Magnet module, sensor module, and method for manufacturing magnet module

Abstract

The present disclosure addresses the problem of achieving improvement in the accuracy of positioning of an object to be detected. A magnet module (10) is for use in a magnetic sensor (3). The magnetic sensor (3) outputs a signal corresponding to a detected magnetic field. The magnet module (10) comprises a first magnet (1) and a second magnet (2). The first magnet (1) and the second magnet (2) are magnetized in a first direction (D1) and a second direction (D2). The first magnet (1) and the second magnet (2) are different bodies from each other, and are integrally joined in a third direction (D3) such that the magnetization directions are different from each other.

Description

Magnet module, sensor module, and method of manufacturing the magnet module

[0001] The present disclosure generally relates to a magnet module, a sensor module, and a method for manufacturing a magnet module, and more particularly to a magnet module used in a magnetic sensor, a sensor module, and a method for manufacturing a magnet module.

[0002] The magnetic sensor device described in Patent Document 1 includes a first bias magnet, a second bias magnet, and a magnetic sensor. The second bias magnet is rotated by a predetermined angle relative to the first bias magnet. The magnetic sensor is disposed between the bottom surface of the first bias magnet and the top surface of the second bias magnet.

[0003] Japanese Patent Application Laid-Open No. 2017-173236

[0004] In a magnetic sensor device such as that described in Patent Document 1, it is desirable to improve the positioning accuracy of a magnetic body (detection target).

[0005] An object of the present disclosure is to provide a magnet module, a sensor module, and a method for manufacturing a magnet module that are capable of improving the positioning accuracy of an object to be detected.

[0006] A magnet module according to one aspect of the present disclosure is a magnet module used in a magnetic sensor. The magnetic sensor outputs a signal corresponding to a detected magnetic field. The magnet module includes a first magnet and a second magnet. The first magnet and the second magnet are magnetized in a first direction and a second direction. The second direction is a direction perpendicular to the first direction. The first magnet and the second magnet are separate bodies and are integrally joined in a third direction such that their magnetization directions are different from each other. The third direction is a direction perpendicular to the first direction and the second direction.

[0007] A sensor module according to an aspect of the present disclosure includes the magnet module, the magnetic sensor, and a resin member for the sensor, the resin member for the sensor covering the magnet module and the magnetic sensor.

[0008] A method for manufacturing a magnet module according to one aspect of the present disclosure is a method for manufacturing a magnet module used in a magnetic sensor. The magnetic sensor outputs a signal according to a detected magnetic field. The method for manufacturing the magnet module includes a generating step and a combining step. In the generating step, a first magnet and a second magnet are generated by magnetizing a magnetic material in a first direction and a second direction. The second direction is a direction perpendicular to the first direction. In the combining step, the first magnet and the second magnet are combined from a third direction such that their magnetization directions are different from each other. The third direction is a direction perpendicular to the first direction and the second direction.

[0009] FIG. 1A is a front view of a magnet module according to embodiment 1. FIG. 1B is a side view of the magnet module according to embodiment 1. FIG. 2A is a front view of a first magnet of the magnet module according to embodiment 1. FIG. 2B is a side view of the first magnet. FIG. 3A is a front view of a second magnet of the magnet module according to embodiment 1. FIG. 3B is a side view of the second magnet. FIG. 4 is a schematic diagram for explaining a magnetization method for the magnet module according to embodiment 1. FIG. 5 is a flowchart showing a manufacturing method of the magnet module according to embodiment 1. FIG. 6 is a front view of a magnet module according to embodiment 2. FIG. 7A is a front view of a magnet module according to embodiment 3. FIG. 7B is a side view of the magnet module according to embodiment 1. FIG. 8A is a front view of a sensor module according to embodiment 4. FIG. 8B is a side view of the sensor module according to embodiment 4.

[0010] The magnet module, sensor module, and magnet module manufacturing method according to embodiments 1 to 4 will be described below with reference to the drawings. The figures described in the following embodiments 1 to 4 are schematic diagrams, and the ratios of the sizes and thicknesses of the components do not necessarily reflect the actual dimensional ratios. Furthermore, the configurations described in the following embodiments 1 to 4 are merely examples of the present disclosure. The present disclosure is not limited to the following embodiments 1 to 4, and various modifications are possible depending on the design, etc., as long as the effects of the present disclosure can be achieved.

