Insert-molded article and sensor device

Abstract

An insert-molded article (90) has: a terminal (48) that is to be connected to a substrate (47); and a resin member (40A) that covers a portion of the terminal (48). The terminal (48) has: a pin part (48A) that is to be connected to the substrate (47); a connection part (48B) to which an electrical wire (46) is to be connected; and a linking part (48C) that links the pin part (48A) and the connection part (48B). The linking part (48C) has a protruding part (82) that protrudes to the side in the direction orthogonal to the direction from the connection part (48B) to the pin part (48A). The resin member (40A) covers at least the linking part (48C) of the terminal (48).

Description

Insert molding product and sensor device

[0001] The present disclosure relates to an insert molding product and a sensor device.

[0002] For example, the torque sensor disclosed in Patent Document 1 includes a sensor board, a harness, and a board holder. The board holder houses a portion of the harness and the sensor board. The harness is pulled out from the inside of the board holder to the outside. The inner end of the harness is connected to the sensor board via a terminal. The terminal is fixed to the sensor board while penetrating the sensor board in the thickness direction.

[0003] Japanese Patent Application Laid-Open No. 2017-075920

[0004] When a sensor in which the harness is pulled out from the circuit board holder, such as the torque sensor in Patent Document 1, is attached to a machine to which it is to be mounted, a tensile force may be applied to the harness due to the wiring work at the outer end of the harness. The tensile force is a force in the direction in which the harness is pulled out. When a tensile force is applied to the harness, the tensile force may be transmitted to the terminals, which may affect the connection between the terminals and the sensor circuit board.

[0005] An insert-molded product according to one aspect of the present disclosure includes a terminal configured to be connected to a substrate and a resin member covering a portion of the terminal. The terminal includes a pin portion configured to be connected to the substrate, a connection portion configured to be connected to an electric wire, and a linking portion connecting the pin portion and the connection portion. The linking portion has a protruding portion that protrudes laterally in a direction perpendicular to the direction from the connection portion toward the pin portion. The resin member covers at least the linking portion of the terminal.

[0006] A sensor device according to one aspect of the present disclosure includes the insert-molded product described above.

[0007] FIG. 1 is an exploded perspective view of a sensor device according to an embodiment. FIG. 2 is an exploded perspective view of a detection unit according to an embodiment. FIG. 3 is a perspective view of a board-in connector according to an embodiment. FIG. 4 is an exploded perspective view of a board-in connector according to an embodiment. FIG. 5 is a front view of a terminal according to an embodiment. FIG. 6 is a perspective view of a terminal according to an embodiment. FIG. 7 is a side view of a terminal according to an embodiment. FIG. 8 is a cross-sectional view of a board-in connector according to an embodiment. FIG. 9 is a cross-sectional view of an insert-molded product according to an embodiment. FIG. 10 is a perspective view showing a first range and a second range of each terminal according to an embodiment. FIG. 11 is a side view showing a projection area of ​​a terminal according to an embodiment. FIG. 12 is a side view of a terminal according to another embodiment. FIG. 13 is a side view of a terminal according to another embodiment. FIG. 14 is a perspective view of a terminal according to another embodiment. FIG. 15 is a front view of a terminal according to another embodiment.

[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 FIG. 1, the sensor device 10 is provided on a rotating shaft 11 that is the detection target. 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 a steering device of a vehicle. A steering wheel is connected to the steering shaft so that they can rotate together.

[0009] The sensor device 10 detects torque applied to the rotary shaft 11 through operation of the steering wheel. The sensor device 10 has 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 with alternating south and north poles in the circumferential direction. The inner peripheral surface of the permanent magnet 21 is fitted and fixed to the outer peripheral surface of the input shaft 12. The permanent magnet 21 can rotate integrally with the input shaft 12.

