CN116067546A - Electrical device - Google Patents

Abstract

The invention provides an electrical device capable of improving electrical connectivity between a substrate and a terminal. An electrical device (1) is provided with: a substrate (2); a terminal (3) that is bonded to the substrate (2); a housing (5) which houses the substrate (2) and the terminals (3) and is provided with a window (512 a) for exposing the joint between the substrate (2) and the terminals (3); a cover member (6) that closes off the window (512 a); and a molding resin (8) that covers the housing (5) and the cover member (6).

Description

Electrical device

Technical Field

The present invention relates to an electrical device.

Background

Patent document 1 discloses a torque detection device for detecting torque applied to a torsion bar of an electric power steering apparatus. The torque detection device described in patent document 1 includes: a magnetic detection element; a sensor housing that houses the magnetic detection element; a circuit board mounted in a housing recess provided in the sensor housing; a terminal soldered to the circuit board; and a waterproof coating material which is made of epoxy resin, is filled in the accommodating concave part of the sensor shell, and coats the circuit substrate and the terminals.

Prior art literature

Patent literature

Patent document 1: japanese patent laid-open No. 2020-134440

Disclosure of Invention

Problems to be solved by the invention

In the torque detection device described in patent document 1, since the soldered portion between the circuit board and the terminal is directly covered with the covering material, stress is generated in the joint portion between the circuit board and the terminal, and there is a concern that the electrical connectivity between the circuit board and the terminal is lowered.

The present invention has been made in view of the above circumstances, and an object thereof is to provide an electrical device capable of improving electrical connectivity between a substrate and a terminal.

Means for solving the problems

In order to achieve the above object, the present invention provides an electrical device including: a substrate; a terminal bonded to the substrate; a housing that houses the substrate and the terminals and that has a window portion that exposes a joint portion between the substrate and the terminals; a cover member that closes the window; and a molding resin covering the housing and the cover member.

The effects of the invention are as follows.

According to the present invention, an electrical device capable of improving electrical connectivity between a substrate and a terminal can be provided.

Drawings

Fig. 1 is a perspective view of a magnetostrictive torque sensor in an embodiment as seen from an obliquely upper side.

Fig. 2 is a perspective view of the magnetostrictive torque sensor in the embodiment as seen from the obliquely lower side.

Fig. 3 is an enlarged cross-sectional view of a portion of the magnetostrictive torque sensor in the embodiment on the opposite side of the cable.

Fig. 4 is an enlarged cross-sectional view of a portion on the cable side of the magnetostrictive torque sensor according to the embodiment.

Fig. 5 is a perspective view of the magnetostrictive torque sensor after removing the molding resin and the heat shrinkable tube in the embodiment as seen from the obliquely upper side.

Fig. 6 is a perspective view of the magnetostrictive torque sensor after removing the molding resin in the embodiment as seen from the obliquely lower side.

Fig. 7 is a perspective view of the substrate, the terminal, the cable, and the first housing member in the embodiment, as viewed from the obliquely upper side.

Fig. 8 is a plan view of the substrate, the terminals, the cables, and the first housing member in the embodiment.

Fig. 9 is an enlarged bottom view of the vicinity of the window of the first housing member, the substrate, the terminals, and the cables in the embodiment.

Fig. 10 is an exploded perspective view of the substrate, the terminal, the cable, and the first housing member in the embodiment as seen from the obliquely upper side.

Fig. 11 is a perspective view of the second housing member and the magnetic ring in the embodiment as seen from the obliquely upper side.

Fig. 12 is a perspective view of the second housing member and the magnetic ring in the embodiment as seen from the obliquely lower side L.

Fig. 13 is a schematic view for explaining a positional relationship between the fitting recess of the second housing member and the insertion hole of the substrate in the embodiment.

Fig. 14 is a view of a cross section of the periphery of the cover member of the magnetostrictive torque sensor after removing the molding resin in the embodiment as seen from an oblique direction.

Fig. 15 is a cross-sectional view of the magnetostrictive torque sensor according to the embodiment, from which the molded resin is removed, through a joint portion between the terminal and the substrate.