[0011] Furthermore, in this disclosure, "orthogonal (perpendicular)" refers not only to a state in which the angle between two things is exactly 90 degrees, but also to a state in which the angle between two things is not 90 degrees but is within a predetermined range (for example, ±10 degrees). Similarly, in this disclosure, "parallel" refers not only to a state in which two things do not strictly intersect, but also to a state in which the angle between two things is within a predetermined range (for example, ±10 degrees).

[0012] First Embodiment (1) Overview First, an overview of a magnet module 10 according to a first embodiment will be described with reference to FIGS. 1A to 3B.

[0013] The magnet module 10 according to the first embodiment is used in, for example, a motor together with the magnetic sensor 3. The motor is used, for example, to adjust the focus of a built-in camera (camera module) of a mobile terminal such as a smartphone. The motor is, for example, a voice coil motor (VCM). In the first embodiment, the detection target of the magnetic sensor 3 is the motor.

[0014] That is, the magnet module 10 is a magnet module used in the magnetic sensor 3. The magnetic sensor 3 outputs a signal (e.g., a voltage signal) according to the detected magnetic field. In the first embodiment, the magnet module 10 is a bias magnet. That is, the magnet module 10 is a magnet for generating a bias magnetic field for the magnetic sensor 3.

[0015] As shown in Figures 1A to 3B, the magnet module 10 according to the first embodiment includes a first magnet 1 and a second magnet 2. The first magnet 1 and the second magnet 2 are magnetized in a first direction D1 and a second direction D2. The second direction D2 is a direction perpendicular to the first direction D1. The first magnet 1 and the second magnet 2 are separate bodies that are joined together in a third direction D3 such that their magnetization directions are different from each other. The third direction D3 is a direction perpendicular to the first direction D1 and the second direction D2.

[0016] In the magnet module 10 according to the first embodiment, the first magnet 1 and the second magnet 2 are coupled in the third direction D3 with their magnetization directions being different from each other. This makes it possible to reduce the neutral zone 102 that occurs between the first magnet 1 and the second magnet 2 in the third direction D3, and as a result, it becomes possible to increase the bias magnetic field that the magnet module 10 applies to the magnetic sensor 3. This makes it possible to improve the detection accuracy of the magnetic sensor 3, and to improve the positioning accuracy of the detection target (e.g., a motor).

[0017] (2) Details Next, the configuration of the magnet module 10 according to embodiment 1 will be described with reference to Figures 1A to 3B. In the following description, the longitudinal direction of each of the first magnet 1 and the second magnet 2 is defined as the first direction D1, the thickness direction as the second direction D2, and the short side direction (width direction) as the third direction D3. However, these directions are not intended to define the directions of the first magnet 1 and the second magnet 2 when in use. Furthermore, these directions are merely indicated for the purpose of explanation and do not represent actual situations.

[0018] As described above, the magnet module 10 according to the first embodiment is a magnet module used in the magnetic sensor 3. The magnet module 10 is, for example, a bias magnet. That is, the magnet module 10 is a magnet for generating a bias magnetic field for the magnetic sensor 3. In short, the first magnet 1 and the second magnet 2 included in the magnet module 10 generate a bias magnetic field for the magnetic sensor 3.

[0019] 1A and 1B, the magnet module 10 includes a first magnet 1 and a second magnet 2. In the magnet module 10 according to the first embodiment, the first magnet 1 and the second magnet 2 are separate bodies. Each of the first magnet 1 and the second magnet 2 is, for example, a double-sided four-pole magnet.

[0020] (2.1) First Magnet The first magnet 1 is, for example, a neodymium magnet. As shown in Figures 2A and 2B, the first magnet 1 has, for example, a rectangular parallelepiped shape. As shown in Figure 2A, the first magnet 1 has a rectangular shape that is longer in the first direction D1 than in the third direction D3 when viewed from the second direction D2. As shown in Figure 2B, the first magnet 1 has a rectangular shape that is longer in the first direction D1 than in the second direction D2 when viewed from the third direction D3.