[0011] The magnetic yoke 22 is cylindrical and has a circular cross section. A permanent magnet 21 is inserted and maintained inside the magnetic yoke 22. The magnetic yoke 22 includes 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 a magnetic material. The first yoke 31 and the second yoke 32 are aligned along the axis O of the rotating 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 portion of the magnetic yoke 22 formed from 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 a plurality of teeth 31a. The teeth 31a are arranged at equal intervals in the circumferential direction of the first yoke 31. The second yoke 32 has a plurality of teeth 32a. The teeth 32a are arranged at equal intervals in the circumferential direction of the second yoke 32. The teeth 31a and the teeth 32a extend in opposite directions in the direction along the axis O of the rotating shaft 11. The teeth 31a and the teeth 32a are arranged alternately in the circumferential direction of the first yoke 31 and the second yoke 32. When no torsional deformation occurs in the torsion bar 13, the circumferential centers of the teeth 31a and 32a coincide with the boundary between the north pole and the south 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 electric signal corresponding to the amount of torsion 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 main body 41 and a first protrusion 42. The first housing main 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 where the first yoke 31 is provided is maintained in a state where it is axially inserted into the first insertion hole 43. The first protrusion 42 is rectangular and protrudes radially outward from the outer circumferential surface of the first housing main body 41.

[0015] A first magnetic flux collecting ring 44 is provided in the first housing main body 41. The first magnetic flux collecting ring 44 is an arc-shaped plate that curves along the inner circumferential surface of the first insertion hole 43. The inner circumferential surface of the first magnetic flux collecting ring 44 is exposed inside the first insertion hole 43. The first magnetic flux collecting ring 44 is held at a position corresponding to the first yoke 31 in the axial direction. The first magnetic flux collecting ring 44 surrounds the periphery of the first yoke 31. The first magnetic flux collecting ring 44 guides magnetic flux from the first yoke 31.

[0016] A board-in connector 45 is provided inside the first protrusion 42. A first end of the board-in connector 45 is exposed to the outside. The first end is an end of the board-in connector 45 radially opposite the first housing body 41. The board-in connector 45 holds a plurality of electric wires 46. The electric wires 46 are, for example, coated wires whose core wires are coated with an insulator. The plurality of electric wires 46 are arranged at intervals in a direction perpendicular 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-in connector 45 to the outside. The first end is connected to an external device. The external device is, for example, a steering device control device.

[0017] The first magnetic flux collecting ring 44 and the board-in connector 45 are provided integrally with the first sensor housing 40 by insert molding. Insert molding is a molding technique in which an insert part is attached to an open mold, and then the mold is closed to perform injection molding. The first magnetic flux collecting ring 44 and the board-in connector 45 are insert parts.

[0018] The second sensor housing 50 is a resin molded product. The second sensor housing 50 includes a second housing main body 51 and a second protrusion 52. The second housing main 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 slightly larger than the outer diameter of the magnetic yoke 22. The portion of the magnetic yoke 22 where the second yoke 32 is provided remains inserted in the axial direction into the second insertion hole 53. The second protrusion 52 has a rectangular plate shape and protrudes radially outward from the outer peripheral surface of the second housing main body 51. The second protrusion 52 overlaps the first protrusion 42 in the axial direction.

[0019] A second magnetic flux collecting ring 54 is provided in the second housing main body 51. Like the first magnetic flux collecting ring 44, the second magnetic flux collecting ring 54 is provided integrally with the second sensor housing 50 by insert molding. The second magnetic flux collecting ring 54 has an arc-shaped plate shape that curves along the inner circumferential surface of the second insertion hole 53. The inner circumferential 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 periphery of the second yoke 32. The second magnetic flux collecting ring 54 guides magnetic flux from the second yoke 32.

[0020] <Supplementary explanation of the detection unit 23> As shown in FIG. 2 , the first protrusion 42 has a board accommodating portion 42A. The board accommodating portion 42A is open in the axial direction. The opening of the board accommodating portion 42A is closed by the second protrusion 52. Two first magnetic flux collecting protrusions 44A are exposed inside the board accommodating portion 42A. The first magnetic flux collecting protrusions 44A are part of the first magnetic flux collecting ring 44. The first magnetic flux collecting protrusions 44A protrude outward from the peripheral wall of the first housing main body 41. Furthermore, pin portions 48A of a plurality of terminals 48 (described later) are arranged inside the board accommodating portion 42A. The terminals 48 are attached to second ends of the electric wires 47. The pin portions 48A extend in the axial direction. The plurality of pin portions 48A are aligned in a row along the long side of the board accommodating portion 42A.

