viewed from the diagonally upper side U. FIG. 8 is a plan view of the board 2, terminals 3, cables 4, and first housing member 51. FIG. 9 is a bottom view enlarging the vicinity of the window portion 512a of the board 2, terminals 3, cables 4, and first housing member 51. FIG. 10 is an exploded perspective view of the board 2, terminals 3, cables 4, and first housing member 51, as viewed from the diagonally upper side U.

[0016] The substrate 2 is made of a flexible printed circuit board (FPC: Flexible Printed Circuits) that has flexibility. The substrate 2 can be configured, for example, by stacking multiple wiring layers. As shown in Fig. 10, the substrate 2 has a substrate cylindrical portion 21 that is curved cylindrically so as to surround the magnetostrictive material 100, a substrate flat portion 22 that is formed in a plane that is approximately perpendicular to the substrate cylindrical portion 21, and a substrate connecting portion 23 that is curved so as to connect the substrate cylindrical portion 21 and the substrate flat portion 22.

[0017] A pattern of detection coils is formed on the substrate cylindrical portion 21, which outputs an electric signal corresponding to the magnitude of the torque applied to the magnetostrictive material 100. The shape, number, and other configuration of the detection coils can be the same as that of a normal magnetostrictive torque sensor 10.

[0018] The substrate flat portion 22 is provided with a wiring pattern (not shown) for electrically connecting the detection coil to the plurality of terminals 3. The substrate flat portion 22 is provided with six terminal holes 221 for inserting the plurality of terminals 3, and one insertion hole 222 for inserting a protrusion 614 (described later) of the cover member 6.

[0019] The six terminal holes 221 are arranged in a U-shape so as to surround the insertion hole 222. That is, pairs of terminal holes 221 arranged in the width direction Y are formed in the board flat portion 22 at three locations in the cable longitudinal direction X, and the pair of terminal holes 221 located farthest from the board connecting portion 23 is spaced closer to each other than the other two pairs of terminal holes 221.

[0020] The insertion hole 222 is formed in a shape that allows a protrusion 614 of the cover member 6, which will be described later, to be inserted therein, and in this embodiment is formed in a generally rectangular shape that is long in the cable longitudinal direction X. In order to prevent dead space from being generated in the board planar portion 22, the insertion hole 222 is formed to pass between the terminal holes 221 that are aligned in the width direction Y among the multiple terminal holes 221. In this embodiment, the insertion hole 222 is formed to pass between the two terminal holes 221 that are aligned in the Y direction and closest to the board connecting portion 23 among the six terminal holes 221, and between the two terminal holes 221 that are adjacent to the two terminal holes 221 in the cable longitudinal direction X.

[0021] 8 and 10, a pair of locking recesses 223 are provided on both ends of the board flat portion 22 in the width direction Y. The pair of locking recesses 223 are located outside, in the width direction Y, a pair of terminal holes 221 located farthest from the board connecting portion 23. The locking protrusions 512b provided on the first housing member 51 are inserted into the locking recesses 223, and the locking recesses 223 are locked by the locking protrusions 512b. Four terminals 3 are connected to the board flat portion 22.

[0022] 7 and 8, the four terminals 3 are connected to different electric wires 41 of the cable 4, and the other ends thereof are inserted into the terminal holes 221 of the board flat portion 22. The four terminals 3 are lined up in the width direction Y, and the two terminals 3 in the center in the width direction Y have substantially the same shape, while the two terminals 3 at both ends in the width direction Y have substantially symmetrical shapes in the width direction Y. The two terminals 3 in the center in the width direction Y are inserted into a pair of terminal holes 221 located on the side farther from the board connecting portion 23. Each of the two terminals 3 at both ends in the width direction Y branches into two on the side opposite the cable 4, and these are inserted into the two terminal holes 221. Of the four terminals 3, the terminal 3 arranged at one end in the width direction Y is inserted into two terminal holes 221 located on one side of the insertion hole 222, and the terminal 3 arranged at the other end in the width direction Y is inserted into two terminal holes 221 located on the other side of the insertion hole 222.

[0023] The four terminals 3 are inserted into the six terminal holes 221 with their tips protruding toward the window portion 512a. The terminals 3 protruding from the six terminal holes 221 are joined to the board flat portion 22 from the window portion 512a side by soldering. That is, the joints between the board flat portion 22 and the terminals 3 (in this embodiment, solder 11 shown in Figures 13 and 15 described later) are provided on the window portion 512a side of the board flat portion 22. Note that Figure 9 shows the state before the solder is provided. The four terminals 3 are integrated with each other by an integrating resin 12. The integrating resin 12 is formed in a substantially rectangular column shape that is elongated in the width direction Y, and holds the four terminals 3 at a predetermined interval. The four terminals 3 on the side opposite to the side connected to the board flat portion 22 are connected to different electric wires 41 of the cable 4.