[0021] In embodiment 1, the first magnet 1 is magnetized in the order of south pole and north pole from left to right when viewed from the second direction D2, as shown in Fig. 2A. Also, in embodiment 1, the first magnet 1 is magnetized in the order of north pole and north pole from left to right when viewed from the third direction D3, as shown in Fig. 2B. In other words, the first magnet 1 is magnetized in the first direction D1 and the second direction D2 that is perpendicular to the first direction D1.

[0022] The first magnet 1 magnetized as described above has multiple neutral zones 11. The multiple neutral zones 11 include a first neutral zone 111 and a second neutral zone 112. The first neutral zone 111 is provided between the south pole and north pole aligned along the first direction D1 when viewed from a plane in the second direction D2. The second neutral zone 112 is provided between the south pole and north pole aligned along the second direction D2 when viewed from a plane in the third direction D3.

[0023] The "neutral zone" referred to in this disclosure is the area located between the south pole and north pole, where the south pole and north pole switch, and is the area between the interface of the south pole on the north pole side and the interface of the north pole on the south pole side. In other words, the first neutral zone 111 and the second neutral zone 112 are not magnetized as either the south pole or the north pole. Note that in Figures 2A and 2B, the first neutral zone 111 and the second neutral zone 112 are marked with dotted hatching to make them easily distinguishable from other parts of the first magnet 1, but these dotted hatching do not indicate a cross section. The same applies to Figures 1A, 1B, 3A, and 3B.

[0024] (2.2) Second Magnet The second magnet 2 is, like the first magnet 1, for example, a neodymium magnet. The second magnet 2 is, for example, rectangular, as shown in Figures 3A and 3B. As shown in Figure 3A, the second magnet 2 has a rectangular shape that is longer in the first direction D1 than in the third direction D3 when viewed from the second direction D2. As shown in Figure 3B, the second magnet 2 has a rectangular shape that is longer in the first direction D1 than in the second direction D2 when viewed from the third direction D3. In embodiment 1, the first magnet 1 and the second magnet 2 are the same size.

[0025] In the first embodiment, the second magnet 2 is magnetized in the order of north pole and south pole from the left when viewed from the second direction D2, as shown in Fig. 3A. Also, in the first embodiment, the second magnet 2 is magnetized in the order of south pole and north pole from the left when viewed from the third direction D3, as shown in Fig. 3B. In other words, the second magnet 2 is magnetized in the first direction D1 and the second direction D2 that is perpendicular to the first direction D1.

[0026] The second magnet 2 magnetized as described above has multiple neutral zones 21. The multiple neutral zones 21 include a first neutral zone 211 and a second neutral zone 212. The first neutral zone 211 is provided between the north and south poles aligned along the first direction D1 when viewed from a plane in the second direction D2. The second neutral zone 212 is provided between the north and south poles aligned along the second direction D2 when viewed from a plane in the third direction D3.

[0027] (2.3) Magnet Module In the first embodiment, the magnet module 10 is generated by combining the first magnet 1 and the second magnet 2 described above. More specifically, as shown in FIG. 1A , the first magnet 1 and the second magnet 2 are combined together in the third direction D3 such that the magnetization direction of the first magnet 1 and the magnetization direction of the second magnet 2 are different from each other. In other words, the first magnet 1 and the second magnet 2 are combined together in the third direction D3 such that the magnetic pole of the first magnet 1 and the magnetic pole of the second magnet 2 that faces the magnetic pole of the first magnet 1 are opposite magnetic poles. At this time, the first magnet 1 and the second magnet 2 are combined together by the magnetic attraction force acting between the first magnet 1 and the second magnet 2. In this disclosure, "the first magnet and the second magnet are bonded" includes cases where the first magnet and the second magnet are bonded directly, and cases where the first magnet and the second magnet are bonded indirectly via another member (for example, adhesive member 4 described below).

[0028] As shown in FIGS. 1A and 1B , the magnet module 10 has a plurality of (two in the illustrated example) first neutral zones 101 and a second neutral zone 102. Each of the plurality of first neutral zones 101 is a neutral zone provided in each of the first magnet 1 and the second magnet 2 described above. The second neutral zone 102 is a neutral zone provided between the first magnet 1 and the second magnet 2 when the first magnet 1 and the second magnet 2 are coupled together. In embodiment 1, as shown in FIG. 1A , the width of the second neutral zone 102 is 0 mm. Therefore, in a plan view from the second direction D2, the width of the second neutral zone 102 between the first magnet 1 and the second magnet 2 is narrower than the width W1 of the first neutral zone 101 in each of the first magnet 1 and the second magnet 2.