[0021] A substrate 47 is accommodated within the substrate accommodation portion 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 multiple terminal connection holes 47C. The first magnetic sensor 47A and the second magnetic sensor 47B are aligned along a first long side of the substrate 47. The first magnetic sensor 47A and the second magnetic sensor 47B are configured to detect the rotation angle of the rotating shaft 11 and are, for example, Hall sensors. The rotation angle of the rotating shaft 11 is a physical quantity related to the rotational motion of the rotating shaft 11. The multiple terminal connection holes 47C are aligned in a row along a 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 figures, the second magnetic flux collecting ring 54 has two second magnetic flux collecting protrusions, similar to the first magnetic flux collecting ring 44. The second magnetic flux collecting protrusions are arranged along the surface of the second protrusion 52 facing the board accommodating portion 42A. The second magnetic flux collecting protrusions protrude outward from the peripheral wall of the second housing main body 51. The second magnetic flux collecting protrusions axially face the first magnetic flux collecting protrusion 44A. The first magnetic sensor 47A and the second magnetic sensor 47B are respectively interposed between the first magnetic flux collecting protrusion 44A and the second magnetic flux collecting protrusion. The first magnetic sensor 47A detects magnetic flux induced in the first magnetic flux collecting ring 44. The second magnetic sensor 47B detects magnetic flux induced in the second magnetic flux collecting ring 52.

[0023] When torque is applied to the input shaft 12, the torsion bar 13 undergoes torsional deformation. A relative rotational displacement occurs between the input shaft 12 and the output shaft 14 in response to the torque applied to the input shaft 12. 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 to the first magnetic flux collector ring 44 through the first yoke 31 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 to the second magnetic flux collector ring 54 through the second yoke 32 changes.

[0024] The first magnetic sensor 47A and the second magnetic sensor 47B each generate an electric signal corresponding to the magnetic flux leaking between the first magnetic flux collecting protrusion 44A of the first magnetic flux collecting ring 44 and the second magnetic flux collecting protrusion of the second magnetic flux collecting ring 54. The electric signal changes according to the torsional deformation of the torsion bar 13, i.e., the torsion angle of the torsion bar 13. For example, the steering device control device calculates the torque acting on the torsion bar 13 based on the electric signals generated by the first magnetic sensor 47A and the second magnetic sensor 47B. Torque is a physical quantity related 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 FIG. 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 electric 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 (not shown) of the electric wire 46 is drawn out to the outside of the board-in connector 45.

[0026] 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 direction of the short sides 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 and has a plurality of first guide grooves 61A. The first guide grooves 61A are arc-shaped grooves extending along the short side direction of the housing 61. The plurality of first guide grooves 61A are arranged at intervals along the long side direction of the housing 61. The first guide grooves 61A support the wires 47.

[0028] The terminal holding portion 62 has a plurality of partition walls 62A. The partition walls 62A are arranged to correspond to the first guide grooves 61A. The partition walls 62A have 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 61. The partition walls 62A form a terminal insertion portion 62B. The terminal insertion portion 62B is a rectangular parallelepiped space portion extending in the short side direction of the housing 61. The terminal insertion portion 62B is located on an extension line of the first guide grooves 61A. A gap 62C is formed between the second wall portions of two partition walls 62A adjacent to each other in the long side direction of the housing 61. The dimension of the gap 62C is 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 multiple positioning grooves 63B. The opening 63A extends in the long side direction of the housing 60. The interior of the opening 63A is in communication 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 on the side opposite the terminal holding portion 62 in the short side direction of the housing 60. The multiple positioning grooves 63B are aligned at intervals along the long side direction of the housing 60. The positioning grooves 63B are notched grooves that are open to the opening 63A and in the protruding direction of the partition wall 62A. The dimension of the positioning groove 63B in the long side direction of the housing 60 is the same as or slightly larger than the outer diameter of the pin portion 48A.

[0030] 4, the cover 70 is attached to the housing 60 from the opening 63A side. 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 a portion that covers the terminal holding portion 62 of the housing 60. The covering portion 71 is L-shaped and has a flat plate-like first portion and a flat plate-like second portion. The first portion is a portion of the covering portion 71 that covers the tip portion including the second wall portion of the terminal holding portion 62. The second portion is a portion that is perpendicular to the first portion and covers the side surface of the terminal holding portion 62 opposite 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 a first portion of the covering portion 71 in the thickness direction. The resin inlet holes 71A in the second row are provided in corners of the covering portion 71. The corners are portions where the first and second portions intersect. The resin inlet holes 71A in the second row penetrate the first and second portions 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 two side edges of the covering portion 71 that are located on opposite sides in the long side direction. The first arm portion 71B and the second arm portion 71C are flat and extend in the attachment direction of the cover 70. The first arm portion 71B and the second arm portion 71C have claw portions (not shown) at their tips.

