Sensor-equipped protector and method for manufacturing the same

Abstract

To provide a protector with a sensor with a simple structure and excellent workability but without particularly spoiling its appearance.SOLUTION: Provided is a protector 30 with a sensor which is covered by a mold forming material together with an insulation part 60, core wires 31 and 32, a resistor 39, legs 39a and 39b, and a wire connection part M, and in which one end side of an insert 50 is press-fitted so as to block a space part 33 disposed in a hollow part 12 attached to a slide door 1, and the insulation part 60 that insulates the wire connection part M of the legs 39a and 39b of the resistor 39 is disposed on the other end side. The insulation part 60 is formed into a flat plate shape, and only both right and left end parts 61 and 62 of the insulation part 60 are exposed from a surface of a portion covered by the mold forming material K. An inside protrusion part 66 is disposed on the one end of the insert 50 and a connection part of the other end so as to protrude further inwardly from an inner surface of the insulation part 60.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a protector with a sensor in which an opening / closing member for opening and closing an opening of a vehicle body, such as a slide door or a back door that moves back and forth on the vehicle body like a wagon car or a one-box car, or a sunroof, etc., and a sensor that outputs a corresponding signal to detect the presence of a foreign object when a foreign object such as a finger is sandwiched between the opening and the opening / closing member is incorporated, and a method for manufacturing the same.

Background Art

[0002] As shown in FIG. 10, in an automobile in which an opening of a vehicle body is opened and closed by a slide door 1 (or a back door) like a wagon car, or as shown in FIG. 11, in an automobile in which an opening of a vehicle body is opened and closed by a sunroof 2, protectors 10 and 20 with sensors are attached.

[0003] For example, on the front end surface of the slide door 1, a protector 10 with a sensor projecting toward the front side of the vehicle body and extending vertically as shown in FIG. 12 is attached. As shown in FIGS. 13 and 14, the protector 10 with a sensor includes a mounting base 11 having a concave cross-section formed by an inner side wall 11a, an outer side wall 11b, and a connecting wall 11c, which is attached to a flange F formed on the front end surface of the slide door 1, and a hollow portion 12 integrally formed therewith. In the hollow portion 12, a sensor (pressure-sensitive sensor) S that detects the sandwiching of a foreign object such as a part of a human body (finger or limb) between the slide door 1 and a body-side opening (which may be a front door (side door) in some cases) and outputs a corresponding electrical signal is attached (for example, see Patent Document 1). The outer peripheral surface of the hollow portion 12 is an outer shell 12a having a concave cross-section, and both end portions 12b and 12c of the outer shell 12a are connected with a space therebetween to the left and right of the mounting base 11. Furthermore, at the lower part of the sensor-equipped protector 10, a channel portion 13 with a C-shaped cross-section is integrally molded on the vehicle-side wall 11a of the mounting base 11, and holds the wire harness W connected to the pressure sensor S. In addition, multiple retaining lips 14, 14 are provided on the inside of the mounting base 11, and a core material 15 with a concave cross-section is embedded in the mounting base 11 to increase its rigidity. Moreover, a lip-shaped sealing portion 16 is provided on the vehicle-side wall 11b of the mounting base 11.

[0004] The sensor (pressure sensor) S consists of two core wires (electrode wires) 31 and 32 extending in the vertical direction (longitudinal direction) of the vehicle, which are fixed within the hollow section 12 so as to be embedded in conductive rubber-like elastic materials (conductive parts) 34 and 35 provided via a space 33. When a foreign object is caught between the sliding door 1 and the body-side opening when the sliding door 1 is closed, the hollow section 12 is partially pressed and crushed, causing the rubber-like elastic materials 34 and 35 to come into contact and short-circuit the two core wires 31 and 32. This change in electrical signal is then transmitted to a control device 40 connected to lead wires 36 and 36 that are connected to the two core wires 31 and 32 at the lower terminal of the sensor-equipped protector 10, thereby detecting the presence of a foreign object. The lead wires 36 and 36 are bundled together by a wire harness W while covered with an insulator, but their ends are bare wires exposed from the covered parts 37 and 37.

[0005] Furthermore, the rubber-like elastic body (conductive part) 34, 35 consists of a concave hollow upper conductive part 34 and a convex hollow lower conductive part 35. In order to widen the detection range of the sensor (pressure sensor) S, the space 33 has a concave cross-section with the same width, and the concave opening is shaped and arranged so that it faces the mounting base 11.

[0006] At the upper terminal portion of the sensor-equipped protector 10, as shown in Figure 15, the leads of the resistor 39 are superimposed on two core wires 31 and 32 that are drawn out in the longitudinal direction (to the right in Figure 15) and connected by resistance welding or soldering. After the space 33 is sealed with an insert 26, the connection portion M, insert 26, and resistor 39 are embedded inside the molded part and not exposed by molding (for example, Patent Document 2). Note that the molded part is indicated by a dotted line in Figure 15.

[0007] However, if the insert 26 is not supported inside the mold (not shown) during molding, the insert 26 may rattle or shift position due to the effects of injection molding pressure.