[0029] 1A and 1B, the magnet module 10 has, for example, a rectangular parallelepiped shape. The length X1 of the magnet module 10 in the first direction D1 is, for example, 5 mm. The length X2 of the magnet module 10 in the third direction D3 is, for example, 5 mm. The length X3 of the magnet module 10 in the second direction D2 is, for example, 1 mm. It is preferable that the length X1 of the magnet module 10 in the first direction D1 is 5 mm or less and the length X2 of the magnet module 10 in the third direction D3 is 5 mm or less. This makes it possible to reduce the size of the magnet module 10.

[0030] In the first embodiment, the magnet module 10 is aligned with the magnetic sensor 3 in the second direction D2, and the surface of the magnetic sensor 3 facing the magnet module 10 (the upper surface in FIG. 1B) is the magnetic sensing surface 31.

[0031] (3) Magnetization Method Next, the magnetization method of the first magnet 1 and the second magnet 2 will be described with reference to FIG.

[0032] First, yokes 61 and 62 are fixed to both ends of magnetic material 100 in first direction D1. Here, magnetic material 100 is, for example, a metal compound containing neodymium, iron, and boron as its main components. Coil 71 is wound around yoke 61. Coil 72 is wound around yoke 62.

[0033] Then, by passing current through the coils 71 and 72, respectively, the magnetic material 100 is magnetized via the yokes 61 and 62, generating the first magnet 1 and the second magnet 2. Here, by reversing the direction of the current flowing through the coils 71 and 72, the magnetic material 100 is magnetized in the first direction D1 and the second direction D2. In this case, by increasing the magnitude of the current flowing through the coils 71 and 72, it is possible to narrow the widths of the neutral zones 11 and 21. Furthermore, by increasing the contact area of ​​the yokes 61 and 62 with the magnetic material 100, it is possible to narrow the widths of the neutral zones 11 and 21.

[0034] The first magnet 1 and the second magnet 2 magnetized by the above-described magnetization method may have the same magnetization direction or different directions. In either case, the first magnet 1 and the second magnet 2 are joined together so that their magnetization directions are different from each other, thereby making it possible to create the magnet module 10.

[0035] (4) Manufacturing Method of Magnet Module Next, a manufacturing method of the magnet module 10 according to the first embodiment will be described with reference to FIG.

[0036] The manufacturing method of the magnet module 10 according to the first embodiment is a manufacturing method of the magnet module 10 used in the magnetic sensor 3. The magnetic sensor 3 outputs a signal (voltage signal) according to the detected magnetic field. The manufacturing method of the magnet module 10 includes a generating step S1 and a combining step S2. In the generating step S1, the first magnet 1 and the second magnet 2 are generated by magnetizing the magnetic material 100 (see FIG. 4) in a first direction D1 and a second direction D2. In the combining step S2, the first magnet 1 and the second magnet 2 are combined from a third direction D3 so that the magnetization directions are different from each other.

[0037] In the manufacturing method of the magnet module 10 according to the first embodiment, in the joining step S2, the first magnet 1 and the second magnet 2 are joined in the third direction D3 so that their magnetization directions are different from each other. This makes it possible to reduce the neutral zone 102 (see FIG. 1A ) that occurs between the first magnet 1 and the second magnet 2 in the third direction D3, and as a result, it becomes possible to increase the bias magnetic field that the magnet module 10 applies to the magnetic sensor 3. This makes it possible to improve the detection accuracy of the magnetic sensor 3 and improve the positioning accuracy of the detection target (e.g., a motor).

[0038] Fig. 5 is a flowchart showing a method for manufacturing the magnet module 10 according to embodiment 1. The method for manufacturing the magnet module 10 includes steps S1 and S2 shown in Fig. 5. Hereinafter, the method for manufacturing the magnet module 10 according to embodiment 1 will be described with reference to Fig. 5.

