Insert molded parts and sensor devices
The insert molded article with a resin inlet hole and projection addresses resin overflow issues in sensor devices, ensuring precise component placement and assembly.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- JTEKT CORP
- Filing Date
- 2022-11-22
- Publication Date
- 2026-05-28
AI Technical Summary
The integration of components with synthetic resin in sensor devices can lead to overflow of molten resin to unintended parts during molding.
An insert molded article comprising a terminal with a pin portion, a retaining member, and a resin member with a resin inlet hole and projection to guide molten resin, along with a covering portion to prevent overflow.
Prevents resin overflow during molding by guiding resin into intended areas, ensuring precise component placement and assembly.
Smart Images
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Abstract
Description
Technical Field
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[0001] The present disclosure relates to insert molded products and sensor devices.
Background Art
[0002] For example, the torque sensor of Patent Document 1 has a sensor substrate, a harness, and a substrate holder. The substrate holder houses a part of the harness and the sensor substrate. The harness is drawn out from the inside to the outside of the substrate holder. The inner end of the harness is connected to the sensor substrate via a terminal. The terminal is fixed to the sensor substrate in a state of penetrating the sensor substrate in the thickness direction. The torque sensor is magnetic and has a magnetic yoke. The magnetic yoke and the substrate holder are integrated with a synthetic resin. <000001~0>
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] In a sensor of the type in which components are integrated with a synthetic resin as in the torque sensor of Patent Document 1, there is a concern that the molten synthetic resin may overflow to an unintended part during molding.
Means for Solving the Problems
[0005] An insert molded article according to one aspect of the present disclosure includes: a terminal having a first end with a pin portion and a second end opposite to the first end; a first retaining member having a terminal retaining portion for holding the terminal when the terminal is inserted; a second retaining member combined with the first retaining member, having a covering portion for covering the terminal retaining portion; and a resin member covering the periphery of a part of the terminal located inside the terminal retaining portion, and the periphery of the first retaining member and the second retaining member. The covering portion has a resin inlet hole configured to guide molten resin into the terminal retaining portion when the resin member is molded, and a projection provided at a position close to the pin portion with respect to the resin inlet hole, which is combined with the first retaining member. The terminal retaining portion and the pin portion are separated from each other by the projection and a part of the terminal.
[0006] A sensor device according to one aspect of this disclosure has the above-described insert molded product. [Brief explanation of the drawing]
[0007] [Figure 1] This is an exploded perspective view of a sensor device according to one embodiment. [Figure 2] This is an exploded perspective view of a detection unit according to one embodiment. [Figure 3] This is a perspective view of a board-in connector according to one embodiment. [Figure 4] This is an exploded perspective view of a board-in connector according to one embodiment. [Figure 5] This is a front view of a terminal according to one embodiment. [Figure 6] This is a perspective view of a terminal according to one embodiment. [Figure 7] This is a side view of a terminal according to one embodiment. [Figure 8] This is a cross-sectional view of a board-in connector according to one embodiment. [Figure 9] This is a perspective view of a cover according to one embodiment. [Figure 10]This is a perspective view of a cover with terminals according to one embodiment attached. [Figure 11] This is a cross-sectional perspective view of a board-in connector according to one embodiment. [Figure 12] This is a cross-sectional perspective view of a board-in connector according to one embodiment. [Modes for carrying out the invention]
[0008] A sensor device according to one embodiment will be described. The sensor device is, for example, a torque sensor. <Overall configuration of sensor device 10> As shown in Figure 1, the sensor device 10 is installed on the rotating shaft 11 that is to be detected. The rotating shaft 11 has an input shaft 12, a torsion bar 13, and an output shaft 14. The input shaft 12 and the output shaft 14 are connected to each other via the torsion bar 13. The input shaft 12, the torsion bar 13, and the output shaft 14 are located on the same axis O. The rotating shaft 11 is, for example, a steering shaft that constitutes the steering system of a vehicle. A steering wheel is integrally rotatably connected to the steering shaft.
[0009] The sensor device 10 detects the torque applied to the rotating shaft 11 through the operation of the steering wheel. The sensor device 10 includes a permanent magnet 21, a magnetic yoke 22, and a detection unit 23.
[0010] The permanent magnet 21 is cylindrical and has a circular cross-section. The permanent magnet 21 is magnetized alternately with south poles and north poles in its circumferential direction. The inner surface of the permanent magnet 21 is fixed in a state where it fits onto the outer surface of the input shaft 12. The permanent magnet 21 is rotatable integrally with the input shaft 12.
[0011] The magnetic yoke 22 is cylindrical and has a circular cross-sectional shape. A permanent magnet 21 is inserted and maintained inside the magnetic yoke 22. The magnetic yoke 22 has a first yoke 31, a second yoke 32, and a holder 33. The first yoke 31 and the second yoke 32 are annular members made of magnetic material. The first yoke 31 and the second yoke 32 are aligned along the axis O of the rotation shaft 11. The magnetic yoke 22 is formed by molding the first yoke 31 and the second yoke 32 with synthetic resin. The holder 33 is a part of the magnetic yoke 22 made of synthetic resin. The holder 33 maintains the positional relationship between the first yoke 31 and the second yoke 32. The magnetic yoke 22 is fixed to the output shaft 14.