Fig. 16 is a perspective view of the cover member in the embodiment, as seen from the obliquely lower side.

Fig. 17 is a perspective view of the cover member in the embodiment, as seen from the obliquely upper side.

Fig. 18 is a plan view of the cover member in the embodiment.

Fig. 19 is a cross-sectional view showing a state in which a magnetostrictive torque sensor before the molding resin and the heat shrinkable tube are provided is arranged in a metal mold that molds the resin in the embodiment.

Fig. 20 is a cross-sectional view showing a state after resin constituting the molding resin is injected into a metal mold for molding the resin in the embodiment.

Symbol description

1-electric device, 10-magnetostrictive torque sensor, 11-solder (joint), 2-substrate, 221-terminal hole, 222-insertion hole, 222 a-inner peripheral surface, 3-terminal, 5-housing, 51-first housing member, 512 a-window portion, 512 e-frame portion, 52-second housing member, 522-support portion, 523-fitting recess portion, 523 a-inner peripheral surface, 6-cover member, 612 a-tip receiving recess portion, 612 b-ridge portion, 614-protrusion portion, 615-holding portion, 8-molded resin, 81-first opening portion.

Detailed Description

Embodiment(s)

An embodiment of the present invention will be described with reference to fig. 1 to 20. The embodiments described below are described as specific examples preferable in carrying out the present invention, and there are also portions specifically illustrating various technical matters preferable in terms of technology, but the technical scope of the present invention is not limited to the specific embodiments.

(magnetostrictive torque sensor 10)

Fig. 1 is a perspective view of the magnetostrictive torque sensor 10 as seen from the obliquely upper side U. Fig. 2 is a perspective view of the magnetostrictive torque sensor 10 as seen from the obliquely lower side L. Fig. 3 is an enlarged cross-sectional view of a portion of magnetostrictive torque sensor 10 opposite cable 4. Fig. 4 is an enlarged cross-sectional view of a portion of magnetostrictive torque sensor 10 on the cable 4 side.

The present embodiment is a system in which the electric device 1 is a magnetostrictive torque sensor 10. The electric device 1 may be a structure in which the substrate 2 is bonded to the terminal 3 and covered with the case 5, the cover member 6, and the mold resin 8, or may be a device other than the magnetostrictive torque sensor 10. For example, the electric device 1 may be a sensor device other than the magnetostrictive torque sensor 10, a relay device that relays electrical connection between a plurality of cables, or the like.

The magnetostrictive torque sensor 10 of the present embodiment is used to measure torque applied to a magnetostrictive material 100 (see fig. 3) having magnetostrictive characteristics. Magnetostriction is a phenomenon in which a ferromagnetic material is strained (strain) when a magnetic field is applied to the ferromagnetic material to magnetize the ferromagnetic material. The magnetostrictive torque sensor 10 conversely uses this phenomenon to detect the magnetic field generated by the strain of the magnetostrictive material 100 with a detection coil, thereby detecting the torque acting on the magnetostrictive material 100. The magnetostrictive torque sensor 10 can be used as a vehicle-mounted member, for example, and the magnetostrictive material 100 to be a measurement target of torque can be used as a predetermined rotating shaft for a vehicle, for example.

The magnetostrictive torque sensor 10 includes a substrate 2, a terminal 3, a cable 4, a housing 5, a cover member 6, a magnetic ring 7, a molded resin 8, and a heat shrinkable tube 9. The substrate 2 has a detection coil, not shown, for detecting an electric signal corresponding to the magnitude of torque applied to the magnetostrictive material 100. As shown in fig. 4, one end of the terminal 3 is bonded to the substrate 2, and the other end is bonded to the cable 4. The cable 4 transmits the output result of the detection coil to an external control device or the like, not shown. The housing 5 is formed by combining a first housing member 51 and a second housing member 52, and accommodates the board 2, the terminals 3, and the cables 4. The cover member 6 closes the window 512a formed in the first housing member 51. As shown in fig. 3, the magnetic ring 7 is provided so as to surround the substrate 2 from the outer peripheral side, and serves to suppress the leakage of the magnetic flux generated by the detection coil of the substrate 2 to the outside, thereby reducing the accuracy of measuring the torque of the magnetostrictive torque sensor 10. As shown in fig. 1 to 4, the molding resin 8 is molded so as to cover the housing 5 and the cover member 6. The heat shrinkable tube 9 seals between the cable 4 and the housing 5 and the molded resin 8. The detailed structure of each part of the magnetostrictive torque sensor 10 will be described below.