[0039] First, the manufacturer of the magnet module 10 executes the production step S1. In the production step S1, currents are passed through the coils 71 and 72 in opposite directions to each other, thereby magnetizing the magnetic material 100 via the yokes 61 and 62. As a result, the first magnet 1 and the second magnet 2 are produced, which are magnetized in the first direction D1 and the second direction D2, as shown in Figures 2A to 3B.

[0040] Next, the manufacturer of the magnet module 10 performs a coupling step S2. In the coupling step S2, the first magnet 1 and the second magnet 2 are coupled together so that the magnetic poles of the first magnet 1 and the second magnet 2 are opposite to each other in the third direction D3, as shown in FIG. 1A. At this time, the first magnet 1 and the second magnet 2 are coupled together by the magnetic attraction force acting between them.

[0041] (5) Effects In the magnet module 10 according to embodiment 1, the first magnet 1 and the second magnet 2 are coupled in the third direction D3 with their magnetization directions being different from each other. This makes it possible to reduce the neutral zone 102 that occurs between the first magnet 1 and the second magnet 2 in the third direction D3, and as a result, it becomes possible to increase the bias magnetic field that the magnet module 10 applies to the magnetic sensor 3. This makes it possible to improve the detection accuracy of the magnetic sensor 3 and improve the positioning accuracy of the detection target (e.g., a motor).

[0042] Furthermore, in the magnet module 10 according to embodiment 1, in a plan view from the second direction D2, the width of the second neutral zone 102 between the first magnet 1 and the second magnet 2 is narrower than the width W1 of the first neutral zone 101 in each of the first magnet 1 and the second magnet 2. This makes it possible to increase the bias magnetic field compared to when the width of the first neutral zone and the width of the second neutral zone are the same.

[0043] Furthermore, in the magnet module 10 according to embodiment 1, the first magnet 1 and the second magnet 2 are bias magnets that generate a bias magnetic field for the magnetic sensor 3, thereby enabling the detection accuracy of the magnetic sensor 3 to be improved.

[0044] (6) Modifications The first embodiment is merely one of various embodiments of the present disclosure. Various modifications of the first embodiment are possible depending on the design, etc., as long as the object of the present disclosure can be achieved. Modifications of the first embodiment are listed below. The modifications described below can be applied in appropriate combinations.

[0045] In embodiment 1, the width of the second neutral zone 102 generated between the first magnet 1 and the second magnet 2 is 0 mm, but the width of the second neutral zone 102 is not limited to 0 mm and may be greater than 0 mm as long as it is narrower than the width W1 of the first neutral zone 101 generated between each of the first magnet 1 and the second magnet 2.

[0046] In the first embodiment, the magnet module 10 is a bias magnet, but the magnet module 10 is not limited to a bias magnet and may be, for example, a drive magnet for driving an object (for example, a lens).

[0047] Second Embodiment Next, a magnet module 10 according to a second embodiment will be described with reference to Fig. 6. Regarding the magnet module 10 according to the second embodiment, the same components as those of the magnet module 10 according to the first embodiment (see Figs. 1A and 1B) are denoted by the same reference numerals, and descriptions thereof will be omitted.

[0048] The magnet module 10 according to the second embodiment differs from the magnet module 10 according to the first embodiment in that it further includes an adhesive member 4 that bonds the first magnet 1 and the second magnet 2 together.

[0049] 6, the magnet module 10 according to the second embodiment includes a first magnet 1 and a second magnet 2. The magnet module 10 according to the second embodiment further includes an adhesive member 4.

[0050] The adhesive member 4 includes, for example, epoxy resin. As shown in FIG. 6 , the adhesive member 4 is applied to at least one of the end face of the first magnet 1 facing the second magnet 2 and the end face of the second magnet 2 facing the first magnet 1. Then, by heating the first magnet 1 and the second magnet 2 after joining them together, the adhesive member 4 thermally hardens, bonding the first magnet 1 and the second magnet 2 together. In other words, the adhesive member 4 is a member that bonds the first magnet 1 and the second magnet 2 together. Here, the width of the adhesive member 4 (the length in the third direction D3) is preferably narrower than the width of the above-mentioned first neutral zone 101 (the length in the first direction D1).