[0012] The first yoke 31 has multiple teeth 31a. The teeth 31a are arranged at equal intervals in the circumferential direction of the first yoke 31. The second yoke 32 has multiple teeth 32a. The teeth 32a are arranged at equal intervals in the circumferential direction of the second yoke 32. The teeth 31a and 32a extend in opposite directions along the axis O of the rotation axis 11. The teeth 31a and 32a are also arranged alternately in the circumferential direction of the first yoke 31 and the second yoke 32. When the torsion bar 13 is not twisted, the centers of the teeth 31a and 32a in the circumferential direction coincide with the boundary between the N pole and S pole of the permanent magnet 21. The permanent magnet 21, the first yoke 31, and the second yoke 32 form a magnetic circuit.
[0013] The detection unit 23 generates an electrical signal corresponding to the amount of twist of the torsion bar 13. The detection unit 23 has a first sensor housing 40 and a second sensor housing 50. The first sensor housing 40 and the second sensor housing 50 are combined with each other in the axial direction.
[0014] The first sensor housing 40 is a resin molded product. The first sensor housing 40 has a first housing body 41 and a first protrusion 42. The first housing body 41 is cylindrical and has a first insertion hole 43 that penetrates in the axial direction. The inner diameter of the first insertion hole 43 is slightly larger than the outer diameter of the magnetic yoke 22. The portion of the magnetic yoke 22 provided with the first yoke 31 is maintained in a state of being inserted axially into the first insertion hole 43. The first protrusion 42 is in the shape of a rectangular parallelepiped and protrudes radially outward from the outer peripheral surface of the first housing body 41.
[0015] A first magnetic flux concentrating ring 44 is provided on the first housing body 41. The first magnetic flux concentrating ring 44 is in the shape of an arc plate that curves along the inner peripheral surface of the first insertion hole 43. The inner peripheral surface of the first magnetic flux concentrating ring 44 is exposed inside the first insertion hole 43. The first magnetic flux concentrating ring 44 is held at a position corresponding to the first yoke 31 in the axial direction. The first magnetic flux concentrating ring 44 surrounds the first yoke 31. The first magnetic flux concentrating ring 44 induces magnetic flux from the first yoke 31.
[0016] A board connector 45 is provided inside the first protrusion 42. The first end of the board connector 45 is exposed to the outside. The first end is the end of the board connector 45 on the side opposite to the first housing body 41 in the radial direction. The board connector 45 holds a plurality of electric wires 46. The electric wires 46 are, for example, coated wires in which the core wire is coated with an insulator. The plurality of electric wires 46 are arranged at intervals in a direction orthogonal to the direction in which the first protrusion 42 protrudes. The first ends of the electric wires 46 are drawn out from the first end of the board connector 45 to the outside. The first ends are connected to an external device. The external device is, for example, a control device for a steering device.
[0017] Note that the first magnetic flux collecting ring 44 and the board connector 45 are integrally provided with the first sensor housing 40 by insert molding. Insert molding is a molding technique in which an insert is mounted in an open mold and then the mold is closed for injection molding. The first sensor housing 40 is an insert molded product. The first magnetic flux collecting ring 44 and the board connector 45 are inserts.
[0018] The second sensor housing 50 is a resin molded product. The second sensor housing 50 has a second housing body 51 and a second protruding portion 52. The second housing body 51 is cylindrical and has a second insertion hole 53 penetrating in the axial direction. The inner diameter of the second insertion hole 53 is the same as the inner diameter of the first insertion hole 42 and is slightly larger than the outer diameter of the magnetic yoke 22. The portion of the magnetic yoke 22 provided with the second yoke 32 is maintained in a state of being inserted axially into the second insertion hole 53. The second protruding portion 52 is in the shape of a rectangular flat plate and protrudes radially outward from the outer peripheral surface of the second housing body 51. The second protruding portion 52 is axially overlapped with the first protruding portion 42.
[0019] The second housing body 51 is provided with a second magnetic flux collecting ring 54. Similar to the first magnetic flux collecting ring 44, the second magnetic flux collecting ring 54 is integrally provided with the second sensor housing 50 by insert molding. The second magnetic flux collecting ring 54 is in the shape of an arc plate curved along the inner peripheral surface of the second insertion hole 53. The inner peripheral surface of the second magnetic flux collecting ring 54 is exposed inside the second insertion hole 53. The second magnetic flux collecting ring 54 is held at a position corresponding to the second yoke 32 in the axial direction. The second magnetic flux collecting ring 54 surrounds the second yoke 32. The second magnetic flux collecting ring 54 induces magnetic flux from the second yoke 32.
[0020] <Supplementary Explanation of the Detection Unit 23> As shown in Figure 2, the first projection 42 has a substrate housing portion 42A. The substrate housing portion 42A is open in the axial direction. The opening of the substrate housing portion 42A is closed by the second projection 52. Two first magnetic collection protrusions 44A are exposed inside the substrate housing portion 42A. The first magnetic collection protrusions 44A are part of the first magnetic collection ring 44. The first magnetic collection protrusions 44A protrude outward from the peripheral wall of the first housing body 41. Also, the pin portions 48A of a plurality of terminals 48, which will be described later, are arranged inside the substrate housing portion 42A. The terminals 48 are attached to the second end of the electric wire 47. The pin portions 48A extend in the axial direction. The plurality of pin portions 48A are arranged in a row along the long side direction of the substrate housing portion 42A.
[0021] A substrate 47 is housed inside the substrate housing section 42A. The substrate 47 is, for example, a rectangular flat plate. The substrate 47 has a first magnetic sensor 47A, a second magnetic sensor 47B, and a plurality of terminal connection holes 47C. The first magnetic sensor 47A and the second magnetic sensor 47B are arranged along the first long side of the substrate 47. The first magnetic sensor 47A and the second magnetic sensor 47B are for detecting the rotation angle of the rotation axis 11, and are, for example, Hall sensors. The rotation angle of the rotation axis 11 is a physical quantity relating to the rotational motion of the rotation axis 11. The plurality of terminal connection holes 47C are arranged in a row along the second long side of the substrate 47. Pin portions 48A are inserted into the terminal connection holes 47C. The pin portions 48A are joined to the substrate 47 by soldering.