[0008] Therefore, a touch sensor unit that prevents misalignment of the insert by supporting the insert with a mold and a method for manufacturing the same have been disclosed (Patent Document 3). As shown in Figures 16 and 17, a plug-in portion 46 extending from one side of the first separator 45 is inserted into a tubular insulating tube 41 on which a pair of electrodes 42 and 43 are arranged spirally, and a housing body portion 47 for housing a resistor R is provided on the other side of the first separator 45. The housing body 47 is provided with a first bottom wall 47a, a second bottom wall 47b, and side walls 47c rising from them, and a partition wall 47d extending in the longitudinal direction of the first separator 45 is provided on the inside of the housing body 47. A resistor R and a crimped member SW, which is crimped by connecting one leg of the resistor R to one electrode 42, are housed between one surface of the partition wall 47d and the side wall portion 47c, and a crimped member SW, which is crimped by connecting the other leg of the resistor R to the other electrode 43, is housed between the other surface of the partition wall 47d and the side wall portion 47c to provide insulation. In addition, the first bottom wall portion 47a is provided with a recessed portion 47e that is recessed from the outside to the inside of the housing body portion 47.

[0009] The first separator 45 is then covered by the first molded resin part 48 through molding. In Figure 16, the outer shell of the first molded resin part 48 is shown by a dashed line. By partially supporting the first separator 45 in the mold during this molding process, the rattling of the first separator 45 is prevented. [Prior art documents] [Patent Documents]

[0010] [Patent Document 1] Japanese Patent Publication No. 2021-062665 [Patent Document 2] Japanese Patent Publication No. 2015-174632 [Patent Document 3] Japanese Patent Publication No. 2019-091618 [Overview of the Initiative] [Problems that the invention aims to solve]

[0011] However, in the invention shown in Patent Document 3, as shown in Figure 18, there is a problem that the finished product has a poor appearance because many parts are exposed from the first molded resin part 48 (shaded parts in Figure 18), including the second bottom wall part 47b, the side wall part 47c, the partition wall part 47d, and the recessed part 47e. Furthermore, the other end of the first separator 45, which consists of the first bottom wall portion 47a, the second bottom wall portion 47b, the side wall portion 47c, the partition wall 47d, and the recessed portion 47e, that is, the portion of the first separator 45 that protrudes from the insulating pipe 41 and excludes the insertion portion 46, has a complex and three-dimensional internal structure, making it more difficult to grasp compared to a flat plate, and thus worsening workability. Furthermore, since the other end of the first separator 45 is larger than the resistor R, covering it with the first molded resin part 48 results in an overall larger size. In addition, there is the problem that the first separator 45 shrinks due to heat, causing depressions and other defects in the first molded resin part 48.

[0012] Therefore, the object of the present invention is to provide a sensor-equipped protector and a method for manufacturing the same that have a simple structure and excellent workability without particularly detracting from the appearance. [Means for solving the problem]

[0013] To achieve the above objective, the sensor-equipped protector of the present invention comprises a mounting base (11) attached to the periphery of an opening or closing device (1,2) that opens and closes an opening in the vehicle body, or to the periphery of the opening, and a tubular hollow portion (12) integrally extruded together with the mounting base (11), in which two conductive portions (34,35) each having two core wires (31,32) embedded therein are provided via a space (33), and when the opening or closing device (1,2) is closed, the hollow portion (12) is pressed and crushed by a foreign object caught between the opening or closing device (1,2) and the opening, the presence of the foreign object is detected by a corresponding change in electrical signal. In the extruded terminal portion, the core wires (31, 32) drawn out in the longitudinal direction are connected to the two legs (39a, 39b) of the resistor (39), and one end of an insert (50) made of a non-conductive material is press-fitted to close the space (33), and an insulating portion (60) is provided on the other end of the insert (50) to insulate the connection portions (M1, M2) of the two legs (39a, 39b), and the other end of the insert (50) is covered with a molded material (K) together with the insulating portion (60), the core wires (31, 32), the resistor (39), the two legs (39a, 39b), and the connection portions (M1, M2), forming a sensor-equipped protector (30). The insulating portion (60) is in the shape of a flat plate, and only the left and right ends (61, 62) of the insulating portion (60) are exposed from the surface of the portion covered with the molded material (K). In this context, "changes in electrical signals" include changes caused by a short circuit between two core wires, as well as changes in capacitance.

[0014] Furthermore, the present invention is characterized in that a recess (63) for housing the resistor (39) is formed on the inner surface of the insulating portion (60), which is on the mounting base (11) side, of the outer and inner surfaces.

[0015] Furthermore, the present invention is characterized in that a step (D) is provided such that the outer surface of the insulating portion (60) protrudes further outward than the outer surface of one end of the insert (50).

[0016] Furthermore, the present invention is characterized in that the outer surface of the insulating portion (60) is flush with the outer surface of one end of the insert (50), and a protruding portion (65) is provided at the connection between one end and the other end of the insert (50) that protrudes further outward than the outer surface.

[0017] Furthermore, the present invention is characterized in that an inner protrusion (66) is provided at the connection portion between one end and the other end of the insert (50) so as to protrude further inward from the inner surface of the insulating portion (60).

[0018] Furthermore, the present invention is characterized in that the space portion (33) has a concave cross-sectional shape with its opening facing the mounting base portion (11), and the shape of one end of the insert (50) is substantially the same as the shape of the space portion (33).