[0051] In the magnet module 10 according to the second embodiment, the first magnet 1 and the second magnet 2 are joined via an adhesive member 4. This allows for a more compact size compared to, for example, a case in which the first magnet 1 and the second magnet 2 are covered with a resin member 5 (described later). Also, the first magnet 1 and the second magnet 2 can be joined more firmly than when the first magnet 1 and the second magnet 2 are joined only by the magnetic attraction force acting between them.

[0052] The adhesive member 4 is not limited to one containing epoxy resin, and may contain, for example, silicone resin. In this case, too, the adhesive member 4 is thermoset by heating, making it possible to bond the first magnet 1 and the second magnet 2 together.

[0053] Furthermore, the various configurations (including modified examples) described in the second embodiment can be adopted in appropriate combination with the various configurations (including modified examples) described in the first embodiment.

[0054] Next, a magnet module 10 according to a third embodiment will be described with reference to Figures 7A and 7B. In the magnet module 10 according to the third embodiment, the same components as those in the magnet module 10 according to the first embodiment (see Figures 1A and 1B) are denoted by the same reference numerals, and descriptions thereof will be omitted.

[0055] The magnet module 10 according to the third embodiment differs from the magnet module 10 according to the first embodiment in that the first magnet 1 and the second magnet 2 are covered with a resin member 5 .

[0056] 7A and 7B, the magnet module 10 according to the third embodiment includes a first magnet 1 and a second magnet 2. The magnet module 10 according to the third embodiment further includes a resin member 5 (resin member for magnet).

[0057] The resin member 5 is made of, for example, epoxy resin. In the third embodiment, the magnet module 10 is molded by, for example, transfer molding. That is, the resin member 5 covers the first magnet 1 and the second magnet 2.

[0058] In embodiment 3, the first magnet 1 and the second magnet 2 may be joined only by the magnetic force between the first magnet 1 and the second magnet 2, or may be bonded using the above-mentioned adhesive member 4 (see Figure 6).

[0059] In the magnet module 10 according to the third embodiment, similarly to the magnet module 10 according to the first embodiment, it is possible to reduce the neutral zone 102 generated between the first magnet 1 and the second magnet 2, and as a result, it is possible to increase the bias magnetic field applied to the magnetic sensor 3. This makes it possible to improve the detection accuracy of the magnetic sensor 3, and to improve the positioning accuracy of the detection target (for example, a motor).

[0060] Furthermore, since the first magnet 1 and the second magnet 2 are covered with the resin member 5, the first magnet 1 and the second magnet 2 can be protected.

[0061] The resin member 5 is not limited to being formed by transfer molding using an epoxy resin, but may also be formed by injection molding using, for example, polyphenylene sulfide resin, polybutylene terephthalate resin, or liquid crystal polymer.

[0062] Furthermore, the various configurations (including modified examples) described in the third embodiment can be adopted in appropriate combination with the various configurations (including modified examples) described in the first and second embodiments.

[0063] (Embodiment 4) Next, a sensor module 20 according to embodiment 4 will be described with reference to Figures 8A and 8B. With regard to the sensor module 20 according to embodiment 4, the same components as those of the magnet module 10 according to embodiment 1 (see Figures 1A and 1B) are denoted by the same reference numerals, and descriptions thereof will be omitted.

[0064] The sensor module 20 of embodiment 4 differs from the magnet module 10 of embodiment 1 (see Figures 1A and 1B), which is provided separately from the magnetic sensor 3, in that the magnet module 10 and the magnetic sensor 3 are an integrated structure covered with a resin member 6, as shown in Figures 8A and 8B.

[0065] As shown in FIGS. 8A and 8B, the sensor module 20 according to the fourth embodiment includes a magnet module 10, a magnetic sensor 3, and a resin member 6 (sensor resin member).

[0066] The resin member 6 is made of, for example, epoxy resin. In the fourth embodiment, the sensor module 20 is formed by, for example, transfer molding. That is, the resin member 6 covers the magnet module 10 and the magnetic sensor 3.

[0067] In embodiment 4, the first magnet 1 and the second magnet 2 may be joined only by the magnetic force between the first magnet 1 and the second magnet 2, or may be bonded with an adhesive member 4 (see Figure 6).