[0022] Although not shown in the diagram, the second magnetic collecting ring 54, like the first magnetic collecting ring 44, has two second magnetic collecting protrusions. The second magnetic collecting protrusions are arranged along the surface of the second projection 52 facing the substrate housing portion 42A. The second magnetic collecting protrusions protrude outward from the peripheral wall of the second housing body 51. The second magnetic collecting protrusions are axially opposed to the first magnetic collecting protrusion 44A. The first magnetic sensor 47A and the second magnetic sensor 47B are interposed between the first magnetic collecting protrusion 44A and the second magnetic collecting protrusion, respectively. The first magnetic sensor 47A detects the magnetic flux induced in the first magnetic collecting ring 44. The second magnetic sensor 47B detects the magnetic flux induced in the second magnetic collecting ring 52.
[0023] When torque is applied to the input shaft 12, the torsion bar 13 undergoes twisting deformation. Depending on the torque applied to the input shaft 12, a relative rotational displacement occurs between the input shaft 12 and the output shaft 14. This changes the relative position of the permanent magnet 21 and the first yoke 31 in the rotational direction. As a result, the magnetic flux induced from the permanent magnet 21 through the first yoke 31 to the first magnetic collecting ring 44 changes. Also, the relative position of the permanent magnet 21 and the second yoke 32 in the rotational direction changes. As a result, the magnetic flux induced from the permanent magnet 21 through the second yoke 32 to the second magnetic collecting ring 54 changes.
[0024] The first magnetic sensor 47A and the second magnetic sensor 47B each generate an electrical signal corresponding to the magnetic flux leaking between the first magnetic collecting projection 44A of the first magnetic collecting ring 44 and the second magnetic collecting projection of the second magnetic collecting ring 54, respectively. The electrical signal changes according to the torsional deformation of the torsion bar 13, i.e., the twist angle of the torsion bar 13. For example, the steering control device calculates the torque acting on the torsion bar 13 based on the electrical signals generated by the first magnetic sensor 47A and the second magnetic sensor 47B. Torque is a physical quantity relating to the rotational motion of the rotating shaft 11.
[0025] <Configuration of board-in connector 45> Next, the configuration of the board-in connector 45 will be described in detail. As shown in Figure 3, the board-in connector 45 has a housing 60 and a cover 70. The housing 60 and the cover 70 are combined with each other. The second end of the wire 46 is held by being sandwiched between the housing 60 and the cover 70. The terminal 48 is housed inside the board-in connector 45. The pin portion 48A protrudes from the surface of the housing 60 to which the cover 70 is attached. The first end of the wire 46 (not shown) is led out to the outside of the board-in connector 45.
[0026] As shown in Figure 4, the housing 60 is a rectangular parallelepiped resin molded product. The housing 60 has a first wire clamping portion 61, a terminal holding portion 62, and an exposed portion 63. In the short-side direction of the housing 60, the terminal holding portion 62 is located between the first wire support portion 61 and the exposed portion 63.
[0027] The first wire clamping portion 61 is flat. The first wire clamping portion 61 has a plurality of first guide grooves 61A. The first guide grooves 61A are arc-shaped grooves that extend along the short side direction of the housing 61. The plurality of first guide grooves 61A are spaced apart along the long side direction of the housing 61. The first guide grooves 61A support the electric wire 47.
[0028] The terminal holding portion 62 has a plurality of partition walls 62A. The partition walls 62A are arranged in correspondence with the first guide groove 61A. Each partition wall 62A has a first wall portion and a second wall portion. The first wall portion is a wall extending in the thickness direction of the housing 61. The second wall portion is a wall provided at the tip of the first wall portion and extends in the long-side direction of the housing 60. The partition walls 62A form a terminal insertion portion 62B. The terminal insertion portion 62B is a rectangular parallelepiped space extending in the short-side direction of the housing 61. The terminal insertion portion 62B is located on the extension of the first guide groove 61A. A gap 62C is formed between the second wall portions of two adjacent partition walls 62A in the long-side direction of the housing 61. The dimensions of the gap 62C are slightly larger than the outer diameter of the pin portion 48A of the terminal 48. The pin portion 48A extends in a direction perpendicular to the electric wire 47.
[0029] The exposed portion 63 has an opening 63A and a plurality of positioning grooves 63B. The opening 63A extends in the direction of the long side of the housing 60. The inside of the opening 63A communicates with each terminal insertion portion 62B of the terminal holding portion 62. The positioning grooves 63B are provided on the inner surface of the opening 63A opposite to the terminal holding portion 62 in the direction of the short side of the housing 60. The plurality of positioning grooves 63B are spaced apart along the direction of the long side of the housing 61. The positioning grooves 63B are notches that open to the opening 63A and to the protruding direction of the partition wall 62A. The dimensions of the positioning grooves 63B in the direction of the long side of the housing 60 are the same as, or slightly larger than, the outer diameter of the pin portion 48A.
[0030] As shown in Figure 4, the cover 70 is attached to the housing 60 from the side of the opening 63A. The cover 70 is a resin molded product and has a covering portion 71 and a second wire clamping portion 72.