[0019] Furthermore, the present invention provides a method for manufacturing a sensor-equipped protector comprising: a mounting base (11) attached to the periphery of an opening or closing mechanism (1,2) that opens and closes an opening in the vehicle body, or to the periphery of the opening; and a tubular hollow section (12) integrally extruded together with the mounting base (11), in which two conductive sections (34,35) each containing two core wires (31,32) are provided via a space (33); when the opening or closing mechanism (1,2) is closed, the hollow section (12) is pressed and crushed by a foreign object caught between the opening or closing mechanism (1,2) and the opening, and the presence of the foreign object is detected by a corresponding change in electrical signal. In the extruded terminal portion, the core wires (31, 32) drawn out in the longitudinal direction are respectively connected to the two legs (39a, 39b) of the resistor (39), and one end side of an insert (50) formed of a non-conductive material is press-fitted so as to close the space portion (33). An insulating portion (60) for insulating the connection portions (M1, M2) of the two legs (39a, 39b) is provided on the other end side of the insert (50). The other end side of the insert (50) is a method for manufacturing a sensor-equipped protector (30) that is molded together with the insulating portion (60), the core wires (31, 32), the resistor (39), the two legs (39a, 39b), and the connection portions (M1, M2). The insulating portion (60) has a flat plate shape, and only the left and right end portions (61, 62) of the insulating portion (60) The portion covered with the molding material (K) to be molded are set to abut against the inner surface of the mold (100) so as to be exposed from the surface of the mold, and then the molding material (K) is poured and molded.

[0020] Further, the present invention provides an intermediate mold (103) in which two protruding portions (103a, 103b) are formed between the upper mold (101) and the lower mold (102) of the mold (100). The tips of the two protruding portions (103a, 103b) are made to abut against the inner surface side on the mounting base portion (11) side among the outer surface and the inner surface of the insulating portion (60), and a space portion (Q) is provided between the two protruding portions (103a, 103b) so as to surround the entire circumference of the leg (39b) of the resistor (39). The molding material (K) is poured into the space portion.

[0021] The symbols in parentheses indicate corresponding elements or corresponding matters described in the drawings and the embodiments for carrying out the invention described later.

Effect of the Invention

[0022] According to the present invention, the sensor-equipped protector consists of a tubular hollow section in which two conductive parts, each containing two embedded core wires, are provided with a space between them. One end of the insert is press-fitted into this hollow section, and the other end of the insert has a flat plate-shaped insulating part that protrudes from the hollow section. This makes it easier for the mold forming operator to grasp the insert, improving work efficiency. Furthermore, the mold forming operator can grasp the orientation of the insert simply by touching the hollow section and the insulating part, without needing to visually inspect it, and can instantly set it in the mold. Furthermore, the other end of the insert is covered with molding material along with the insulating part, core wire, resistor, two leads, and connection part. By making the insulating part a flat plate shape, the thickness (dimensions) covered by the molding material can be reduced compared to conventional examples (Figures 16 to 18). This prevents cosmetic defects such as shrinkage of the outer surface due to thermal shrinkage after molding. Moreover, since the insulating part is a flat plate shape, the structure is simple and the volume can be reduced. Furthermore, after molding, only the left and right ends of the insulating portion are exposed from the surface of the portion covered with the molding material, resulting in a better appearance compared to conventional examples (Figures 16 to 18).

[0023] Furthermore, in this invention, a recess for housing a resistor is formed on the inner surface of the insulating portion, making it easier to position the insulating portion of the insert relative to the resistor.

[0024] Furthermore, in this invention, a step is provided on the outer surface of the insulating part so that it protrudes further outward than the outer surface of one end of the insert, or the outer surface of the insulating part is made flush with the outer surface of one end of the insert, and a protrusion is provided at the connection point between one end and the other end of the insert so that it protrudes further outward than the outer surface, or an inner protrusion is provided at the connection point between one end and the other end of the insert so that it protrudes further inward than the inner surface of the insulating part. As a result, the step, protrusion, or inner protrusion acts as a stopper when one end of the insert is press-fitted into the hollow part, making positioning easier. This makes it less likely to over-insert the insert when pressing one end into the end of the extruded cross-section, allowing it to be set in the correct position.

[0025] Furthermore, in this invention, the space has a concave cross-sectional shape with its opening facing the mounting base, and the shape of one end of the insert is substantially the same as the shape of the space. Therefore, one end of the insert can be reliably pressed into the space, and it is possible to prevent it from easily coming loose after being pressed in.

[0026] Furthermore, during molding, the insulating part is made into a flat plate shape, and the insulating part Both ends After setting the components so that they contact the inner surface of the mold, the molding material is poured in to perform the molding. As a result, only the left and right ends of the insulating portion are exposed on the surface side of the sensor-equipped protector, resulting in a good appearance. Furthermore, since the insulating portion is supported by the mold at both ends during molding, the molding process can be performed in a stable state.