Hereinafter, the axial direction of the magnetostrictive material 100 is referred to as a rotation axis direction Z, the longitudinal direction of the cable 4 is referred to as a cable longitudinal direction X, and the directions orthogonal to both the rotation axis direction Z and the cable longitudinal direction X are referred to as a width direction Y.

Fig. 5 is a perspective view of the magnetostrictive torque sensor 10 after removing the molding resin 8 and the heat shrinkable tube 9, as seen from the obliquely upper side U. Fig. 6 is a perspective view of the magnetostrictive torque sensor 10 after removing the molding resin 8, as seen from the obliquely lower side L. Fig. 7 is a perspective view of the substrate 2, the terminals 3, the cables 4, and the first housing member 51, as viewed from the obliquely upper side U. Fig. 8 is a plan view of the substrate 2, the terminals 3, the cables 4, and the first housing member 51. Fig. 9 is an enlarged bottom view of the vicinity of the window 512a of the first housing member 51, the substrate 2, the terminals 3, and the cables 4. Fig. 10 is an exploded perspective view of the substrate 2, the terminals 3, the cables 4, and the first housing member 51 as seen from the obliquely upper side U.

The substrate 2 is constituted by a flexible printed circuit board (FPC: flexible Printed Circuits) having flexibility. The substrate 2 is configured by, for example, overlapping a plurality of wiring layers. As shown in fig. 10, the substrate 2 includes: a substrate cylinder portion 21 that is bent into a cylindrical shape so as to surround the magnetostrictive material 100; a substrate flat portion 22 formed in a flat shape substantially perpendicular to the substrate cylindrical portion 21; and a substrate connection portion 23 that is bent so as to connect the substrate cylindrical portion 21 and the substrate planar portion 22.

A detection coil for outputting an electric signal corresponding to the magnitude of torque applied to the magnetostrictive material 100 is pattern-formed in the substrate cylinder portion 21. The detection coils of the normal magnetostrictive torque sensor 10 can be configured in the shape, number, and the like.

The substrate plane portion 22 is formed with a wiring pattern, not shown, for electrically connecting the detection coil to the plurality of terminals 3. Six terminal holes 221 for inserting the plurality of terminals 3 and one insertion hole 222 for inserting a projection 614 described below of the cover member 6 are provided in the substrate planar portion 22.

The six terminal holes 221 are formed in a U-shape so as to surround the insertion hole 222. That is, a pair of terminal holes 221 aligned in the width direction Y are formed in three portions of the substrate planar portion 22 in the cable longitudinal direction X, and the pair of terminal holes 221 located on the farthest side from the substrate connecting portion 23 are spaced at a narrower distance from each other than the other two pairs of terminal holes 221.

The insertion hole 222 is formed in a shape capable of being inserted into a projection 614 of the cover member 6, which will be described later, and is formed in a substantially rectangular shape longer in the cable longitudinal direction X in the present embodiment. In order to suppress generation of dead space in the substrate planar portion 22, the insertion holes 222 are formed to pass between the terminal holes 221 arranged in the width direction Y among the plurality of terminal holes 221. In this embodiment, the insertion hole 222 is formed so as to pass between two terminal holes 221 arranged in the Y direction on the side closest to the substrate connection portion 23 among the six terminal holes 221 and between two terminal holes 221 adjacent to the two terminal holes 221 in the cable longitudinal direction X.

As shown in fig. 8 and 10, a pair of locking recesses 223 are provided at both ends of the substrate planar portion 22 in the width direction Y. The pair of locking recesses 223 are located on the outer sides in the width direction Y of the pair of terminal holes 221 on the side farthest from the substrate connection portion 23. The locking convex portion 512b provided in the first housing member 51 is inserted into the locking concave portion 223, and the locking concave portion 223 is locked to the locking convex portion 512b. Four terminals 3 are connected to the substrate planar portion 22.