[0031] The covering portion 71 is the part that covers the terminal holding portion 62 of the housing 60. The covering portion 71 is L-shaped. The covering portion 71 has a flat first portion and a flat second portion. The first portion is the part of the covering portion 71 that covers the tip portion of the terminal holding portion 62, including the second wall portion. The second portion is the part perpendicular to the first portion and is the part of the covering portion 71 that covers the side of the terminal holding portion 62 opposite to the opening 63A.
[0032] The covering portion 71 has a plurality of resin inlet holes 71A. The resin inlet holes 71A are, for example, rectangular holes. The resin inlet holes 71A are arranged in two rows along the long side direction of the housing 60. The resin inlet holes 71A in the first row penetrate the first portion of the covering portion 71 in the thickness direction. The resin inlet holes 71A in the second row are provided at the corners of the covering portion 71. The corners are where the first portion and the second portion intersect. The resin inlet holes 71A in the second row penetrate the first portion and the second portion of the covering portion 71 in the same direction as the resin inlet holes 71A in the first row.
[0033] The covering portion 71 has a first arm portion 71B and a second arm portion 71C. The first arm portion 71B and the second arm portion 71C are provided on the two side edges of the covering portion 71, which are located opposite each other in the long-side direction. The first arm portion 71B and the second arm portion 71C are flat and extend in the direction in which the cover 70 is attached. The tips of the first arm portion 71B and the second arm portion 71C are provided with claw portions (not shown).
[0034] The second wire clamping portion 72 is the portion of the housing 60 that corresponds to the first wire clamping portion 61, and is the portion for clamping the electric wire 46 between itself and the first wire clamping portion 61. The second wire clamping portion 72 is a rectangular flat plate. The second wire clamping portion 72 has a plurality of second guide grooves 72A. The second guide grooves 72A are arc-shaped grooves that extend along the short side direction of the second wire clamping portion 72. The plurality of second guide grooves 72A are arranged at intervals along the long side direction of the second wire clamping portion 72. The second guide grooves 72A are positioned in a location corresponding to the first guide groove 61A of the housing 60.
[0035] The second wire clamping portion 72 has a third arm portion 72B and a fourth arm portion 72C. The third arm portion 72B and the fourth arm portion 72C are provided on the two side edges of the second wire clamping portion 72, which are located opposite each other in the long-side direction. The third arm portion 72B and the fourth arm portion 72C are flat and extend in the direction in which the cover 70 is attached. The tips of the third arm portion 72B and the fourth arm portion 72C are provided with claw portions (not shown).
[0036] <Configuration of terminal 48> Next, the configuration of terminal 48 will be explained in detail. As shown in Figure 5, the terminal 48 is formed, for example, by plastically deforming a metal sheet material that has been punched into a predetermined shape. The terminal 48 has a pin portion 48A, a connecting portion 48B, and a linking portion 48C.
[0037] The pin portion 48A is provided at the first end of the terminal 48. The pin portion 48A is rod-shaped. The pin portion 48A is formed, for example, by plastically deforming a part of the metal plate material corresponding to the pin portion 48A into a cylindrical shape having a circular cross-section.
[0038] The connector 48B is provided at the second end of the terminal 48. The second end is the end of the terminal 48 opposite to the first end. The connector 48B is the part of the terminal 48 to which the second end of the electric wire 46 is connected. At the second end of the electric wire 46, the core wire is exposed from the insulation. The connector 48B and the electric wire 46 are connected by crimping a part of the connector 48B so as to enclose the exposed core wire. The connector 48B has a flat portion. The flat portion is a flat plate-shaped part of the connector 48B that extends along the exposed core wire from the crimping portion of the connector 48B.
[0039] The connecting portion 48C is the intermediate part of the terminal 48 that connects the pin portion 48A and the connection portion 48B. As shown in Figure 6, the connecting portion 48C has a connecting portion body 81 and an overhanging portion 82.
[0040] The connecting body 81 is a rectangular flat plate. The short side of the connecting body 81 extends along the pin portion 48A. The long side of the connecting body 81 extends in a direction perpendicular to the pin portion 48A. The first end of the connecting body 81 in the direction of the long side is connected to the base end of the pin portion 48A. The pin portion 48A and the connecting body 81 form a first corner portion. The second end of the connecting body 81 in the direction of the long side is connected to the flat portion of the connecting portion 48B. When viewed from a direction perpendicular to the connecting body 81, the connecting body 81 is connected to the flat portion located on the opposite side of the first guide groove 51A, with the electric wire 46 supported in the first guide groove 61A. The connecting body 81 and the connecting portion 48B form a second corner portion.
[0041] The protruding portion 82 extends laterally from the connecting portion body 81. The protruding portion 82 extends in the direction of the longer side of the connecting portion body 81 and has the shape of a cylinder with a polygonal cross-section. The protruding portion 82 has a first protruding piece 83 and a second protruding piece 84.
[0042] The first protruding piece 83 is provided on the first long side of the connecting body 81. The first protruding piece 83 has a first wall portion and a second wall portion. The first wall portion is rectangular in shape. The first wall portion is perpendicular to the connecting body 81. The second wall portion is rectangular in shape. The second wall portion is connected to the end of the first wall portion opposite to the connecting body 81. The second wall portion is parallel to the connecting body 81.
[0043] The first wall portion has a projection 83A. The projection 83A is a rectangular plate shape. The projection 83A is formed by cutting and bending. That is, notches corresponding to the three sides of the projection 83A are made in the first wall portion, and the projection 83A is formed by bending the remaining portion. The bending direction is opposite to that of the second wall portion. The projection 83A opens on the opposite side from the pin portion 48A.