[0027] Furthermore, in this invention, during mold forming, an intermediate mold is provided between the upper and lower molds of the mold, the tips of the two protrusions are brought into contact with the inner surface of the insulating part, and the resistor legs are positioned with a space between the two protrusions so as to surround their entire circumference, and the mold forming material is flowed into the space, so that the mold forming material also enters the space formed between the insulating part and the resistor, and the resistor can be supported in a stable state. Furthermore, by providing an intermediate mold with two protrusions between the upper and lower molds, it is possible to remove material from the thicker parts of the molded section, thereby further preventing surface defects such as shrinkage due to heat shrinkage after mold forming. [Brief explanation of the drawing]

[0028] [Figure 1] This is a perspective view showing the main part of the upper terminal portion of a sensor-equipped protector according to an embodiment of the present invention. [Figure 2] Figure 1 is an enlarged perspective view showing the insert of the sensor-equipped protector. [Figure 3] Figure 1 shows an insert of the sensor-equipped protector, where (a) is an enlarged front view, (b) is an enlarged side view, (c) is a cross-sectional view of (a) along line XX, and (d) is a cross-sectional view of (a) along line YY. [Figure 4]Figure 1 shows the sensor-equipped protector with a resistor attached to the insert, with (a) being an enlarged bottom view and (b) being an enlarged side view. [Figure 5] This is a perspective view showing the appearance of the upper terminal portion of a sensor-equipped protector according to an embodiment of the present invention. [Figure 6] This is a cross-sectional view showing a mold for manufacturing a sensor-equipped protector according to an embodiment of the present invention. [Figure 7] This is an enlarged front view showing another insert of a sensor-equipped protector according to an embodiment of the present invention. [Figure 8] This is an enlarged side view showing yet another insert of a sensor-equipped protector according to an embodiment of the present invention. [Figure 9] This is an enlarged side view showing a state in which a resistor is mounted in a different position relative to the insert of a sensor-equipped protector according to an embodiment of the present invention. [Figure 10] This is a side view of a car with sliding doors that open and close. [Figure 11] This is a perspective view of a car equipped with a sunroof. [Figure 12] Figure 10 is a side view showing the sensor-equipped protector. [Figure 13] This is an enlarged cross-sectional view along line AA in Figure 12. [Figure 14] Figure 12 is an enlarged cross-sectional view along the BB line. [Figure 15] This is a perspective view showing the general configuration of the upper terminal portion of a sensor-equipped protector after molding, according to a conventional example. [Figure 16] This is a perspective view showing the configuration overview of a protector terminal part with a sensor, similar to a conventional example. [Figure 17] Figure 16 is an enlarged perspective view showing the first separator, where (a) shows the front side containing the resistor and (b) shows the back side. [Figure 18] Figure 16 is a perspective view showing the general structure of the sensor-equipped protector terminal portion after molding, with (a) showing the front side and (b) showing the back side. [Figure 19]This is a perspective view showing the main part of the upper terminal portion of another sensor-equipped protector according to an embodiment of the present invention. [Figure 20] Figure 19 is an enlarged perspective view showing the insert of the sensor-equipped protector. [Figure 21] Figure 19 shows an insert of the sensor-equipped protector, where (a) is an enlarged front view, (b) is an enlarged side view, (c) is a cross-sectional view of (a) along the line X2-X2, (d) is a cross-sectional view of (a) along the line Y2-Y2, (e) is a cross-sectional view of (a) along the line Z1-Z1, and (f) is a cross-sectional view of (a) along the line Z2-Z2. [Figure 22] Figure 19 shows the sensor-equipped protector with a resistor attached to the insert, with (a) being an enlarged bottom view and (b) being an enlarged side view. [Modes for carrying out the invention]

[0029] A sensor-equipped protector 30 according to an embodiment of the present invention will be described with reference to the drawings. The sensor-equipped protector 30 according to an embodiment of the present invention is mounted on the front end surface of the sliding door 1 of an automobile, which opens and closes an opening in the vehicle body by the sliding door 1 as shown in Figure 10, so as to protrude toward the front of the vehicle body. A sensor (pressure sensor) S is attached to the front end surface of the sliding door 1 so as to protrude toward the front of the vehicle body when a foreign object such as a part of the human body (fingers or limbs) gets caught between the sliding door 1 and the body-side opening (which may be a front door (side door)). The sensor detects the pinching and outputs a corresponding electrical signal. The parts shown in Figures 12 to 14 have the same configuration as those shown in the conventional example, but the configuration of the insert 50 differs from that of the insert 26 shown in the conventional example. The same reference numerals are used for parts that are the same as in the conventional example. Here, "change in electrical signal" includes changes due to a short circuit between the two core wires 31 and 32, and changes in capacitance.

[0030] This sensor-equipped protector 30, similar to those shown in Figures 13 and 14, includes a mounting base 11 that is directly attached to a flange F formed on the sliding door 1, a hollow portion 12 integrally molded with the mounting base 11 that elastically contacts foreign objects such as fingers when the sliding door 1 is closed and there are foreign objects between the front end surface of the sliding door 1 and the body-side opening facing that front end surface, and a sensor (pressure sensor) S incorporated in the hollow portion 12 that detects foreign objects and outputs a corresponding electrical signal. The sensor (pressure sensor) S has two core wires (electrode wires (including stranded wires)) 31, 32 extending in the vertical direction (longitudinal direction) and is fixed within the hollow portion 12 by being embedded in conductive rubber-like elastic bodies 34, 35 provided via a space 33. In addition, a plurality of retaining lips 14, 14 are provided on the inside of the mounting base 11, and a core material 15 with a roughly U-shaped cross-section is embedded in the mounting base 11 to increase its rigidity. Furthermore, a lip-shaped (or hollow) sealing portion 16 is provided on the outer wall 11b of the mounting base 11. Then, at the upper end portion of the sensor-equipped protector 30, as shown in Figure 1, the space 33 of the hollow portion 12 that opens at the upper end portion is closed by the insert 50. Figure 1 shows the upper end portion of the sensor-equipped protector 30 attached to the front end surface of the right sliding door 1, one of the sliding doors 1 provided on both the left and right sides of the vehicle body. Note that in Figure 1, the molded parts are indicated by dotted lines.