[0024] The cable 4 has four electric wires 41 and a sheath 42 that surrounds the four electric wires 41 collectively. Each electric wire 41 is a coated electric wire having a core wire and a coating. The sheath 42 is made of an electrically insulating resin or the like formed into a cylindrical shape. The cable 4 has the four electric wires 41 housed in the housing 5, and the sheath 42 is arranged outside the housing 5 and the molded resin 8, at a position separated from the housing 5 and the molded resin 8. The board 2, four terminals 3, integrated resin 12, and cable 4 are assembled into a first housing member 51.

[0025] In this embodiment, the first housing member 51, the second housing member 52, the cover member 6, and the molded resin 8 can all be made of the same resin, such as PPS (polyphenylene sulfide). However, the first housing member 51, the second housing member 52, the cover member 6, and the molded resin 8 do not all have to be made of the same resin.

[0026] 10, the first housing member 51 has a cylindrical portion 511 formed in a substantially cylindrical shape and an extension portion 512 extending from the cylindrical portion 511 toward the cable 4 in the cable longitudinal direction X. In this specification, one side in the rotation axis direction Z from which the cylindrical portion 511 of the first housing member 51 protrudes (the upper side in FIGS. 1 and 5) is referred to as the upper side U, and the opposite side is referred to as the lower side L. Note that the expressions "upper" and "lower" do not limit the orientation of the magnetostrictive torque sensor 10 relative to the vertical direction when in use.

[0027] As shown in Fig. 3, the cylindrical portion 511 is disposed so as to surround the magnetostrictive material 100, and the substrate cylindrical portion 21 is fixed to its outer circumferential surface using an adhesive (not shown). As shown in Fig. 10, the extension portion 512 extends from the lower end of the cylindrical portion 511 toward the cable 4 side.

[0028] 7, 8, and 10, a board arrangement recess 512c for arranging the board planar portion 22 and a cable arrangement recess 512d for arranging the multiple electric wires 41 of the cable 4 are formed on the upper side U of the extension portion 512. The board arrangement recess 512c and the cable arrangement recess 512d are recesses that are each open at least to the upper side U and communicate with each other.

[0029] The board arrangement recess 512c is located closer to the cylindrical portion 511 than the cable arrangement recess 512d. As shown in FIGS. 8 and 9, a window 512a is formed so as to penetrate the bottom wall of the board arrangement recess 512c in the rotation axis direction Z. The window 512a is formed at a position facing the board flat portion 22. As shown in FIG. 9, the window 512a exposes the tips of the terminals 3 protruding from the board flat portion 22 from the first housing member 51. In FIG. 9, the outline positions of a protrusion 614, a clamping portion 615, and a tip accommodating recess 612a (described later) of the cover member 6 projected onto the board flat portion 22 in the rotation axis direction Z are indicated by two-dot chain lines. In addition, FIG. 9 shows a state before solder (see reference numeral 11 in FIGS. 13 and 15 described later) is provided to join the terminals 3 to the board 2.

[0030] The window portion 512a is provided to enable joining of the board 2 and the terminals 3 after the board 2 and the terminals 3 are assembled to the first housing member 51. As shown in Fig. 8, the window portion 512a is formed in a rectangular shape that is slightly smaller than the board flat portion 22, and the peripheral edge of the board flat portion 22 is placed around the window portion 512a on the bottom wall of the board placement recess 512c.

[0031] 6 and 9, the first housing member 51 is formed with a frame portion 512e that protrudes downward L from the periphery of the window portion 512a. As shown in Fig. 9, the frame portion 512e is formed in a rectangular ring shape so as to surround the window portion 512a at a position spaced apart from the window portion 512a. As will be described in detail later, the cover member 6 is fitted inside the frame portion 512e.

[0032] As shown in FIGS. 7, 8, and 10, the cable arrangement recess 512d is provided with three wire compartment walls 512f that are elongated in the cable longitudinal direction X and that separate the four wires 41 from one another. A resin arrangement recess 512g in which the integrated resin 12 is arranged is formed between the cable arrangement recess 512d and the board arrangement recess 512c. The resin arrangement recess 512g is defined by one end of at least the three wire compartment walls 512f. The resin arrangement recess 512g is also defined by an integrated resin compartment wall 512h that is provided opposite the central wire compartment wall 512f of the three wire compartment walls 512f, with the integrated resin 12 interposed between them. The board arrangement recess 512c, the cable arrangement recess 512d, and the resin arrangement recess 512g are covered by the second housing member 52.

[0033] 5 and 6, the second housing member 52 is formed along the extension portion 512 of the first housing member 51. The second housing member 52 has a pair of flexible pieces 521 extending to the lower side L, and is snap-fitted to the first housing member 51 by the pair of flexible pieces 521.

[0034] Fig. 11 is a perspective view of the second housing member 52 and the magnetic ring 7 as seen obliquely from the upper side U. Fig. 12 is a perspective view of the second housing member 52 and the magnetic ring 7 as seen obliquely from the lower side L.