[0044] The second overhang 84 is provided on the second long side of the connecting body 81. The length of the connecting body 81 in the long side direction is shorter than the length of the first overhang 83 in the long side direction. The second overhang 84 has a third wall and a fourth wall. The third wall is rectangular in shape. The third wall is perpendicular to the connecting body 81. The fourth wall is rectangular in shape. The fourth wall is connected to the end of the third wall opposite to the connecting body 81. The fourth wall is parallel to the connecting body 81. The end of the fourth wall opposite to the third wall is maintained in contact with the end of the second wall opposite to the first wall along its entire length.
[0045] As shown in Figure 7, when viewed from the direction from the connection portion 48B toward the pin portion 48A, the protruding portion 82 has a closed loop shape. The shape of the loop is rectangular. A single cylinder is formed from the first protruding piece 83 and the second protruding piece 84. The cylinder has a polygonal cross-sectional shape. Note that Figure 7 shows the connection portion 48B before crimping.
[0046] As shown in Figure 5, when viewed from a direction perpendicular to the direction from the connecting portion 48B to the pin portion 48A, the terminal 48 has a crank shape. The crank shape is a shape in which two right-angle curves are alternately connected. The first corner portion formed by the pin portion 48A and the connecting portion body 81, and the second corner portion formed by the connecting portion body 81 and the connecting portion 48B, are the parts of the terminal 48 that correspond to right-angle curves.
[0047] <Assembly procedure for board-in connector 45> Next, the assembly procedure for the board-in connector 45 will be explained. As shown in Figure 4, first, the terminal 48 is inserted into each terminal insertion portion 62B of the terminal holding portion 62 from the opposite side of the opening 63A. The terminal 48 is inserted into each terminal insertion portion 62B until the pin portion 48A reaches the end wall of the positioning groove 63B in the insertion direction. This determines the position of the terminal 48 in the insertion direction, i.e., in the short-side direction of the housing 60. The positioning groove 63B also has two opposing inner surfaces in the long-side direction of the housing 60. In the long-side direction of the housing 60, the movement of the pin portion 48A in the long-side direction of the housing 60 is restricted by the pin portion 48A contacting the inner surface of the positioning groove 63B. This determines the position of the terminal 48 in the long-side direction of the housing 60. The second end of the electric wire 46 is maintained in a state supported by the first guide groove 61A. In this state, the cover 70 is attached to the housing 60 from the side facing the opening 63A.
[0048] The claws of the first arm 71B, second arm 71C, third arm 72B, and fourth arm 72C of the cover 70 elastically engage with a portion of the housing 60 in the direction opposite to the mounting direction. This prevents the cover 70 from falling off the housing 60. The cover 70 remains attached to the housing 60. This completes the assembly of the board-in connector 45.
[0049] <Assembly state of board-in connector 45> Next, the assembled state of the board-in connector 45 will be described. As shown in Figure 3, when the cover 70 is mounted on the housing 60, the exposed portion 63 is exposed to the outside without being covered by the cover 70. The pin portion 48A protrudes from the positioning groove 63B in the direction opposite to the mounting direction of the cover 70. The opening 63A and the terminal holding portion 62 of the housing 60 are covered by the covering portion 71. However, the opening 63A and the terminal insertion portion 62B are open to the outside through the resin inflow hole 71A of the cover 70.
[0050] With the cover 70 mounted on the housing 60, the second wire clamping portion 72 is maintained in a state where it overlaps the first wire clamping portion 61 in the mounting direction of the cover 70. The second end of the wire 46 is clamped between the first guide groove 61A and the second guide groove 72A. This restricts the movement of the second end of the wire 46 in the long-side direction of the board-in connector 45. The second end of the wire 46 is held in a predetermined position.
[0051] The housing 60 corresponds to the first retaining member, and the cover 70 corresponds to the second retaining member. <Manufacturing method for the first sensor housing 40> Next, a method for manufacturing the first sensor housing 40 will be described.
[0052] First, the first magnetic collecting ring 44 and the board-in connector 45, which are insert parts, are set into the open mold. The board-in connector 45 is in a state where it is holding the electric wire 46. After this, the mold is closed and injection molding is performed. When the mold is closed, a cavity is formed inside the mold. The cavity is a space that corresponds to the outer shape of the first sensor housing 40.
[0053] Next, molten resin is injected into the cavity. Molten resin is a synthetic resin that has been heated and melted. Inside the mold, the first magnetic collecting ring 44 is encased in the molten resin, except for its inner circumferential surface. The board-in connector 45 is encased in the molten resin, except for at least its first end. The molten resin also flows into the terminal insertion portion 62B and the opening 63A through the resin inlet hole 71A of the cover 70. That is, the resin inlet hole 71A is configured to guide the molten resin into the terminal holding portion 62.
[0054] After the cavity is filled with molten resin, the filled molten resin is cooled and solidified. Then the mold is opened and the first sensor housing 40, which is a resin molded product, is removed. This yields the first sensor housing 40 shown in Figure 2, that is, the first sensor housing 40 with the first magnetic collecting ring 44 and board-in connector 45 embedded in it.
[0055] This completes the manufacturing of the first sensor housing 40. As shown in Figure 8, after removing the first sensor housing 40 from the mold, the pin portion 48A is inserted into the terminal connection hole 47C of the substrate 47. The pin portion 48A is joined to the substrate 47 by solder 47D. The pin portion 48A and the pattern wiring of the substrate 47 are electrically connected.