[0031] As shown in Figures 2 and 3, the insert 50 is made of a non-conductive material such as polypropylene, polyethylene, polyethylene terephthalate, nylon, nylon 6, nylon 6-6, TPO, and TPS, and consists of an insertion portion 51 with a recessed cross-sectional shape provided on one end and an insulating portion 60 provided on the other end.

[0032] The insertion portion 51 has a cross-sectional shape that is almost the same as or slightly larger than the space portion 33 of the hollow portion 12, so as to be press-fitted into the space portion 33 of the hollow portion 12, thereby sealing the space portion 33 without any gaps and preventing the molding material from flowing into the space portion 33 during subsequent molding and impairing the sensor function. The cross-sectional shape of the insertion portion 51 is matched to the cross-sectional shape of the space portion 33. As in this embodiment, if the cross-sectional shape of the space portion 33 is a recessed shape, the cross-sectional shape of the insertion portion 51 will also be a recessed shape, as shown in Figure 3(c). Also, for example, if the cross-sectional shape of the space portion 33 is rectangular, the cross-sectional shape of the insertion portion 51 will also be rectangular.

[0033] The insulating portion 60 is flat (rhombic in this embodiment) and is joined and integrated with the top of the end face of the insertion portion 51. Furthermore, since the surface of the rhombic plate of the insulating portion 60 is positioned parallel to the plane passing through the bottom of both sides of the insertion portion 51, when the insertion portion 51 of the insert 50 is press-fitted into the space 33 of the hollow portion 12, the surface of the rhombic plate extends in a left-right direction perpendicular to the plane T passing through the centers of the two core wires 31, 32 drawn out at the extruded terminal portion (rhombic in this embodiment), as shown in Figures 1 and 4(b), and the left and right ends 61, 62 protrude, but is not limited to this. In this embodiment, the plane T extends in the longitudinal direction of the vehicle, and the rhombic flat plate surface extending perpendicular to it extends in the in-vehicle and out-vehicle directions, with the plate thickness in the vertical direction. Here, it is shown as the in-vehicle end (left end) 61 and the out-vehicle end (right end) 62.

[0034] Furthermore, as shown in Figure 3(b), a step D is provided on the outer surface of the insulating portion 60, on the side opposite to the mounting base 11 (vehicle front side), so that it protrudes further outward than the outer surface of one end of the insert 50, thereby positioning it as a stopper when the insertion portion 51 is press-fitted into the hollow portion 12.

[0035] Of the outer and inner surfaces of the insulating portion 60, the inner surface (vehicle rear side) facing the mounting base 11 has a recess 63 for housing the resistor 39, as shown in Figure 3(d). The formation of the recess 63 makes it easier to position the resistor 39. Specifically, as shown in Figure 4, the resistor 39 is positioned on the inner side (rear side of the vehicle) of the insulating part 60. One of the two legs 39a and 39b extending from the resistor 39, leg 39a, is connected to one core wire 31 that is drawn longitudinally from the terminal portion where the mounting base 11 and the hollow portion 12 are integrally extruded on the outer side (front side of the vehicle) of the insulating part 60, forming connection part M1. The other leg 39b of the two legs 39a and 39b extending from the resistor 39 is connected to the other core wire 32 that is drawn longitudinally from the terminal portion where the mounting base 11 and the hollow portion 12 are integrally extruded on the inner side (rear side of the vehicle), forming connection part M2. The two core wires 31 and 32 and the legs 39a and 39b of the resistor 39 are superimposed and connected by resistance welding or soldering. The connection section M1 is designed to be housed in a recess 64 formed on the outer surface (front side of the vehicle) of the insulating section 60.

[0036] Then, the other end of the insert 50, whose insertion portion 51 at one end is press-fitted into the hollow portion 12, is covered with molding material K along with the insulating portion 60, core wires 31 and 32, resistor 39, two legs 39a and 39b, and connection portions M1 and M2. In this case, as shown in Figure 5, only the left and right (inside and outside the vehicle) ends 61 and 62 of the insulating part 60 are exposed from the surface of the part covered with the molded material K. The left and right (inside and outside the vehicle) ends 61 and 62 of the insulating portion 60 are protruding parts, so even if they are exposed from the surface of the part covered with the molding material K, they are hardly noticeable and do not particularly detract from the appearance. In Figure 5, only the inside end (left end) 61 is visible.