[0035] 12, the second housing member 52 is formed in a concave shape that is open at least to the lower side L. The second housing member 52 has a support portion 522 that protrudes from the bottom wall of the second housing member 52 to the lower side L and supports the board flat portion 22 from the lower side L. The support portion 522 is formed in a substantially rectangular shape, and is provided with a fitting recess 523 for inserting a protrusion 614 (described later) of the cover member 6, and a terminal insertion recess 524 for inserting a plurality of terminals 3, which open downward. Then, as shown in FIG. 4, the lower surface of the support portion 522 supports the board flat portion 22.

[0036] 13 is a schematic diagram illustrating the positional relationship between the fitting recess 523 of the second housing member 52 and the insertion hole 222, as viewed from the bottom side L with the cover member 6 removed from the housing 5. At least a portion of an inner circumferential surface 523a of the fitting recess 523 is located more inward than the inner circumferential surface 222a of the insertion hole 222. In this embodiment, the fitting recess 523 is formed shorter than the insertion hole 222 in the cable longitudinal direction X, and a pair of side surfaces 523b of the inner circumferential surface 523a of the fitting recess 523 that face the cable longitudinal direction X are located more inward than the inner circumferential surface 222a of the insertion hole 222. However, this is not limited to this, and for example, only a portion of one of the surfaces constituting the inner surface 523a of the mating recess 523 may be arranged more inward than the inner surface 222a of the insertion hole 222, or the entire inner surface 523a of the mating recess 523 may be arranged more inward than the inner surface 222a of the insertion hole 222.

[0037] 11 and 12, the second housing member 52 is formed integrally with the magnetic ring 7. As shown in FIGS. 4 and 11, a retaining projection 525 that protrudes upward U is provided at the end of the second housing member 52 closer to the magnetic ring 7. As shown in FIG. 4, the retaining projection 525 is disposed so as to fill a retaining recess 712 provided on the underside of the magnetic ring 7. When the second housing member 52 is molded, the resin constituting the second housing member 52 fills the retaining recess 712, thereby forming the retaining projection 525 in the same shape as the space within the retaining recess 712 and uniting the second housing member 52 with the magnetic ring 7. In this embodiment, the inner peripheral surface of the retaining recess 712 is formed in a screw groove shape, and accordingly, the outer peripheral surface of the retaining projection 525 is formed in a screw thread shape. It should be noted that other uneven shapes may be adopted for the inner peripheral surface of the retaining recess 712 and the outer peripheral surface of the retaining protrusion 525, as long as they are mutually retained. Details of the magnetic ring 7 will be described later.

[0038] A cover member 6 is provided to close the window portion 512a from the lower side L. FIG. 14 is a cross-sectional view of the area around the cover member 6 of the magnetostrictive torque sensor 10, with the molded resin 8 removed, seen obliquely. FIG. 15 is a cross-sectional view of the magnetostrictive torque sensor 10, with the molded resin 8 removed, taken along a line passing through the joint between the terminal 3 and the substrate 2. FIG. 16 is a perspective view of the cover member 6, seen obliquely from the lower side L. FIG. 17 is a perspective view of the cover member 6, seen obliquely from the upper side U. FIG. 18 is a plan view of the cover member 6.

[0039] The cover member 6 has a cover main body 61 in the shape of a substantially rectangular plate and three snap-fit ​​pieces 62 extending upward from the cover main body 61 toward the upper side U. As shown in FIGS. 17 and 18 , the cover main body 61 has a first step 611 protruding toward the upper side U and a second step 612 protruding further toward the upper side U from the center of the first step 611. The first step 611 is formed one turn inward from an outer edge 613 of the cover main body 61. As shown in FIGS. 14 and 15 , the outer edge 613 of the cover main body 61 is placed on the lower surface of a frame 512e of the first housing member 51. The first step 611 is fitted into the inner side of the frame 512e. The first step 611 is fitted into the inner side of the frame 512e in a loose fit.

[0040] The upper surface of the second step portion 612 faces the board flat portion 22 with a gap therebetween. As shown in FIGS. 15, 17, and 18, the second step portion 612 is formed with six tip accommodating recesses 612a that respectively accommodate the six tips of the terminals 3. The six tip accommodating recesses 612a are formed at positions that overlap with the six terminal holes 221 in the rotational axis direction Z. In this embodiment, the tip accommodating recesses 612a also accommodate some of the solder 11. The lower surface of the cover main body 61 is provided with a protruding portion 612b that protrudes from the lower side L. The protruding portion 612b is formed at a position that overlaps with the tip accommodating recesses 612a in the thickness direction of the cover main body 61 (i.e., the rotational axis direction Z). As shown in FIG. 18, the protruding portion 612b is formed in a U-shape so as to overlap with all of the U-shaped arranged tip accommodating recesses 612a in the rotational axis direction Z.