[0056] <Internal state of board-in connector 45> The internal state of the board-in connector 45 is as follows: As shown in Figure 8, inside the board-in connector 45, the area around the connecting portion 48C of the terminal 48 is covered with synthetic resin. That is, the opening 63A of the housing 61 and each terminal insertion portion 62B are filled with synthetic resin. The inside of the protruding portion 82 is also filled with synthetic resin. In addition, the gap between the connecting portion 48C and the partition wall 62A (see Figure 4) is also filled with synthetic resin. The gap 62C between two adjacent partition walls 62A in the long-side direction of the housing 61 (see Figure 4) is also filled with synthetic resin. The protrusion 83A bites into the synthetic resin. The direction of biting is opposite to the direction in which the terminal 48 is inserted into the terminal insertion portion 62B. By filling the area around the connecting portion 48C with resin without any gaps, the terminal 48 is held inside the terminal insertion portion 62B. Figure 8 shows the board-in connector 45 and the synthetic resin and other materials filled inside the board-in connector 45 in a state where they have been temporarily removed. The synthetic resin portion 40A that covers at least the periphery of the connecting portion 48C of the terminal 48 is part of the first sensor housing 40.
[0057] The first sensor housing 40 corresponds to a resin member that covers the area around the connecting portion 48C of the terminal 48 and the areas around the housing 60 and cover 70. The connecting portion 48C is the part of the terminal 48 that is held inside the terminal holding portion 62.
[0058] <Supplementary explanation of board-in connector 45> The sensor device 10 has the following concerns. Specifically, when the first sensor housing 40 is injection molded, there is a concern that the molten resin may overflow into unintended areas. For example, when the first sensor housing 40 is injection molded, there is a risk that the molten resin flowing in from the resin inlet hole 71A of the cover 70 may flow into the positioning groove 63B through the terminal insertion portion 62B and the opening 63A. In this case, there is a concern that the molten resin that has flowed into the positioning groove 63B may overflow onto the surface of the exposed portion 63 on the side opposite to the mounting direction of the cover 70, i.e., the side where the pin portion 48A protrudes.
[0059] Therefore, in this embodiment, the following configuration is adopted for the board-in connector 45. As shown in Figure 9, the cover 70 has a plurality of damming projections 73. The number of damming projections 73 is the same as the number of terminal insertion portions 62B. The damming projections 73 are provided on the inner surface of the covering portion 71. The damming projections 73 are provided on the side edge of the covering portion 71 opposite the second wire clamping portion 72 in the short-side direction. The damming projections 73 are arranged in a row with spacing in the long-side direction of the covering portion 71. The long-side direction of the covering portion 71 is also the long-side direction of the cover 70. The damming projections 73 protrude from the inner surface of the covering portion 71 in the direction of mounting the cover 70. The height of the damming projections 73 protruding from the inner surface of the covering portion 71 is the same as the depth of the opening 63A in the thickness direction of the housing 61.
[0060] The damming projection 73 has a crank-shaped cross-section. The damming projection 73 has a first fitting portion 73A and a second fitting portion 73B. The first fitting portion 73A and the second fitting portion 73B are each rectangular parallelepipeds. The long sides of the first fitting portion 73A and the long sides of the second fitting portion 73B each extend in the direction of the long side of the covering portion 71. The first fitting portion 73A and the second fitting portion 73B are connected offset in the direction of the long side of the covering portion 71. The corner of the first fitting portion 73A on the side connected to the second fitting portion 73B is the first corner of the crank. The corner of the second fitting portion 73B on the side connected to the first fitting portion 73A is the second corner of the crank. The first fitting portions 73A are arranged in a row with spacing between them in the direction of the long side of the covering portion 71. The second fitting portions 73B are arranged in a row with spacing between them in the direction of the long side of the covering portion 71.
[0061] In the short-side direction of the covering portion 71, the length of the connecting portion between the first fitting portion 73A and the second fitting portion 73B is, for example, the same as the length of the opening 63A in the short-side direction of the housing 61. Multiple damming projections 73 can be fitted into the opening 63A. In two adjacent damming projections 73 in the long-side direction of the covering portion 71, the first fitting portion 73A of one damming projection 73 and the second fitting portion 73B of the other damming projection 73 are separated from each other by a distance equivalent to the thickness of the connecting portion body 81 of the terminal 48.
[0062] As shown in Figure 10, in two adjacent damming projections 73 in the long-side direction of the covering portion 71, the connecting portion body 81 of the terminal 48 can be interposed between the first fitting portion 73A of one damming projection 73 and the second fitting portion 73B of the other damming projection 73. The length of the damming projection 73 in the long-side direction of the covering portion 71 is the same as the distance between the two adjacent connecting portion bodies 81. The damming projection 73 can be interposed between the two adjacent connecting portion bodies 81. Figure 10 shows the cover 70 viewed from the inside, with the terminal 48 temporarily attached to the cover 70.
[0063] As shown in Figure 11, the opening 63A has a plurality of narrow sections 63C. The width of the narrow sections 63C is the same as the width of the second fitting section 73B of the damming projection 73. The width is the length in the insertion direction of the terminal 48. The second fitting section 73B can be fitted into the narrow sections 63C. The width of the opening 63A other than the narrow sections 63C is the same as the width of the widest part of the damming projection 73, i.e., the width of the connecting section between the first fitting section 73A and the second fitting section 73B. Figure 11 shows the board-in connector 45 as viewed from the opposite side of the cover 70, and shows a state where it has been cut near the inner end wall of the opening 63A.