[0034] The second wire clamping portion 72 is a portion that corresponds to the first wire clamping portion 61 of the housing 60 and is a portion that clamps the wires 46 between the second wire clamping portion 72 and the first wire clamping portion 61. The second wire clamping portion 72 has a rectangular flat plate shape. 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 arranged at positions that correspond to the first guide grooves 61A of the housing 60.

[0035] The second wire clamping portion 72 has a third arm 72B and a fourth arm 72C. The third arm 72B and the fourth arm 72C are provided on two side edges of the second wire clamping portion 72 that are located on opposite sides in the long side direction. The third arm 72B and the fourth arm 72C are flat and extend in the attachment direction of the cover 70. The third arm 72B and the fourth arm 72C have claws (not shown) at their tips.

[0036] <Configuration of Terminal 48> Next, the configuration of the terminal 48 will be described in detail. As shown in Fig. 5, the terminal 48 is formed, for example, by plastically deforming a metal plate 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 a first end of the terminal 48. The pin portion 48A is rod-shaped and is formed, for example, by plastically deforming a portion of a metal plate corresponding to the pin portion 48A into a cylindrical shape having a circular cross section.

[0038] The connection portion 48B is provided at a second end of the terminal 48. The second end is the end of the terminal 48 opposite the first end. The connection portion 48B is the portion 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 coating. The connection portion 48B and the electric wire 46 are connected by crimping a portion of the connection portion 48B so as to enclose the exposed core wire. The connection portion 48B has a flat portion. The flat portion is a flat portion of the connection portion 48B that extends from the crimped portion of the connection portion 48B along the exposed core wire.

[0039] The linking portion 48C is an intermediate portion of the terminal 48 that links the pin portion 48A and the connection portion 48B. As shown in FIG.

[0040] The connecting portion body 81 has a rectangular, flat plate shape. The short sides of the connecting portion body 81 extend along the pin portion 48A. The long sides of the connecting portion body 81 extend in a direction perpendicular to the pin portion 48A. A first end of the connecting portion body 81 in the long side direction is connected to the base end of the pin portion 48A. The pin portion 48A and the connecting portion body 81 form a first corner portion. A second end of the connecting portion body 81 in the long side direction is connected to the flat portion of the connecting portion 48B. When viewed in a direction perpendicular to the connecting portion body 81, the connecting portion body 81 is connected to the portion of the flat portion located opposite the first guide groove 51A, with the electric wire 46 supported in the first guide groove 61A. The connecting portion body 81 and the connecting portion 48B form a second corner portion.

[0041] The protruding portion 82 protrudes to the side of the connecting portion main body 81. The protruding portion 82 extends in the direction of the long sides of the connecting portion main body 81 and has a tubular shape 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 a first long side of the connecting portion main body 81. The first protruding piece 83 has a first wall portion and a second wall portion. The first wall portion is a rectangular plate-like portion. The first wall portion is perpendicular to the connecting portion main body 81. The second wall portion is a rectangular plate-like portion. The second wall portion is connected to the end of the first wall portion opposite the connecting portion main body 81. The second wall portion is parallel to the connecting portion main body 81.

[0043] The first wall portion has a protrusion 83A. The protrusion 83A is a rectangular plate. The protrusion 83A is formed by cutting and bending. That is, the protrusion 83A is formed by making cuts in the first wall portion corresponding to three sides of the protrusion 83A and bending the remaining cut portions. The bending direction is opposite to that of the second wall portion. The protrusion 83A opens on the side opposite the pin portion 48A.

[0044] The second overhanging piece 84 is provided on the second long side of the connecting portion main body 81. The length of the connecting portion main body 81 in the long side direction is shorter than the length of the first overhanging piece 83 in the long side direction. The second overhanging piece 84 has a third wall portion and a fourth wall portion. The third wall portion is a rectangular plate-like portion. The third wall portion is perpendicular to the connecting portion main body 81. The fourth wall portion is a rectangular plate-like portion. The fourth wall portion is connected to the end of the third wall portion opposite the connecting portion main body 81. The fourth wall portion is parallel to the connecting portion main body 81. The end of the fourth wall portion opposite the third wall portion is maintained in contact with the end of the second wall portion opposite the first wall portion 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 extension portion 82 has a closed loop shape. The loop shape is rectangular. The first extension piece 83 and the second extension piece 84 form a single tube. The tube has a polygonal cross-sectional shape. Note that Figure 7 shows the connection portion 48B before it is crimped.