[0041] As shown in FIGS. 17 and 18 , the cover main body 61 has a protruding portion 614 and a clamping portion 615 that protrude further upward from the second step portion 612 toward the upper side U. The protruding portion 614 is formed to protrude upward from the clamping portion 615 toward the upper side U. The protruding portion 614 is formed in a plate shape that is long in the cable longitudinal direction X and thick in the width direction Y. The longitudinal direction of the protruding portion 614 coincides with the longitudinal direction of the cover member 6. The protruding portion 614 is formed in approximately the center of the cover main body 61. As shown in FIG. 14 , the protruding portion 614 is inserted into the insertion hole 222 of the board flat portion 22 and the fitting recess 523 of the second housing member 52. The protruding portion 614 is fitted into the fitting recess 523 in a loose fit. The end surface of the upper side U of the protruding portion 614 closely faces or abuts against the bottom surface of the fitting recess 523.

[0042] 15 , the clamping portion 615 has a role of sandwiching the board flat portion 22 between itself and the support portion 522 of the second housing member 52 and a role of reinforcing the cover member 6. As shown in FIGS. 17 and 18 , the clamping portion 615 has a vertical portion 615a extending from the protruding portion 614 toward the cable 4 in the cable longitudinal direction X, a pair of first horizontal portions 615b extending from the protruding portion 614 on both sides in the width direction Y, a pair of second horizontal portions 615c extending from an end of the vertical portion 615a on the protruding portion 614 side on both sides in the width direction Y, and a pair of third horizontal portions 615d extending from an end of the vertical portion 615a opposite to the protruding portion 614 on both sides in the width direction Y. The vertical portion 615a is formed to pass between two of the six tip end accommodating recesses 612a that are located closest to the cable 4. The first horizontal portion 615b and the second horizontal portion 615c are formed to pass between the tip accommodating recesses 612a that are adjacent in the cable longitudinal direction X. That is, the protrusion 614, the vertical portion 615a, the first horizontal portion 615b, and the second horizontal portion 615c are formed to separate the six tip accommodating recesses 612a from one another. The third horizontal portion 615d is formed so that the edge of the second step portion 612 on the cable 4 side is raised upward U across the entire width direction Y.

[0043] The snap-fit ​​pieces 62 are formed to extend from the second step portion 612 to the upper side U. The snap-fit ​​pieces 62 are flexible in the cable longitudinal direction X, and are fixed to the first housing member 51 by snap-fitting. As shown in Fig. 14, one snap-fit ​​piece 62 is engaged with the upper surface of the integrated resin partition wall 512h.

[0044] 3, the magnetic ring 7 is formed to face the cylindrical portion 511 of the first housing member 51 across the cylindrical substrate portion 21 of the substrate 2. The magnetic ring 7 is made of a ferromagnetic material (soft magnetic material) made of a metal (including an alloy) such as iron, formed into a substantially cylindrical shape. By covering the outer periphery of the detection coil, the magnetic ring 7 serves to prevent magnetic flux generated by the detection coil from leaking to the outside, thereby reducing the accuracy of torque measurement by the magnetostrictive torque sensor 10.

[0045] 3 and 11, the magnetic ring 7 has a large diameter portion 71 at its lower end, and a small diameter portion 72, which is located above the large diameter portion 71 on the upper side U, and has an outer diameter smaller than that of the large diameter portion 71. A ring recess 711 is formed on the lower surface of the large diameter portion 71, and is recessed toward the upper side U, with the second housing member 52 disposed inside. As shown in FIG. 3, the aforementioned retaining recess 712 is formed so as to open into the bottom surface of the ring recess 711. Furthermore, the portion of the lower surface of the large diameter portion 71 other than the portion where the ring recess 711 is formed faces the upper surface of the first housing member 51.

[0046] 1 to 4, the molded resin 8 is molded to cover the housing 5, the cover member 6, and a portion of the magnetic ring 7. The molded resin 8 is molded to cover the housing 5 and the cover member 6 while leaving the small diameter portion 72 of the magnetic ring 7 exposed. As shown in FIG. 3, the contact portion 13 between the outer circumferential surface of the large diameter portion 71 and the molded resin 8 has a portion whose diameter decreases toward the upper side U. This prevents the magnetic ring 7 from slipping out of the molded resin 8 to the upper side U.

[0047] As shown in FIGS. 2 and 4, the molded resin 8 has a first opening 81 that opens to the lower surface of the cover member 6. As a result, when viewed from the bottom side L, the cover member 6 can be seen inside the first opening 81. When viewed from the bottom side L, the first opening 81 is formed at a position surrounded by the U-shaped protrusion 612b. Also, as shown in FIGS. 1 and 4, the molded resin 8 has a second opening 82 that opens to the upper surface of the second housing member 52. The first opening 81 and the second opening 82 are portions that a mold abuts against when molding the molded resin 8. As shown in FIG. 1, a pair of ribs 526 are provided on the second housing member 52 so as to sandwich the second opening 82. When molding the molded resin 8, the mold is aligned between the pair of ribs 526.