As shown in fig. 7 and 8, the four terminals 3 are connected to mutually different electric wires 41 of the cable 4, and the other end side is inserted into the terminal hole 221 of the substrate planar portion 22. The four terminals 3 are arranged in the width direction Y, and the two terminals 3 at the center in the width direction Y have substantially the same shape as each other, and the two terminals 3 at both ends in the width direction Y have substantially symmetrical shapes in the width direction Y. The two terminals 3 at the center in the width direction Y are inserted into a pair of terminal holes 221 located on the side away from the substrate connecting portion 23. The two terminals 3 at both ends in the width direction Y are branched into two on the opposite side to the cable 4, respectively, and are inserted into the two terminal holes 221. The terminal 3 arranged at one end portion in the width direction Y of the four terminals 3 is inserted into the two terminal holes 221 located at one side of the insertion hole 222, and the terminal 3 arranged at the other end portion in the width direction Y of the four terminals 3 is inserted into the two terminal holes 221 located at the other side of the insertion hole 222.

The four terminals 3 are inserted into the six terminal holes 221 in such a direction that the front ends thereof protrude toward the window 512a side. Then, the terminals 3 protruding from the six terminal holes 221 are joined to the substrate planar portion 22 by soldering from the window portion 512a side. That is, the joint portion between the substrate flat portion 22 and the terminal 3 (in this embodiment, the solder 11 shown in fig. 13 and 15 described below) is provided on the window portion 512a side of the substrate flat portion 22. Fig. 9 shows a state before the solder is set. The four terminals 3 are formed integrally with each other by the integration resin 12. The integrated resin 12 is formed in a substantially rectangular columnar shape long in the width direction Y, and holds the four terminals 3 at predetermined intervals. The side of the four terminals 3 opposite to the side connected to the substrate planar portion 22 is connected to the mutually different electric wires 41 of the cable 4.

The cable 4 has four wires 41 and a sheath 42 surrounding the four wires 41. Each of the wires 41 is a covered wire having a core wire and a covering portion. The sheath 42 is formed by forming a resin or the like having electrical insulation into a cylindrical shape. Four wires 41 of the cable 4 are accommodated in the housing 5, and the sheath 42 is disposed at a position apart from the housing 5 and the mold resin 8 outside the housing 5 and the mold resin 8. The substrate 2, the four terminals 3, the integrated resin 12, and the cable 4 are assembled to the first housing member 51.

In this embodiment, the first case member 51, the second case member 52, the cover member 6, and the molding resin 8 can each be made of the same resin, for example, PPS (polyphenylene sulfide) or the like. Further, the first case member 51, the second case member 52, the cover member 6, and the molding resin 8 may not all be composed of the same resin.

As shown in fig. 10, the first housing member 51 includes a cylindrical portion 511 formed in a substantially cylindrical shape and an extension portion 512 extending from the cylindrical portion 511 toward the cable 4 side in the cable longitudinal direction X. In the present specification, one side in the rotation axis direction Z on which the cylindrical portion 511 of the first housing member 51 protrudes (the upper side in fig. 1 and 5) is referred to as an upper side U, and the opposite side is referred to as a lower side L. The vertical posture of the magnetostrictive torque sensor 10 in the use state is not limited to the vertical posture.

As shown in fig. 3, the cylindrical portion 511 is disposed so as to surround the magnetostrictive material 100, and the substrate cylindrical portion 21 is fixed to the outer peripheral surface thereof by using an adhesive material, not shown. As shown in fig. 10, the extension portion 512 extends from the lower end of the cylindrical portion 511 toward the cable 4 side.

As shown in fig. 7, 8 and 10, a substrate placement recess 512c in which the substrate planar portion 22 is placed and a cable placement recess 512d in which the plurality of wires 41 of the cable 4 are placed are formed in the upper side U of the extension portion 512. The substrate placement recess 512c and the cable placement recess 512d are recesses that are open at least at the upper side U, and communicate with each other.