[0046] 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-like shape. The crank shape is formed by two alternating right-angle curves. The first corner formed by the pin portion 48A and the connecting portion main body 81 and the second corner formed by the connecting portion main body 81 and the connecting portion 48B are the parts of the terminal 48 that correspond to the right-angle curves.

[0047] <Assembly Procedure of Board-In Connector 45> Next, the assembly procedure of the board-in connector 45 will be described. As shown in FIG. 4 , first, the terminals 48 are inserted into the terminal insertion portions 62B of the terminal holder 62 from the side opposite the opening 63A. The terminals 48 are inserted into the terminal insertion portions 62B until the pin portions 48A reach the end walls of the positioning grooves 63B in the insertion direction. This determines the position of the terminals 48 in the insertion direction, i.e., in the short-side direction of the housing 60. The positioning grooves 63B have two inner surfaces facing each other in the long-side direction of the housing 60. In the long-side direction of the housing 60, the pin portions 48A abut against the inner surfaces of the positioning grooves 63B, thereby restricting movement of the pin portions 48A in the long-side direction of the housing 60. This determines the position of the terminals 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 opening 63A side.

[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 is maintained in a state attached to the housing 60. This completes the assembly of the board-in connector 45.

[0049] <Assembled State of Board-in Connector 45> Next, the assembled state of the board-in connector 45 will be described. As shown in Fig. 3, when the cover 70 is attached to 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 attachment 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 via the resin inlet hole 71A of the cover 70.

[0050] When the cover 70 is attached to the housing 60, the second wire clamping portion 72 is maintained overlapping the first wire clamping portion 61 in the attachment 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 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] <Method of Manufacturing First Sensor Housing 40> Next, a method of manufacturing the first sensor housing 40 will be described. First, the first magnetic flux collecting ring 44 and the board-in connector 45, which are insert parts, are set in an open mold. The board-in connector 45 holds the electric wires 46. The mold is then closed and injection molding is performed. With the mold 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.

[0052] Next, molten resin is injected into the cavity. The molten resin is a synthetic resin that has been heated and melted. Inside the mold, the first magnetic flux collector ring 44 is enveloped in the molten resin, except for its inner circumferential surface. The board-in connector 45 is enveloped 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 71A of the cover 70.

[0053] After the cavity is filled with the molten resin, the molten resin is cooled and solidified. The mold is then opened, and the first sensor housing 40, which is a resin molded product, is removed. This results in the first sensor housing 40 shown in FIG. 2, i.e., the first sensor housing 40 with the first magnetic flux collecting ring 44 and the board-in connector 45 embedded therein.

[0054] This completes the manufacturing of the first sensor housing 40. After the first sensor housing 40 is removed from the mold, as shown in Fig. 8, the pins 48A are inserted into the terminal connection holes 47C of the substrate 47. The pins 48A are joined to the substrate 47 with solder 47D. The pins 48A and the pattern wiring of the substrate 47 are electrically connected.

[0055] <Internal Condition of Board-in Connector 45> The internal condition of the board-in connector 45 is as follows. As shown in FIG. 8 , inside the board-in connector 45, the periphery of 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. The gap between the connecting portion 48C and the partition wall 62A (see FIG. 4 ) is also filled with synthetic resin. The gap 62C (see FIG. 4 ) between two adjacent partition walls 62A along the long side of the housing 61 is also filled with synthetic resin. The protrusion 83A is embedded in the synthetic resin in the opposite direction to the insertion direction of the terminal 48 into the terminal insertion portion 62B. The periphery of the connecting portion 48C is completely filled with resin, so that the terminal 48 is held inside the terminal insertion portion 62B. 8 shows the board-in connector 45 and the synthetic resin and other components filled inside the board-in connector 45, with the synthetic resin portion 40A covering at least the periphery of the connecting portion 48C of the terminal 48, which is a part of the first sensor housing 40 and corresponds to a resin member.

[0056] 9, the terminal 48 and the synthetic resin part 40A covering at least the periphery of the connecting portion 48C of the terminal 48 constitute an insert-molded product 90. Fig. 9 shows the terminal 48 and the synthetic resin covering at least the periphery of the connecting portion 48C of the terminal 48 in a state where they are temporarily extracted.