[0048] As shown in FIGS. 1 , 2 , and 4 , a heat-shrinkable tube 9 is provided to prevent liquids and the like from penetrating into the housing 5 and the molded resin 8 through gaps between the housing 5 and the molded resin 8 and the cable 4. The heat-shrinkable tube 9 is formed to cover the boundary between the housing 5 and the molded resin 8 and the cable 4 when viewed from the outside. The heat-shrinkable tube 9 is configured to shrink at least toward the inner periphery of the heat-shrinkable tube 9 when heated to a predetermined temperature or higher. The heat-shrinkable tube 9 covers the molded resin 8 and the end of the housing 5 facing the sheath 42, as well as the end of the sheath 42 facing the housing 5. As shown in FIG. 4 , in this embodiment, the length of the portion of the heat-shrinkable tube 9 covering the sheath 42 in the cable longitudinal direction X is longer than the length of the portion covering the end of the housing 5 and the molded resin 8 in the cable longitudinal direction X. Furthermore, a portion of the heat-shrinkable tube 9 is inserted between the sheath 42 and the housing 5. The inner periphery of the heat-shrinkable tube 9 may be provided with a hot melt adhesive, which is an adhesive material that melts at a predetermined temperature or higher and hardens again when the temperature drops below the predetermined temperature.

[0049] (Method of manufacturing the magnetostrictive torque sensor 10) Next, an example of a method for manufacturing the magnetostrictive torque sensor 10 will be described. First, the substrate 2, the four terminals 3 integrated with the integration resin 12, and the cable 4 are assembled into the first housing member 51. This results in the state shown in FIGS.

[0050] Next, the second housing member 52 integrated with the magnetic ring 7 is attached to the first housing member 51. As a result, one surface of the board flat portion 22 of the board 2 is supported by the support portion 522 of the first housing member 51.

[0051] Next, the terminals 3 and the board flat portion 22 are joined through the window 512a of the first housing member 51. To join the terminals 3 and the board flat portion 22, a tool (not shown) for forming solder 11 is inserted into the housing 5 through the window 512a, and the terminals 3 and the board flat portion 22 are joined using the solder 11. At this time, because the board flat portion 22 is supported by the support portion 522, deformation of the board flat portion 22 due to being pressed by the tool, etc. is suppressed. After the terminals 3 and the board flat portion 22 are joined, the window 512a is closed with the cover member 6.

[0052] Next, the mold resin 8 is formed. Fig. 19 is a cross-sectional view showing the state in which the magnetostrictive torque sensor 10 is placed in the mold for the mold resin 8 before the mold resin 8 and the heat-shrinkable tube 9 are provided. Fig. 20 is a cross-sectional view showing the state after the resin that constitutes the mold resin 8 has been injected into the mold for the mold resin 8.

[0053] 19, the magnetostrictive torque sensor 10 is placed in a mold without the mold resin 8 and heat-shrinkable tube 9. The mold has at least an upper mold 141 and a lower mold 142 that overlap in the rotation axis direction Z. The lower mold 142 has a lower mold abutment portion 142a that abuts against a part of the lower surface of the cover member 6, and the upper mold 141 has an upper mold abutment portion 141a that abuts against a part of the upper surface of the second housing member 52. This presses the cover member 6 toward the second housing member 52, preventing the mold resin 8 from penetrating into the interface between the cover member 6 and the window portion 512a. The mold resin 8 is formed by injecting molten resin that will become the mold resin 8 into a cavity surrounded by the upper mold 141 and the lower mold 142 and curing the resin. During molding of the mold resin 8, the region where the lower die contact portion 142a was present becomes the first opening 81, and the region where the upper die contact portion 141a was present becomes the second opening .

[0054] Next, the heat-shrinkable tube 9 is provided. To provide the heat-shrinkable tube 9, first, the heat-shrinkable tube 9 before heat shrinking, which has an outer diameter larger than the portions of the housing 5, the molded resin 8, and the cable 4 to be covered by the heat-shrinkable tube 9, is arranged so as to surround the portions of the housing 5, the molded resin 8, and the cable 4 to be covered by the heat-shrinkable tube 9. Next, the heat-shrinkable tube 9 is heated and shrunk, so that the heat-shrinkable tube 9 is adhered to the surfaces of the housing 5, the molded resin 8, and the cable 4 directly or via a hot melt, if present. At this time, the diameter of a portion of the heat-shrinkable tube 9 is reduced so as to enter the space between the sheath 42 and the housing 5. As described above, the magnetostrictive torque sensor 10 of this embodiment can be manufactured.

[0055] (Actions and Effects of the Embodiments) In the magnetostrictive torque sensor 10 of this embodiment, the housing 5 is provided with a window 512a that exposes the joints (solder 11) between the substrate 2 and the terminals 3, and the cover member 6 closes the window 512a. The housing 5 and the cover member 6 are covered with a molded resin 8. This prevents the molded resin 8 from entering the space where the joints between the substrate 2 and the terminals 3 are located. This prevents the molded resin 8 from entering around the joints between the substrate 2 and the terminals 3, which would cause stress between the substrate 2 and the terminals 3 and inhibit the electrical connectivity between the substrate 2 and the terminals 3 from being impaired.