The substrate placement recess 512c is located on a side closer to the cylindrical portion 511 than the cable placement recess 512d. As shown in fig. 8 and 9, a window portion 512a is formed so as to penetrate the bottom wall of the substrate placement recess 512c in the rotation axis direction Z. The window 512a is formed at a position facing the substrate planar portion 22. As shown in fig. 9, the window 512a exposes the tip of the terminal 3 protruding from the substrate planar portion 22 from the first housing member 51. In fig. 9, the outer shape positions of the projection 614, the clamp 615, and the tip accommodating recess 612a of the cover member 6, which will be described below, are projected on the substrate plane portion 22 in the rotation axis direction Z are indicated by two-dot chain lines. Fig. 9 shows a state before solder (see symbol 11 in fig. 13 and 15 described below) for bonding the terminal 3 to the substrate 2 is provided.

The window 512a is provided to enable bonding between the substrate 2 and the terminals 3 after the substrate 2 and the terminals 3 are assembled to the first housing member 51. As shown in fig. 8, the window portion 512a is formed in a rectangular shape smaller than the substrate flat portion 22 by one turn, and the peripheral edge of the substrate flat portion 22 is placed around the window portion 512a in the bottom wall of the substrate placement recess 512 c.

As shown in fig. 6 and 9, a frame portion 512e protruding downward L from the periphery of the window portion 512a is formed in the first housing member 51. As shown in fig. 9, the frame portion 512e is formed in a rectangular ring shape so as to surround the window portion 512a at a position apart from the window portion 512a. The cover member 6 is fitted inside the frame portion 512e, which will be described in detail below.

As shown in fig. 7, 8 and 10, three wire dividing walls 512f that divide the four wires 41 from each other and are long in the cable longitudinal direction X are provided in the cable placement recess 512d. A resin placement recess 512g in which the integrated resin 12 is placed is formed between the cable placement recess 512d and the substrate placement recess 512 c. The resin placement recess 512g is partitioned by at least one end of the three electric wire partition walls 512f. The resin placement recess 512g is also divided by an integrated resin dividing wall 512h, and the integrated resin dividing wall 512h is provided to face the wire dividing wall 512f located at the center among the three wire dividing walls 512f via the integrated resin 12. The substrate placement recess 512c, the cable placement recess 512d, and the resin placement recess 512g are covered with the second case member 52.

As shown in fig. 5 and 6, the second housing member 52 is formed along the extension portion 512 of the first housing member 51. The second housing member 52 has a pair of flexible pieces 521 extending downward L, and the first housing member 51 is snap-fitted by the pair of flexible pieces 521.

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

As shown in fig. 12, the second housing member 52 is formed in a concave shape that opens at least at the lower side L. The second housing member 52 has a support portion 522 that protrudes from the bottom wall of the second housing member 52 toward the lower side L and supports the substrate planar portion 22 from the lower side L. The support portion 522 is formed in a substantially rectangular shape, and has a fitting recess 523 into which a projection 614 described below of the cover member 6 is inserted and a terminal insertion recess 524 into which a plurality of terminals 3 are inserted so as to be opened at the lower side. Further, as shown in fig. 4, the lower surface of the support portion 522 supports the substrate planar portion 22.

Fig. 13 is a schematic view for explaining the positional relationship between the fitting recess 523 of the second housing member 52 and the insertion hole 222, and is a view of the state in which the cover member 6 is removed from the housing 5 as seen from the lower side L. At least a part of the inner peripheral surface 523a of the fitting recess 523 is located on the inner peripheral side from the inner peripheral surface 222a of the insertion hole 222. In this embodiment, the fitting recess 523 is formed shorter than the insertion hole 222 in the cable longitudinal direction X, and a pair of side surfaces 523b of the inner peripheral surface 523a of the fitting recess 523, which are opposed to each other in the cable longitudinal direction X, are positioned inside the inner peripheral surface 222a of the insertion hole 222. For example, at least a part of one surface of the inner peripheral surface 523a constituting the fitting recess 523 may be disposed on the inner peripheral side with respect to the inner peripheral surface 222a of the insertion hole 222, or the inner peripheral surface 523a of the fitting recess 523 may be disposed entirely on the inner peripheral side with respect to the inner peripheral surface 222a of the insertion hole 222.