[0037] The upper terminal portion of the sensor-equipped protector 30, constructed in this manner, is manufactured by molding as follows. First, the connection portions M1 and M2 are created as described above. Next, the insertion portion 51 of the insert 50 is press-fitted into the hollow portion 12 of the extruded sensor-equipped protector 30, weaving it between the core wires 31 and 32. At this time, the plate surface of the flat insulating portion 60 of the insert 50 is positioned so as to extend in a left-right direction perpendicular to the plane T containing the two core wires 31 and 32 that were drawn out at the extruded terminal portion.

[0038] Here, in more detail, first, with the core wires 31 and 32 and the two legs 39a and 39b of the resistor 39 connected at the connection points M1 and M2, all of these are twisted together at a certain angle, either towards the inside or outside of the vehicle, while maintaining a certain distance between them (not shown in the diagram). By twisting all of these, the connection parts M1 and M2, the two legs 39a and 39b, and the resistor 39 are moved away from the hollow part 12, making it less likely for them to interfere with the insert 50 when the insertion part 51 on one end of the insert 50 is pressed into the hollow part 12, and thus less likely to get in the way of press-fitting (not shown). Finally, after the insertion portion 51 of the insert 50 has been pressed into the hollow portion 12, all of these are returned to their original state from the twisted position, and the resistor 39 is set in the desired position in the recess 63, thereby completing the installation of the insert 50.

[0039] Next, the upper end of the sensor-equipped protector 30, into which the insertion portion 51 of the insert 50 has been press-fitted, is set into the mold 100 as shown in Figure 6. The mold 100 has an upper part 101, a lower part 102, and a medium part 103 and a slide part 104 located between them. When setting the upper end of the sensor-equipped protector 30 between the upper mold 101 and the lower mold 102, the vehicle-side end (left end) 61 of the insulating part 60 is brought into contact with the inner surface of the lower mold 102, and the vehicle-side end (right end) 62 of the insulating part 60 is brought into contact with the inner surface of the upper mold 101.

[0040] Next, insert the medium-sized 103 and the sliding type 104 between the upper type 101 and the lower type 102. The medium-sized 103 has two protrusions 103a and 103b, and the tips of the two protrusions 103a and 103b are brought into contact with the inner surface of the insulating part 60. The inner surface of the base of the two protrusions 103a and 103b is recessed, and the legs 39b of the resistor 39 are positioned between the two protrusions 103a and 103b with a space Q provided around their entire circumference. The legs 39b of the resistor 39 are not brought into contact with the insulating part 60 and the two protrusions 103a and 103b, that is, a space Q is provided around the entire circumference of the legs 39b of the resistor 39. Furthermore, the slide mold 104 is inserted between the upper mold 101 and the middle mold 103 to form a molded portion that is connected to the extruded lip-shaped sealing portion 16 of the sensor-equipped protector 30.

[0041] Subsequently, when the molding material K is poured and released from the mold 100, a molded end as shown in Figure 5 is produced. During molding, the inner end (left end) 61 and outer end (right end) 62 of the insulating part 60 come into contact with the upper mold 101 and lower mold 102, so the molding material K does not flow into those parts, and these parts are exposed from the surface of the part covered with the molding material K. Furthermore, the tips of the two protrusions 103a and 103b of the medium-sized 103 abut against the inner surface of the insulating part 60, so the molding material K does not flow into that area and remains exposed. However, the areas where the tips of the two protrusions 103a and 103b abut are on the back side of the part covered with the molding material K, and are therefore hidden from the surface. As a result, when the sensor-equipped protector 30 is attached to the vehicle, only the inner end (left end) 61 and the outer end (right end) 62 of the insulating part 60 are locally visible.

[0042] Furthermore, the material of the insert 50 and the material of the mold molding material K can both be similar flexible materials. For example, the material of the insert 50 can be PP and the material of the mold molding material K can be TPO. According to this, the bond between the insert 50 and the molded material K creates a sense of unity, making it easier to handle the sensor-equipped protector 30. The hardness is preferably in the range of JIS A20 to 90, and more preferably in the range of JIS A40 to 90. If it is less than JIS A40, there are concerns about the function of the molded part (e.g., ease of assembly to the vehicle body), and if it is less than JIS A20, the function will be insufficient. In addition, to prevent water from entering the internal electrical components and wiring from the outside, the insert 50 may be wrapped in a different resin material (e.g., adhesive), but if this other resin material is as soft as or softer (lower hardness) than the molded material, it will not hinder the aforementioned sense of unity.

[0043] Furthermore, the material of the insert 50 and the material of the molding material K can be made of compatible materials. In this case as well, a sense of unity can be achieved between the insert 50 and the molded part, making it easier to handle the sensor-equipped protector 30. Moreover, even if it is necessary to wrap the insert 50 with a different resin material (adhesive) to further prevent water ingress, if the material of the insert 50 and the material of the molding material are compatible, it is easy to select an adhesive that adheres well to both. Also, if the two are homogeneous to the extent that they fuse together, the insert 50 can be tightly attached during molding without the use of adhesives, thus preventing water from entering the internal electrical components and wiring from the outside without the use of adhesives. In a narrow sense, compatibility means that the two are homogeneous to the extent that they fuse together. For example, if one material is TPO, it can be polypropylene, polyethylene, TPO, or various TPEs containing olefin resins. Examples of various TPEs containing olefin resins include styrene-based thermoplastic elastomer (TPS). Furthermore, if one of the materials is TPS, then if it contains an olefin resin, a material similar to that used for TPO can be selected as having good compatibility and being particularly similar in nature to the extent that it will weld or fuse. Also, the molding material K may be a foamed material or a non-foamed material.