[0064] The narrow portion 63C is formed by providing a low-profile projection 63D on the inner end wall of the opening 63A. The end wall is a plane that extends in a direction perpendicular to the depth direction of the opening 63A. The height of the low-profile projection 63D from the end wall is such that the low-profile projection 63D is not exposed from the opening 63A. The amount of protrusion of the low-profile projection 63D may be small. The narrow portions 63C are arranged at intervals in the direction of the arrangement of the terminals 48. The spacing of the narrow portions 63C is also the spacing of the low-profile projections 63D. The spacing is the same as the sum of the length of the first fitting portion 73A in the direction of the arrangement of the terminals 48 and the thickness of the connecting portion body 81 of the terminal 48. The side surface of the connecting portion body 81 of the terminal 48 is in contact with the first wall portion of the partition wall 62A. The first fitting portion 73A can be fitted between the low-profile projection 73C and the connecting portion body 81.
[0065] <Operation of the Embodiment> This embodiment provides the following effects. As shown in Figure 11, after the terminal 48 has been attached to the housing 60, the cover 70 is fitted onto the housing 60. When the cover 70 is fitted onto the housing 60, the damming projection 73 is inserted into the opening 63A of the housing 60. As a result, the first fitting portion 73A of the damming projection 73 is fitted between the connecting body 81 of the terminal 48 and the low-profile projection 63D. In addition, the second fitting portion 73B of the damming projection 73 is fitted into the narrow portion 63C.
[0066] At the moment the tip of the damming projection 73 contacts the inner end wall of the opening 63A, the claws of each arm (71B, 71C, 72B, 72C) of the cover 70 elastically engage with a portion of the housing 60 in the direction opposite to the mounting direction of the cover 70. This fixes the cover 70 to the housing 60, completing the assembly of the board-in connector 45.
[0067] When the board-in connector 45 is assembled, the side of the first mating portion 73A opposite to the low-profile projection 63D is maintained in contact with the side of the connector body 81. The side of the second mating portion 73B is maintained in contact with the side of the connector body 81 of the terminal 48 that the first mating portion 73A is in contact with and the adjacent terminal 48. The damming projection 73 is interposed between the connector body 81 of two adjacent terminals 48. The connector body 81 is sandwiched between the two adjacent damming projections 73. The connector body 81 is sandwiched between the first mating portion 73A of the damming projection 73 and the second mating portion 73B of the other damming projection 73.
[0068] In two adjacent damming projections 73, the end of the first fitting portion 73A of one damming projection 73 and the end of the second fitting portion 73B of the other damming projection 73 sandwich the connecting portion body 81 of the terminal 48 in the thickness direction at two different positions in the insertion direction of the terminal 48. In other words, in two adjacent damming projections 73, the end of the first fitting portion 73A of one damming projection 73 and the end of the second fitting portion 73B of the other damming projection 73 are positioned so as not to face each other via the connecting portion body 81.
[0069] The end of the first mating portion 73A corresponds to the end of the damming projection 73 on the opposite side of the second mating portion 73B in the direction of the alignment of the terminals 48, and is the first contact end. The end of the second mating portion 73B corresponds to the end of the damming projection 73 on the opposite side of the first mating portion 73A in the direction of the alignment of the terminals 48, and is the second contact end.
[0070] As shown in Figure 12, when the board-in connector 45 is assembled, the path between the terminal holding portion 62 and the pin portion 48A is blocked by the damming projection 73 and the connecting portion body 81 of the terminal 48. The path is the portion of the internal space of the board-in connector 45 from the terminal insertion portion 62B to the positioning groove 63B (see Figure 4). The connecting portion body 81 is part of the terminal 48.
[0071] During injection molding of the first sensor housing 40, molten resin flows into the terminal insertion portion 62B through the resin inlet hole 71A of the cover 70. However, the molten resin flowing from the terminal insertion portion 62B toward the opening 63A is blocked by the first fitting portion 73A of the damming projection 73. This prevents the molten resin from passing through the opening 63A and flowing into the positioning groove 63B.
[0072] In addition, there may be some locations between two adjacent damming protrusions 73 where terminals 48 are not interposed. Since terminal insertion portions 62B are not formed at those locations, the molten resin will not flow toward the positioning grooves 63B in the first place.
[0073] Due to dimensional tolerances of the cover 70 or the housing 60, a small gap may be formed between the outer surface of the second fitting portion 73B on the side furthest from the terminal insertion portion 62B and the inner surface of the opening 63A on the side furthest from the terminal insertion portion 62B.
[0074] In this regard, during injection molding of the first sensor housing 40, the pressure of the molten resin acts on the damming projection 73. The direction of the pressure is the same as the flow direction FD of the molten resin, for example, from the terminal insertion portion 62B toward the opening 63A. The pressure of the molten resin pushes the damming projection 73 in the flow direction FD of the molten resin. As a result, in the flow direction FD of the molten resin, the second fitting portion 73B of the damming projection 73 is pressed against the inner surface of the opening 63A on the side furthest from the terminal insertion portion 62B.
[0075] As a result, in the flow direction FD of the molten resin, the outer surface of the second fitting portion 73B on the side farther from the terminal insertion portion 62B and the inner surface of the opening 63A on the side farther from the terminal insertion portion 62B are in close contact with each other. Therefore, it is suppressed that the molten resin passes through the opening 63A and flows into the interior of the positioning groove 63B.
[0076] Furthermore, the inner surface of the opening 63A on the side furthest from the terminal insertion portion 62B is a part of the housing 60 in the direction of terminal 48 insertion. <Effects of the Embodiment> This embodiment provides the following effects.