As shown in fig. 11 and 12, the second housing member 52 is formed integrally with the magnetic ring 7. As shown in fig. 4 and 11, a drop preventing protrusion 525 protruding toward the upper side U is provided at an end portion of the second case member 52 on a side closer to the magnetic ring 7. As shown in fig. 4, the drop-preventing protrusion 525 is disposed so as to fill the drop-preventing recess 712 provided on the lower surface of the magnetic ring 7. At the time of molding the second housing member 52, the resin constituting the second housing member 52 enters the drop-preventing concave portion 712, and the drop-preventing convex portion 525 is formed in the same shape as the space in the drop-preventing concave portion 712, and the second housing member 52 and the magnetic ring 7 are formed integrally. In this embodiment, the inner peripheral surface of the drop-preventing concave portion 712 is formed in a screw groove shape, and the outer peripheral surface of the drop-preventing convex portion 525 is formed in a screw thread shape. The inner peripheral surface of the drop-preventing concave portion 712 and the outer peripheral surface of the drop-preventing convex portion 525 may have other concave-convex shapes as long as the drop-preventing is established. The detailed structure of the magnetic ring 7 is explained hereinafter.

The cover member 6 is provided so as to close the window portion 512a from the lower side L. Fig. 14 is a view of a cross section of the periphery of the cover member 6 of the magnetostrictive torque sensor 10 after removing the molding resin 8, as seen from an oblique direction. Fig. 15 is a cross-sectional view of the magnetostrictive torque sensor 10 through the junction of the terminal 3 and the substrate 2, with the mold resin 8 removed. Fig. 16 is a perspective view of the cover member 6 as seen from the obliquely lower side L. Fig. 17 is a perspective view of the cover member 6 as seen from the obliquely upper side U. Fig. 18 is a plan view of the cover member 6.

The cover member 6 has a cover main body 61 having a substantially rectangular plate shape and three engaging pieces 62 provided upright from the cover main body 61 to the upper side U. As shown in fig. 17 and 18, the cover main body 61 includes a first step portion 611 protruding upward U and a second step portion 612 protruding further upward U from a central portion of the first step portion 611. The first step 611 is formed to be looped inward from the outer edge 613 of the cover body 61. As shown in fig. 14 and 15, the outer edge portion 613 of the cover main body 61 is placed on the lower surface of the frame portion 512e of the first housing member 51. The first step 611 is fitted inside the frame 512e. The first step 611 is fitted inside the frame 512e in a clearance fit.

The upper surface of the second step portion 612 faces the substrate planar portion 22 via a gap. As shown in fig. 15, 17 and 18, six front end receiving recesses 612a for receiving six front ends of the terminals 3 are formed in the second step portion 612. Six front end receiving recesses 612a are formed at positions overlapping with the six terminal holes 221 in the rotation axis direction Z. In this embodiment, a part of the solder 11 is also accommodated in the tip accommodation recess 612a. A protruding portion 612b protruding downward L is provided on the lower surface of the cover main body 61. The ridge portion 612b is formed at a position overlapping the tip receiving recess 612a in the thickness direction (i.e., the rotation axis direction Z) of the cover main body 61. As shown in fig. 18, the ridge portion 612b is formed in a U-shape so as to overlap all of the front end accommodating recess portions 612a arranged in the U-shape in the rotation axis direction Z.

As shown in fig. 17 and 18, the cover main body 61 includes a protruding portion 614 protruding further upward U from the second step portion 612, and a holding portion 615. The protruding portion 614 is formed to protrude further toward the upper side U than the clamp portion 615. The protruding portion 614 is formed in a plate shape that is long in the cable longitudinal direction X and has a thickness in the width direction Y. The length direction of the protruding portion 614 coincides with the length direction of the cover member 6. The protruding portion 614 is formed in the substantially center of the cover main body 61. As shown in fig. 14, the protruding portion 614 is inserted into the insertion hole 222 of the substrate planar portion 22 and the fitting recess 523 of the second housing member 52. The protruding portion 614 is fitted in the fitting recess 523 in a clearance fit. The end surface of the upper side U of the protruding portion 614 is closely opposed to or in contact with the bottom surface of the fitting recess 523.