[0057] 10 , in a first area S1, each terminal 48 is covered with synthetic resin. The first area S1 is a rectangular parallelepiped area that includes the opening 63A of the exposed portion 63 and the terminal holding portion 62. In a second area S2, each pin portion 48A is connected to the substrate 47. The second area is a rectangular area that includes each terminal connection hole 47 of the substrate 47.

[0058] <Operations of the embodiment> The present embodiment provides the following operations. When, for example, the sensor device 10 is assembled to a steering device, or when the steering device is assembled to a vehicle, an external force may be applied to the electric wire 46 due to the operation of connecting the electric wire 46. The external force includes a tensile force. The tensile force is a force in a direction that pulls the electric wire 46 out of the board-in connector 45. The pull-out direction of the electric wire 46 is opposite to the insertion direction of the terminal 48 into the terminal insertion portion 62B. When a tensile force is applied to the electric wire 46, the portion of the terminal 48 facing the pull-out direction engages with the synthetic resin that covers the periphery of the terminal 48. In particular, the protruding portion 82 protrudes laterally from the connecting portion main body 81, and therefore is easily engaged with the synthetic resin.

[0059] As indicated by numerous dots in Figure 11, the terminal 48 engages with the synthetic resin surrounding it in a projection area S3 obtained by projecting the terminal 48 from the direction opposite to the pull-out direction. In the pull-out direction of the electric wire 46, the synthetic resin surrounding the terminal 48 receives pressure corresponding to the tensile force via the projection area S3 of the terminal 48. The projection area S3 is an area that includes the connecting portion 48C. Therefore, the area of ​​the projection area S3 is larger by the area of ​​the end face of the protrusion 80 than when a configuration is adopted in which the protrusion 80 is omitted as the connecting portion 48C.

[0060] Therefore, the tensile force is effectively received by the synthetic resin covering the periphery of the terminal 48 via the projection area S3 of the terminal 48. That is, the tensile force is effectively transmitted to the synthetic resin covering the periphery of the terminal 48 via the projection area S3 of the terminal 48 and then released. Therefore, the tensile force is prevented from being directly transmitted to the connection portion between the pin portion 48A and the substrate 47. This prevents the tensile force from affecting the connection portion between the pin portion 48A and the substrate 47. For example, since the tensile force is less likely to be transmitted to the pin portion 48A, stress generated at the connection portion between the pin portion 48A and the substrate 47 is reduced. Furthermore, change in the position of the pin portion 48A relative to the substrate 47 is also reduced.

[0061] Effects of the Embodiment This embodiment provides the following effects. (1) The connecting portion 48C of the terminal 48 has a protruding portion 82 that protrudes laterally from the connecting portion main body 81. The periphery of the connecting portion 48C is covered with synthetic resin. Therefore, when a tensile force is applied to the electric wire 46, the portion of the terminal 48 facing the direction in which the electric wire 46 is pulled out engages with the synthetic resin that surrounds the terminal 48. In particular, because the protruding portion 82 protrudes laterally from the connecting portion main body 81, it easily engages with the synthetic resin. Furthermore, the portion of the terminal 48 that engages with the synthetic resin is a projected area S3 obtained by projecting the terminal 48 from the direction opposite the pull-out direction. The area of ​​the projected area S3 is increased by the amount of the protruding portion 80. Therefore, the tensile force is preferably received by the synthetic resin that surrounds the terminal 48 via the projected area S3 of the terminal 48. By suppressing the direct transmission of tensile force to the connection portion between the pin portion 48A and the substrate 47, the tensile force is prevented from affecting the connection portion between the pin portion 48A and the substrate 47. Furthermore, the resistance of the electric wire 46 to pulling is improved.

[0062] (2) When viewed from the direction from the connecting portion 48B toward the pin portion 48A, the protruding portion 80 has a closed loop shape. This allows molten resin to easily enter the connecting portion 80 during manufacturing of the first sensor housing 40. This also contributes to increasing the projection area S3 of the terminal 48.

[0063] (3) The connecting portion 48C has a connecting portion main body 81 that connects the pin portion 48A and the connecting portion 48B. The connecting portion main body 81 is plate-shaped and has a first long side extending in a direction from the connecting portion 48B toward the pin portion 48A and a second long side parallel to the first long side. The overhang portion 82 has a first overhang piece 83 provided on the first long side and a second overhang piece 84 provided on the second long side. The first overhang piece 83 and the second overhang piece 84 are arranged to form a single tube. Therefore, the cylindrical overhang portion 82 can be easily formed from the first overhang piece 83 and the second overhang piece 84.