[0077] (1) The damming projection 73 is positioned close to the pin portion 48A relative to the resin inlet hole 71A. In other words, the damming projection 73 is located between the resin inlet hole 71A and the pin portion 48A. The terminal holding portion 62 and the pin portion 48A are separated from each other by the damming projection 73 and the connecting portion body 81 of the terminal 48. During injection molding of the first sensor housing 40, the molten resin flowing from the terminal insertion portion 62B toward the opening 63A is dammed by the damming projection 73. As a result, the molten resin is prevented from passing through the opening 63A and flowing into the positioning groove 63B. Therefore, it is possible to prevent the molten resin from spilling out into unintended areas.
[0078] (2) The damming member 73 is interposed between two adjacent terminals 48 without any gaps. Therefore, when the first sensor housing 40 is injection molded, the damming projection 73 can properly dam the molten resin flowing from the terminal insertion portion 62B toward the opening 63A.
[0079] (3) Two adjacent damming projections 73 clamp the connecting body 81 of one terminal 48 at two different positions in the insertion direction of the terminal 48. That is, in two adjacent damming projections 73, the first fitting portion 73A of one damming projection 73 and the second fitting portion 73B of the other damming projection 73 do not face each other via the connecting body 81. Since the cover 70 does not have a gap portion corresponding to the thickness of the connecting body 81, the mold can be easily manufactured. Therefore, the resin molded product cover 70 can be easily molded.
[0080] Incidentally, one possible configuration is to provide the damming projection 73 in a single rectangular parallelepiped shape, and to have two adjacent damming projections 73 facing each other via the connecting body 81 in the direction of the arrangement of the terminals 48. In this case, it is necessary to provide a minute gap between the two adjacent damming projections 73, corresponding to the thickness of the connecting body 81. Providing a mold with minute shaped parts corresponding to such minute gaps is time-consuming.
[0081] (4) During injection molding of the first sensor housing 40, the pressure of the molten resin presses the second fitting portion 73B of the damming projection 73 against the inner surface of the opening 63A on the side furthest from the terminal insertion portion 62B. As a result, the outer surface of the second fitting portion 73B on the side furthest from the terminal insertion portion 62B and the inner surface of the opening 63A on the side furthest from the terminal insertion portion 62B come into close contact. Therefore, it is possible to suppress the molten resin from passing through the opening 63A and flowing into the interior of the positioning groove 63B.
[0082] (5) Each terminal insertion portion 62B of the housing 61 is filled with synthetic resin without any gaps. This prevents dust and other debris from entering the inside of the board-in connector 45. This improves the dust resistance of the board-in connector 45.
[0083] <Other Embodiments> This embodiment may be implemented with the following modifications. The damming projection 73 may be provided in the shape of a single rectangular parallelepiped. In this case, for example, two adjacent damming projections 73 are arranged so as not to face each other in the direction in which the terminals 48 are aligned. That is, the positions of the multiple damming projections 73 differ every other one in the direction in which the terminals 48 are inserted. Even in this way, the cover 70 does not have a gap portion corresponding to the thickness of the connecting part body 81, making it easy to manufacture the mold.
[0084] The sensor device 10 may be a rotation angle sensor that detects the rotation angle of the rotating shaft 11. In this case, for example, a drive gear is integrally and rotatably mounted on the outer circumferential surface of the rotating shaft 11. Two driven gears are rotatably supported in the substrate housing portion 42A of the first sensor housing 40. The number of teeth on each driven gear is different from that of the other. The substrate 47 is provided with a sensor that generates an electrical signal corresponding to the rotation angle of each driven gear. The driven gears mesh with the drive gear through an opening provided in the portion of the first sensor housing 40 between the substrate housing portion 42A and the first insertion hole 43. Therefore, the two driven gears rotate in conjunction with the rotation of the drive gear. Since the number of teeth on the two driven gears is different from that of the other, the rotation angles of the two driven gears with respect to the rotation angle of the drive gear are different from those of the other. Therefore, the phases of the electrical signals generated by the first sensor and the second sensor are different from those of the other. For example, the steering control device detects the rotation angle of the rotation axis 11 based on electrical signals generated by the first sensor and the second sensor.
Claims
1. A terminal having a first end with a pin portion and a second end opposite to the first end, A first holding member having a terminal holding portion that holds the terminal in the state in which the terminal is inserted, A second retaining member to be combined with the first retaining member, the second retaining member having a covering portion that covers the terminal retaining portion, An insert molded product having a resin member that covers the periphery of a part of the terminal located inside the terminal holding portion, and the periphery of the first holding member and the second holding member, The aforementioned covering portion is A resin inlet hole is configured to guide molten resin into the terminal holding portion during the molding of the resin member, A projection provided in a position close to the pin portion with respect to the resin inflow hole, having a projection that is combined with the first holding member, An insert molded product in which the terminal holding portion and the pin portion are separated from each other by the protrusion and a part of the terminal.
2. The terminals are a plurality of terminals, arranged in a direction perpendicular to the direction in which the terminals are inserted into the terminal holding portion. The aforementioned protrusions are numerous and are arranged in the direction of the arrangement of the terminals. The insert molded product according to claim 1, wherein each of the protrusions is interposed between two adjacent terminals.
3. Each of the aforementioned protrusions has a first contact end and a second contact end located on opposite sides of the terminals in the direction of arrangement of the terminals. The first contact end and the second contact end are located at different positions from each other in the insertion direction of the terminal. The insert molded product according to claim 2, wherein a part of the terminal is held between two adjacent protrusions in the direction of the arrangement of the terminals, by the first contact end of one protrusion and the second contact end of the other protrusion.
4. The insert molded product according to claim 2, wherein the projection is in close contact with a part of the first retaining member in the insertion direction of the terminal.
5. A sensor device having an insert molded article according to any one of claims 1 to 4.