[0044] With such a sensor-equipped protector 30, the other end of the insert 50 is covered with molding material K along with the insulating part 60, core wires 31 and 32, resistor 39, two legs 39a and 39b, and connection parts M1 and M2. By making the insulating part 60 a flat plate shape, the thickness (dimension) covered by the molding material K can be reduced. Therefore, it is possible to prevent cosmetic defects such as shrinkage of the outer surface due to thermal shrinkage after molding. Moreover, since the insulating part 60 is a flat plate shape, the structure is simple and the volume can be reduced, and it is also easier for the molding operator to grasp, improving work efficiency. Furthermore, after molding, only the left and right ends 61 and 62 of the insulating part 60 are exposed from the surface of the part covered with the molding material K, resulting in a good appearance. Also, during molding, the insulating part 60 is supported by the upper mold 101, lower mold 102 and middle mold 103 by the left and right ends 61 and 62, so it can be molded in a stable state.

[0045] In this embodiment, the insulating portion 60 is rhombic in shape, but it can be any flat shape, such as a triangle as shown in Figure 7, or a polygon such as a hexagon (not shown), or a circle (not shown) or an ellipse (not shown). However, a smaller contact amount with the upper mold 101 and lower mold 102 reduces the amount exposed from the surface of the sensor-equipped protector 30 after molding, so a rhombic or triangular shape that can make point contact with the upper mold 101 and lower mold 102 is more preferable.

[0046] Furthermore, in this embodiment, as shown in Figure 3(b), the insulating portion 60 at one end of the insert 50 is made to protrude outward relative to the insertion portion 51 at the other end to create a step D. However, as shown in Figure 8, the outer surface of the insulating portion 60 may be made flush with the outer surface of the insertion portion 51, and a protruding portion 65 that protrudes further outward than the outer surface may be provided at the connection between the insertion portion 51 and the insulating portion 60.

[0047] Furthermore, as shown in Figures 19 to 22, the placement of the resistor 39 may be changed, the shape of the end of the insulating portion 60 may be changed, or an inner protrusion 66 may be provided.

[0048] Regarding the placement of the resistor 39, in Figures 1 to 4 it is placed in the center of the inner surface (rear side of the vehicle) of the insulating portion 60 on the other end of the insert 50, but in Figures 19 to 22 it is placed at the tip of the inner surface (rear side of the vehicle) of the insulating portion 60 on the other end of the insert 50. By doing so, space can be secured during the wiring work of the connection portions M1 and M2, and the length of exposed core wires 31 and 32 can be set to be shorter, and as a result, the molded portion can be prevented from becoming unnecessarily large. Conversely, it is also possible to position the resistor 39 on the outer side (front side of the vehicle) of the insulating portion 60, or, as shown in Figure 9, on the outer side of the insulating portion 60 (outer end of the other end of the insert 50).

[0049] As shown in Figure 21(f), the shape of the end side of the insulating portion 60 is such that an outer chamfer ME1 is provided on the outside of the end side of the insulating portion 60, and an inner chamfer ME2 is provided on the inside of the end side of the insulating portion 60. By providing outer chamfers ME1 and inner chamfers ME2, when setting the resistor 39 at the desired position in the recess 63 on the inner side (rear end of the vehicle) of the insulating portion 60, it is possible to prevent the end of the insulating portion 60 from interfering with or contacting the resistor 39, thereby preventing deterioration of workability.

[0050] As shown in Figures 21(b) and 21(e), the inner protrusion 66 is formed by the insulating portion 60 at the other end of the insert 50 protruding inward relative to the insertion portion 51 at one end. In other words, it protrudes further inward from the inner surface of the insulating portion 60 at the connection point between the two ends of the insert 50. The inner protrusion 66, like the step D and the protrusion 65 shown in Figure 8, acts as a stopper when one end of the insert 50 is press-fitted into the hollow portion 12, making positioning easier. This makes it less likely to over-insert one end of the insert 50 when press-fitting it from the end of the extruded cross-section, allowing it to be set in the correct position. Note that the step D and the inner protrusion 66 may be provided individually or both may be provided. Also, as shown in Figure 8, the protrusion 65 and the inner protrusion 66 may be provided individually or both may be provided.

[0051] Furthermore, although the mold forming material K is designed to flow around the entire circumference of the resistor 39 using the medium mold 103 during mold forming, it is also possible to fix the resistor 39 in close contact with the insulating part 60 so that the mold forming material K does not flow between the resistor 39 and the insulating part 60. Furthermore, instead of providing two protrusions 103a and 103b on the medium-sized 103, two pins (not shown) may be provided facing inward from the inner surface side of the insulating portion 60, so as to sandwich the legs 39b of the resistor 39 without contact, and then molded.