[0056] Furthermore, in this embodiment, the housing 5 is provided with a window 512a that exposes the joint between the substrate 2 and the terminals 3, so that the substrate 2 and the terminals 3 can be joined through the window 512a after the substrate 2 and the terminals 3 are assembled to the housing 5. This improves the flexibility of the manufacturing method of the magnetostrictive torque sensor 10.

[0057] The housing 5 also has a first housing member 51 in which a window portion 512a is formed, and a second housing member 52 that covers the board 2 and the terminals 3 from the side opposite to the first housing member 51. This makes it easy to attach the board 2 and the terminals 3 to the housing 5.

[0058] Furthermore, the cover member 6 has a protrusion 614 that protrudes toward the second housing member 52, and the substrate 2 has an insertion hole 222 into which the protrusion 614 is inserted. Therefore, the protrusion 614 ensures the strength of the cover member 6 and the second housing member 52. Furthermore, in this embodiment, when the molded resin 8 is formed, the injection pressure of the molded resin 8 acts on the housing 5 and the cover member 6, but the second housing member 52 and the cover member 6 abut against each other via the protrusion 614, thereby suppressing deformation of the cover member 6 and the second housing member 52. Before molding the molded resin 8, the cover member 6 and the second housing member 52 do not need to be in contact with each other via the protrusion 614. However, when the injection pressure of the molded resin 8 acts on the cover member 6 and the second housing member 52, the cover member 6 and the second housing member 52 are pushed by this injection pressure, and the protrusion 614 comes into contact with the second housing member 52, thereby suppressing deformation of the second housing member 52 and the cover member 6.

[0059] Here, although it is possible to adopt a configuration in which the protrusion is provided on the second housing member 52 and the protrusion of the second housing member 52 abuts against the cover member 6, in this embodiment, the protrusion 614 is provided on the cover member 6. This makes it easier to assemble the magnetostrictive torque sensor 10. Unlike this embodiment, if the protrusion 614 is formed on the second housing member 52, the protrusion 614 would protrude from the insertion hole 222 of the board 2 toward the window 512a when the first housing member 51, the second housing member 52, the board 2, and the terminals 3 are assembled together. In this case, there is a concern that a joining tool may interfere with the protrusion 614 when joining the board 2 and the terminals 3 from the window 512a side. On the other hand, in this embodiment, the protrusion 614 is provided on the cover member 6, so this concern is resolved.

[0060] Further, the second housing member 52 is provided with a fitting recess 523 that fits with the protrusion 614. Therefore, when the window portion 512a is closed with the cover member 6, the protrusion 614 of the cover member 6 is guided straight into the fitting recess 523, and therefore, it is possible to prevent the protrusion 614 from interfering with the insertion hole 222 of the board 2 and causing deformation, displacement, etc. of the board 2.

[0061] Furthermore, at least a part of the inner circumferential surface 523a of the fitting recess 523 is located more inward than the inner circumferential surface 222a of the insertion hole 222. Therefore, when the protruding portion 614 of the cover member 6 is inserted into the insertion hole 222 of the board 2 and the fitting recess 523 of the second housing member 52, the protruding portion 614 interferes with the inner circumferential surface 523a of the fitting recess 523, which is located more inward than the insertion hole 222, thereby preventing the protruding portion 614 from interfering with the inner circumferential surface 222a of the insertion hole 222 of the board 2.

[0062] Furthermore, the protrusion 614 has a plate shape that is long in the longitudinal direction of the cover member 6. This increases the rigidity of the cover member 6. Furthermore, in this embodiment, even if the injection pressure of the molded resin 8 acts on the second housing member 52 and the cover member 6 when the molded resin 8 is formed, the protrusion 614 of the cover member 6 abuts against the second housing member 52 over a long range in the cable longitudinal direction X, thereby further suppressing deformation of the second housing member 52 and the cover member 6.

[0063] Furthermore, the substrate 2 is formed with a plurality of terminal holes 221 into which the terminals 3 are inserted, and the insertion hole 222 is provided at a position sandwiched between at least one pair of the plurality of terminal holes 221. In the substrate 2, the space between the terminal holes 221 tends to become dead space, but according to this embodiment, this dead space can be effectively utilized, and an increase in the size of the substrate 2 can be prevented.

[0064] The second housing member 52 also has a support portion 522 that supports one surface of the board 2. Therefore, when the board 2 and the terminals 3 are assembled inside the housing 5, the board 2 is supported by the support portion 522, and deformation and displacement of the board 2 are suppressed. Furthermore, in this embodiment, when joining the board 2 and the terminals 3 from the window portion 512a side, the board 2 is prevented from being pressed by a joining tool, resulting in deformation and displacement of the board 2.