[0068] In the sensor module 20 according to the fourth embodiment, the magnet module 10 and the magnetic sensor 3 are aligned along the second direction D2 in an integrated structure in which the magnet module 10 and the magnetic sensor 3 are covered with a resin member 6. In the sensor module 20 according to the fourth embodiment, the surface of the magnetic sensor 3 facing the magnet module 10 (the upper surface in FIG. 8B ) is the magnetic sensing surface 31.

[0069] The sensor module 20 according to the fourth embodiment includes the magnet module 10, which makes it possible to reduce the neutral zone 102 generated between the first magnet 1 and the second magnet 2, thereby increasing the bias magnetic field applied to the magnetic sensor 3. This improves the detection accuracy of the magnetic sensor 3, and also improves the positioning accuracy of the detection target (for example, a motor).

[0070] Furthermore, since the magnet module 10 and the magnetic sensor 3 are covered with the resin member 6, the magnet module 10 and the magnetic sensor 3 can be protected.

[0071] Furthermore, since the magnet module 10 and the magnetic sensor 3 are positioned by the resin member 6, it is possible to suppress misalignment of the magnet module 10 with respect to the magnetic sensor 3.

[0072] The resin member 6 is not limited to being formed by transfer molding using an epoxy resin, but may also be formed by injection molding using, for example, polyphenylene sulfide resin, polybutylene terephthalate resin, or liquid crystal polymer.

[0073] Furthermore, the various configurations (including modified examples) described in the fourth embodiment can be adopted in appropriate combination with the various configurations (including modified examples) described in the first to third embodiments.

[0074] (Aspects) The present specification discloses the following aspects.

[0075] A magnet module (10) according to a first aspect is a magnet module (10) used in a magnetic sensor (3). The magnetic sensor (3) outputs a signal corresponding to a detected magnetic field. The magnet module (10) includes a first magnet (1) and a second magnet (2). The first magnet (1) and the second magnet (2) are magnetized in a first direction (D1) and a second direction (D2). The second direction (D2) is a direction perpendicular to the first direction (D1). The first magnet (1) and the second magnet (2) are separate bodies and are integrally connected in a third direction (D3) such that their magnetization directions are different from each other. The third direction (D3) is a direction perpendicular to the first direction (D1) and the second direction (D2).

[0076] According to this aspect, it is possible to reduce the neutral zone (102) generated between the first magnet (1) and the second magnet (2) in the third direction (D3), thereby increasing the bias magnetic field that the magnet module (10) applies to the magnetic sensor (3). This improves the detection accuracy of the magnetic sensor (3) and improves the positioning accuracy of the detection target (e.g., a motor).

[0077] In the magnet module (10) of the second aspect, in the first aspect, when viewed in a plane from the second direction (D2), the width of the neutral zone (102) between the first magnet (1) and the second magnet (2) is narrower than the width (W1) of the neutral zone (101) in each of the first magnet (1) and the second magnet (2).

[0078] According to this embodiment, it is possible to increase the bias magnetic field applied to the magnetic sensor (3) compared to when the width of the neutral zone (102) and the width (W1) of the neutral zone (101) are the same.

[0079] In the magnet module (10) according to the third aspect, in the first or second aspect, the first magnet (1) and the second magnet (2) generate a bias magnetic field for the magnetic sensor (3).

[0080] According to this aspect, it is possible to improve the detection accuracy of the magnetic sensor (3).

[0081] The magnet module (10) according to a fourth aspect is the magnet module (10) of any one of the first to third aspects, further comprising an adhesive member (4). The adhesive member (4) bonds the first magnet (1) and the second magnet (2).

[0082] According to this aspect, it is possible to reduce the size of the magnet module (10).

[0083] In the magnet module (10) according to the fifth aspect, in the fourth aspect, the adhesive member (4) contains an epoxy resin or a silicone resin.

[0084] This embodiment has the advantage that the adhesive member (4) is easy to handle.

[0085] The magnet module (10) according to a sixth aspect is any one of the first to fifth aspects, further comprising a magnet resin member (5). The magnet resin member (5) covers the first magnet (1) and the second magnet (2).

[0086] According to this aspect, it is possible to firmly fix the first magnet (1) and the second magnet (2), and it is also possible to protect the first magnet (1) and the second magnet (2).