[0064] (4) The terminal 48 is formed by plastically deforming a single metal plate. The protruding portion 82 is formed by plastically deforming portions of the metal plate corresponding to the first protruding piece 83 and the second protruding piece 84. Therefore, the terminal 48, including the protruding portion 82, can be easily produced.

[0065] (5) The opening 63A of the housing 61 and each terminal insertion portion 62B are tightly filled with synthetic resin, which prevents dust and other particles from entering the board-in connector 45. This improves the dustproofness of the board-in connector 45.

[0066] Other Embodiments This embodiment may be modified as follows. As shown in Fig. 12, the protruding portion 80 may have only a first protruding piece 83. The second wall portion of the first protruding piece 83 may be provided by extending slightly in the opposite direction to the protrusion 83A. The second wall portion is the wall portion of the first protruding piece 83 that is parallel to the connecting portion main body 81.

[0067] 13 , the protruding portion 80 may have only a first protruding piece 83. The first protruding piece 83 may have only a first wall portion. The first wall portion is a wall portion of the first protruding piece 83 that is perpendicular to the connecting portion main body 81.

[0068] 14, the protruding portion 80 may have only a first protruding piece 83. The second wall portion of the first protruding piece 83 may be provided at the end of the first wall portion opposite the pin portion 48A.

[0069] 12 and 13, the protruding portion 80 may have only the second protruding piece 84. As shown in FIG. 15, the pin portion 48A may be a press-fit terminal. A press-fit terminal is a terminal that can be connected to the board 47 simply by being press-fitted into the terminal connection hole 47C of the board 47. The press-fit terminal is held in the terminal connection hole 47C by a restoring force generated by elastic deformation during press-fitting. In this way, soldering is not required.

[0070] 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 main gear is integrally rotatably mounted on the outer circumferential surface of the rotating shaft 11. Two driven gears are rotatably supported in the board accommodating portion 42A of the first sensor housing 40. The driven gears have different numbers of teeth. A sensor that generates an electrical signal corresponding to the rotation angle of each driven gear is provided on the board 47. The driven gears mesh with the main gear through openings provided in a portion of the first sensor housing 40 between the board accommodating portion 42A and the first insertion hole 43. Therefore, the two driven gears rotate in conjunction with the rotation of the main gear. Because the two driven gears have different numbers of teeth, the rotation angles of the two driven gears relative to the rotation angle of the main gear are different. Therefore, the phases of the electrical signals generated by the first sensor and the second sensor are different from each other. For example, the control device for the steering device detects the rotation angle of the rotary shaft 11 based on the electrical signals generated by the first sensor and the second sensor.

[0071] As used herein, the term "cylinder" or "cylindrical" may refer to any structure having a peripheral wall. For example, but not limited to, the terms "cylinder" or "cylindrical" may refer to any structure having a cross-sectional shape that is circular, oval, and polygonal with sharp or rounded corners.

Claims

1. An insert molding product having a terminal configured to be connected to a substrate and a resin member covering a portion of the terminal, the terminal has a pin portion configured to be connected to the board, a connection portion configured to be connected to an electric wire, and a coupling portion coupling the pin portion and the connection portion, the coupling portion has a protruding portion protruding laterally in a direction perpendicular to a direction from the connection portion toward the pin portion, the resin member covers at least the connecting portion of the terminal, When viewed in a direction from the connection portion toward the pin portion, the protrusion portion has a closed loop shape, the coupling portion has a coupling portion main body that couples the pin portion and the connection portion, the coupling portion body has a plate shape having a first long side extending in a direction from the connection portion toward the pin portion and a second long side parallel to the first long side, the protruding portion has a first protruding piece provided on the first long side and a second protruding piece provided on the second long side, An insert molded product, wherein the first protruding piece and the second protruding piece are arranged to form a single tube.

2. The terminal is formed by plastically deforming a single metal plate material, The insert molded product according to claim 1 , wherein the protruding portion is formed by plastically deforming a portion of the metal plate material corresponding to the first protruding piece and the second protruding piece.

3. A sensor device comprising the insert molding according to claim 1 or 2.

4. (delete)

5. (delete)

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