[0065] Furthermore, the cover member 6 has a clamping portion 615 that clamps the substrate 2 between itself and the support portion 522. Therefore, deformation and displacement of the substrate 2 are suppressed.

[0066] Furthermore, housing 5 has frame portion 512e formed in an annular shape that protrudes toward the side where window portion 512a opens (i.e., downward) and surrounds window portion 512a at a position away from window portion 512a, and cover member 6 is fitted inside frame portion 512e. This allows the shape of the interface between cover member 6 and second housing member 52 to be complex, and prevents mold resin 8 from seeping into housing 5 from the interface between cover member 6 and second housing member 52 when molding mold resin 8.

[0067] Furthermore, a tip accommodating recess 612a in which the tip of the terminal 3 is disposed is formed on the inner surface (upper surface) of the cover member 6. This prevents the tip of the terminal 3 from interfering with the cover member 6. Furthermore, a protruding portion 612b protruding from the lower side L is provided on the outer surface (lower surface) of the cover member 6 at a position overlapping the tip accommodating recess 612a in the thickness direction of the cover member 6 (i.e., the rotation axis direction Z). Unless special measures are taken, the thickness of the cover member 6 is likely to be thin at the portion where the tip accommodating recess 612a is formed, which could reduce the strength of the cover member 6 or cause molding defects of the cover member 6. However, in this embodiment, by forming the protruding portion 612b at the portion where the tip accommodating recess 612a is formed, it is possible to prevent a reduction in the strength of the cover member 6 and molding defects of the cover member 6.

[0068] Furthermore, a first opening 81 that opens into the cover member 6 is formed in the molded resin 8. The first opening 81 is an opening that is created when the mold abuts against the cover member 6 during molding of the molded resin 8. Therefore, during molding of the molded resin 8, the cover member 6 is pressed toward the second housing member 52 by the clamping force of the mold, and the formation of a gap between the cover member 6 and the second housing member 52 is suppressed. This suppresses the molded resin 8 from seeping into the housing 5 and the cover member 6.

[0069] As described above, according to this embodiment, it is possible to provide an electric device that can improve the electrical connectivity between the substrate and the terminals.

[0070] (Summary of the embodiment) Next, the technical ideas grasped from the above-described embodiments will be described by using the reference numerals and the like in the embodiments. However, the reference numerals and the like in the following description do not limit the components in the claims to the members and the like specifically shown in the embodiments.

[0071] [1] An electrical device (1) comprising: a substrate (2); terminals (3) joined to the substrate (2); a housing (5) that accommodates the substrate (2) and the terminals (3) and has a window (512a) that exposes a joint (11) between the substrate (2) and the terminals (3); a cover member (6) that closes the window (512a); and a molded resin (8) that covers the housing (5) and the cover member (6).

[0072] [2] The housing (5) has a first housing member (51) in which the window portion (512a) is formed, and a second housing member (52) that covers the board (2) and the terminals (3) from the side opposite the first housing member (51), in the electrical device (1) described in [1].

[0073] [3] The electrical device (1) described in [2], wherein one of the cover member (6) and the second housing member (52) has a protrusion (614) that protrudes toward the other side, and the substrate (2) has an insertion hole (222) into which the protrusion (614) is inserted.

[0074] [4] The electrical device (1) according to [3], wherein the protrusion (614) is provided on the cover member (6).

[0075] [5] The electric device (1) according to [4], wherein the second housing member (52) is provided with a fitting recess (523) that fits onto the protrusion (614).

[0076] [6] The electric device (1) described in [5], wherein at least a portion of the inner peripheral surface (523a) of the fitting recess (523) is located more inward than the inner peripheral surface (222a) of the insertion hole (222).

[0077] [7] The electric device (1) according to any one of [3] to [6], wherein the protrusion (614) has a plate shape that is long in the longitudinal direction of the cover member (6).

[0078] [8] An electrical device (1) according to any one of [3] to [7], wherein the substrate (2) is formed with a plurality of terminal holes (221) into which the terminals (3) are inserted, and the insertion hole (222) is located at a position sandwiched between at least a pair of the terminal holes (221) among the plurality of terminal holes (221).

[0079] [9] The electric device (1) described in any one of [2] to [8], wherein the second housing member (52) has a support portion (522) that supports one surface of the substrate (2).

[0080]

[10] The electric device (1) according to [9], wherein the cover member (6) has a clamping portion (615) that clamps the substrate (2) between the cover member (6) and the support portion (522).

[0081]

[11] An electrical device (1) according to any one of [1] to

[10] , wherein the housing (5) has a frame portion (512e) formed in an annular shape that protrudes toward the side where the window portion (512a) opens and surrounds the window portion (512a) at a position away from the window portion (512a), and the cover member (6) is fitted inside the frame portion (512e).