[0052] In the embodiments of the present invention, an example was described in which a protector 30 with a sensor is attached to the side of the sliding door 1 in a vehicle in which the sliding door 1 moves in the front-rear direction. However, the protector 30 with a sensor may be attached to the opening on the body side to detect foreign objects between it and the sliding door 1. Furthermore, the sensor-equipped protector 30 can also be applied to the back door (not shown) and sunroof 2 (Figure 11). [Explanation of Symbols]

[0053] 1. Sliding door 2 sunroofs 10 Sensor-equipped protectors 11 Mounting base 11a Interior wall of the vehicle 11b Vehicle outside wall 11c Connecting wall 12 Hollow part 12a Outer shell 12b End 12c end 13 Channel Section 14 Retaining Lip 15 Core material 16. Seal part 20 Sensor-equipped protectors 26 Inserts 30 Sensor-equipped protectors 31,32 Core wires 33 Space section 34,35 Conductive rubber-like elastic material (conductive part) 36 Lead wires 37 Covering part 39 Resistor 39a, 39b Resistor leads 40 Control device 41 Insulating tube 42,43 electrode 45 First Separator 46 Insertion part 47 Main housing section 47a 1st bottom wall part 47b Second bottom wall 47c Side wall part 47d Bulkhead 47e Recess 48. First mold resin part 50 inserts 51 Insertion part 60 Insulation part 61 Inside end (left end) 62 Outer side edge (right side edge) 63 recess 64 recess 65 Protrusion 66 Inner protrusion 100 molds 101 Upper mold 102 Lower mold 103 Medium size 104 Slide type D Step F flange K type molding material M connection section M1,M2 connection section ME1 External chamfer ME2 Inner chamfer Q Space R resistor S sensor (pressure sensor) SW crimping member T plane W Wire Harness

Claims

1. The device comprises a mounting base attached to the periphery of an opening or closing mechanism that opens and closes an opening in the vehicle body, or to the periphery of the opening, and a tubular hollow section integrally extruded together with the mounting base, in which two conductive sections, each with two embedded core wires, are provided with a space between them. When the opening or closing mechanism is closed, if a foreign object is caught between the opening or closing mechanism and the opening, the hollow section is pressed and crushed, and the presence of the foreign object is detected by a corresponding change in the electrical signal. In the extruded terminal portion, the core wire drawn out in the longitudinal direction is connected to the two legs of the resistor, and one end of an insert made of a non-conductive material is press-fitted to close the space, and an insulating portion is provided on the other end of the insert to insulate the connection of the two legs, and the other end of the insert is covered with a molded material together with the insulating portion, the core wire, the resistor, the two legs, and the connection, thus forming a sensor-equipped protector. A sensor-equipped protector characterized in that the insulating portion is in the shape of a flat plate, and only the left and right ends of the insulating portion are exposed from the surface of the portion covered with the molded material.

2. The sensor-equipped protector according to claim 1, characterized in that a recess for housing the resistor is formed on the inner surface of the insulating portion, which is on the mounting base side, of the outer and inner surfaces of the insulating portion.

3. The sensor-equipped protector according to claim 1 or 2, characterized in that a step is provided so that the outer surface of the insulating portion protrudes further outward than the outer surface of one end of the insert.

4. The sensor-equipped protector according to claim 1 or 2, characterized in that the outer surface of the insulating portion is flush with the outer surface of one end of the insert, and a protruding portion is provided at the connection between one end and the other end of the insert that protrudes further outward than the outer surface.

5. The sensor-equipped protector according to claim 1 or 2, characterized in that an inner protrusion is provided at the connection portion between one end and the other end of the insert, such that it protrudes further inward from the inner surface of the insulating portion.

6. The sensor-equipped protector according to claim 1 or 2, characterized in that the space has a concave cross-sectional shape with its opening facing the mounting base, and the shape of one end of the insert is substantially the same as the shape of the space.

7. The device comprises a mounting base attached to the periphery of an opening or closing mechanism that opens and closes an opening in the vehicle body, or to the periphery of the opening, and a tubular hollow section integrally extruded together with the mounting base, in which two conductive sections, each with two embedded core wires, are provided with a space between them. When the opening or closing mechanism is closed, if a foreign object is caught between the opening or closing mechanism and the opening, the hollow section is pressed and crushed, and the presence of the foreign object is detected by a corresponding change in the electrical signal. In the extruded terminal portion, the core wire drawn out in the longitudinal direction is connected to the two legs of the resistor, and one end of an insert made of a non-conductive material is press-fitted to close the space, and an insulating portion is provided on the other end of the insert to insulate the connection portion of the two legs, and the other end of the insert is molded together with the insulating portion, the core wire, the resistor, the two legs, and the connection portion, in a method for manufacturing a sensor-equipped protector. A method for manufacturing a sensor-equipped protector, characterized in that the insulating portion is in the shape of a flat plate, and the left and right ends of the insulating portion are set to contact the inner surface of a mold, respectively, so that only the left and right ends of the insulating portion are exposed from the surface of the portion covered with the molding material to be molded, and then the molding material is poured to mold it.

8. A method for manufacturing a sensor-equipped protector according to claim 7, characterized in that an intermediate mold having two protrusions formed between the upper and lower molds of the aforementioned mold is provided, the tips of the two protrusions are brought into contact with the inner surface of the insulating part, which is the mounting base side, and the leads of the resistor are positioned between the two protrusions with a space provided so as to surround their entire circumference, and the mold molding material is flowed into the space.

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