[0087] In the magnet module (10) of the seventh aspect, in any one of the first to sixth aspects, the length (X1) in the first direction (D1) is 5 mm or less, and the length (X2) in the third direction (D3) is 5 mm or less.

[0088] According to this aspect, it is possible to reduce the size of the magnet module (10).

[0089] A sensor module (20) according to an eighth aspect includes the magnet module (10) according to any one of the first to seventh aspects, a magnetic sensor (3), and a resin member for the sensor (6). The resin member for the sensor (6) covers the magnet module (10) and the magnetic sensor (3).

[0090] According to this aspect, it is possible to protect the magnet module (10) and the magnetic sensor (3), and also to suppress misalignment of the magnet module (10) relative to the magnetic sensor (3).

[0091] A manufacturing method for a magnet module (10) according to a ninth aspect is a manufacturing method for a magnet module (10) used in a magnetic sensor (3). The magnetic sensor (3) outputs a signal according to a detected magnetic field. The manufacturing method for the magnet module (10) includes a generating step (S1) and a combining step (S2). In the generating step (S1), a first magnet (1) and a second magnet (2) are generated by magnetizing a magnetic material (100) in a first direction (D1) and a second direction (D2). The second direction (D2) is a direction perpendicular to the first direction (D1). In the combining step (S2), the first magnet (1) and the second magnet (2) are combined from a third direction (D3) such that the magnetization directions are different from each other. The third direction (D3) is a direction perpendicular to the first direction (D1) and the second direction (D2).

[0092] According to this aspect, it is possible to reduce the neutral zone (102) generated between the first magnet (1) and the second magnet (2) in the third direction (D3), thereby increasing the bias magnetic field that the magnet module (10) applies to the magnetic sensor (3). This improves the detection accuracy of the magnetic sensor (3) and improves the positioning accuracy of the detection target (e.g., a motor).

[0093] The configurations according to the second to seventh aspects are not essential for the magnet module (10) and can be omitted as appropriate.

[0094] REFERENCE SIGNS LIST 1 First magnet 2 Second magnet 3 Magnetic sensor 4 Adhesive member 5 Resin member (resin member for magnet) 6 Resin member (resin member for sensor) 10 Magnet module 20 Sensor module 100 Magnetic material 101 First neutral zone (neutral zone) 102 Second neutral zone (neutral zone) D1 First direction D2 Second direction D3 Third direction X1, X2 Length S1 Generation step S2 Combining step W1 Width

Claims

1. A magnet module used in a magnetic sensor that outputs a signal according to a detected magnetic field, A first magnet and a second magnet are magnetized in a first direction and a second direction perpendicular to the first direction, The first magnet and the second magnet are separate bodies and are integrally joined in a third direction perpendicular to the first direction and the second direction such that their magnetization directions are different from each other. Magnet module.

2. When viewed from the second direction, a width of a neutral zone between the first magnet and the second magnet is narrower than a width of a neutral zone in each of the first magnet and the second magnet. The magnet module according to claim 1 .

3. the first magnet and the second magnet generate a bias magnetic field for the magnetic sensor; The magnet module according to claim 1 or 2.

4. Further comprising an adhesive member for adhering the first magnet and the second magnet. The magnet module according to claim 1 or 2.

5. The adhesive member includes an epoxy resin or a silicone resin. The magnet module according to claim 4 .

6. The magnet further includes a resin member for a magnet that covers the first magnet and the second magnet. The magnet module according to claim 1 or 2.

7. The length in the first direction is 5 mm or less, and the length in the third direction is 5 mm or less. The magnet module according to claim 1 or 2.

8. A magnet module according to claim 1 or 2; The magnetic sensor; a resin member for a sensor that covers the magnet module and the magnetic sensor, Sensor module.

9. A method for manufacturing a magnet module used in a magnetic sensor that outputs a signal according to a detected magnetic field, comprising the steps of: a generating step of generating a first magnet and a second magnet by magnetizing a magnetic material in a first direction and a second direction perpendicular to the first direction; and a coupling step of coupling the first magnet and the second magnet from a third direction perpendicular to the first direction and the second direction such that the magnetization directions of the first magnet and the second magnet are different from each other. A method for manufacturing a magnet module.