[0082]

[12] An electrical device (1) according to any one of [1] to

[11] , wherein a tip accommodating recess (612a) in which the tip of the terminal (3) is disposed is formed on the inner surface of the cover member (6), and a protruding portion (612b) protruding outward is provided on the outer surface of the cover member (6) at a position overlapping the tip accommodating recess (612a) in the thickness direction of the cover member (6).

[0083]

[13] The electric device (1) according to any one of [1] to

[12] , wherein the molded resin (8) has an opening (81) that opens into the cover member (6).

[0084]

[14] The electric device (1) according to any one of [1] to

[13] , which is used as a magnetostrictive torque sensor (10).

[0085] (Addendum) Although the embodiments of the present invention have been described above, the invention according to the claims is not limited to the above-described embodiments. It should be noted that not all of the combinations of features described in the embodiments are necessarily essential to the means for solving the problems of the invention. Furthermore, the present invention can be appropriately modified and implemented within the scope of its spirit. [Explanation of symbols]

[0086] 1. Electrical equipment 10...Magnetostrictive torque sensor 11...Solder (joint) 2...Substrate 221...Terminal hole 222...insertion hole 222a...Inner peripheral surface 3...Terminal 5. Housing 51...first housing member 512a...Window section 512e…Frame part 52...Second housing member 522...Support part 523...Mating recess 523a…Inner peripheral surface 6...Cover member 612a...tip receiving recess 612b...Protuberance 614...Protrusion 615...Holding part 8...Molding resin 81...First opening

Claims

1. A substrate; a terminal joined to the substrate; a housing that accommodates the substrate and the terminals and has a window that exposes a joint between the substrate and the terminals; a cover member that closes the window portion; a molding resin that covers the housing and the cover member, the housing includes a first housing member in which the window portion is formed, and a second housing member that covers the board and the terminals from the side opposite to the first housing member, one of the cover member and the second housing member has a protruding portion that protrudes toward the other side, The substrate has an insertion hole formed therein into which the protrusion is inserted. Electrical equipment.

2. The protrusion is provided on the cover member.

10. The electrical device of claim 1.

3. The second housing member is provided with a fitting recess that fits into the protrusion.

3. The electrical device of claim 2.

4. At least a part of the inner peripheral surface of the fitting recess is located more inward than the inner peripheral surface of the insertion hole. are 4. The electrical device of claim 3.

5. The protrusion has a plate shape that is elongated in the longitudinal direction of the cover member.

5. An electrical device according to any one of claims 1 to 4.

6. The substrate is formed with a plurality of terminal holes into which the terminals are inserted, The insertion hole is located at a position sandwiched between at least a pair of terminal holes among the plurality of terminal holes. It is being 6. An electrical device according to any one of claims 1 to 5.

7. the second housing member has a support portion that supports one surface of the substrate; 7. An electrical device according to any one of claims 1 to 6.

8. A substrate; a terminal joined to the substrate; a housing that accommodates the substrate and the terminals and has a window that exposes a joint between the substrate and the terminals; a cover member that closes the window portion; a molding resin that covers the housing and the cover member, the housing includes a first housing member in which the window portion is formed, and a second housing member that covers the board and the terminals from the side opposite to the first housing member, the second housing member has a support portion that supports one surface of the substrate; Electrical equipment.

9. the cover member has a clamping portion that clamps the substrate between itself and the support portion, 9. An electrical device according to claim 7 or 8.

10. the housing has a frame portion that protrudes toward the opening of the window portion and is formed in an annular shape so as to surround the window portion at a position spaced from the window portion, The cover member is fitted inside the frame portion.

10. An electrical device according to any one of claims 1 to 9.

11. A substrate; a terminal joined to the substrate; a housing that accommodates the substrate and the terminals and has a window that exposes a joint between the substrate and the terminals; a cover member that closes the window portion; a molding resin that covers the housing and the cover member, the housing has a frame portion that protrudes toward the opening of the window portion and is formed in an annular shape so as to surround the window portion at a position spaced from the window portion, The cover member is fitted inside the frame portion. Electrical equipment.

12. a tip receiving recess in which the tip of the terminal is disposed is formed on the inner surface of the cover member; An outer surface of the cover member is provided with a protruding portion that protrudes outward at a position that overlaps the tip end accommodating recess in the thickness direction of the cover member.

12. An electrical device according to any one of the preceding claims.

13. A substrate; a terminal joined to the substrate; a housing that accommodates the substrate and the terminals and has a window that exposes a joint between the substrate and the terminals; a cover member that closes the window portion; a molding resin that covers the housing and the cover member, a tip receiving recess in which the tip of the terminal is disposed is formed on the inner surface of the cover member; An outer surface of the cover member is provided with a protruding portion that protrudes outward at a position that overlaps the tip end accommodating recess in the thickness direction of the cover member. Electrical equipment.

14. The molding resin has an opening formed therein that opens to the cover member.

14. An electrical device according to any one of claims 1 to 13.

15. Used as a magnetostrictive torque sensor, 15. An electrical device according to any one of the preceding claims.

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