As shown in fig. 15, the clamp portion 615 has the function of sandwiching the substrate flat portion 22 with the support portion 522 of the second case member 52 and the function of reinforcing the cover member 6. As shown in fig. 17 and 18, the clamp portion 615 includes: a vertical portion 615a extending from the protruding portion 614 toward the cable 4 side in the cable longitudinal direction X; a pair of first cross portions 615b extending from the protruding portion 614 to both sides in the width direction Y; a pair of second lateral portions 615c extending from the end of the vertical portion 615a on the projecting portion 614 side to both sides in the width direction Y; and a pair of third lateral portions 615d extending from an end portion of the longitudinal portion 615a on the opposite side to the protruding portion 614 to both sides in the width direction Y. The vertical portion 615a is formed so as to pass between two front end accommodating concave portions 612a located on the side closest to the cable 4 among the six front end accommodating concave portions 612a. The first lateral portion 615b and the second lateral portion 615c are formed so as to pass between the front end accommodating concave portions 612a adjacent to each other in the cable longitudinal direction X. That is, the protruding portion 614, the vertical portion 615a, the first lateral portion 615b, and the second lateral portion 615c are formed so as to divide the six front end accommodating recesses 612a from each other. The third lateral portion 615d is formed such that an end edge of the second step portion 612 on the cable 4 side bulges upward U in the entire width direction Y.

The catch piece 62 is formed to extend from the second step portion 612 to the upper side U. The snap piece 62 has flexibility in the cable length direction X, and is fixed to the first housing member 51 by snap fitting. As shown in fig. 14, one of the snap pieces 62 is snapped onto the upper surface of the integrated resin partition wall 512 h.

As shown in fig. 3, the magnetic ring 7 is formed so as to face the cylindrical portion 511 of the first housing member 51 through the substrate cylindrical portion 21 of the substrate 2. The magnetic ring 7 is formed by forming a ferromagnetic material (soft magnetic material) made of a metal (including an alloy) such as iron into a substantially cylindrical shape. The magnetic ring 7 has the following function: the detection coil is covered from the outer peripheral side to suppress the leakage of the magnetic flux generated by the detection coil to the outside, thereby reducing the measurement accuracy of the torque of the magnetostrictive torque sensor 10.

As shown in fig. 3 and 11, the magnetic ring 7 has a large diameter portion 71 at a lower end portion, and a small diameter portion 72 having an outer diameter smaller than that of the large diameter portion 71 at a position above the large diameter portion 71 by U. An annular recess 711 recessed toward the upper side U and inside which the second housing member 52 is disposed is formed on the lower surface of the large diameter portion 71. As shown in fig. 3, the above-described drop-preventing recess 712 is formed so as to open at the bottom surface of the annular recess 711. The portion other than the portion of the lower surface of the large diameter portion 71 where the annular recess 711 is formed is opposed to the upper surface of the first housing member 51.

As shown in fig. 1 to 4, the molding resin 8 is molded so as to cover the housing 5, the cover member 6, and a part of the magnetic ring 7. The molding resin 8 is molded so as to expose the small diameter portion 72 of the magnetic ring 7 and cover the housing 5 and the cover member 6. As shown in fig. 3, the contact portion 13 between the outer peripheral surface of the large-diameter portion 71 and the molding resin 8 has a portion having a diameter smaller toward the upper side U. Thereby, the magnetic ring 7 is restrained from falling off from the mold resin 8 to the upper side U.

As shown in fig. 2 and 4, a first opening 81 is formed in the mold resin 8 so as to open at the lower surface of the cover member 6. Thus, the cover member 6 can be visually confirmed inside the first opening 81 when viewed from the lower side L. The first opening 81 is formed at a position surrounded by the U-shaped ridge 612b when viewed from the lower side L. As shown in fig. 1 and 4, a second opening 82 is formed in the mold resin 8, and is opened in the upper surface of the second case member 52. The first opening 81 and the second opening 82 are portions where a metal mold is in contact at the time of molding the molding resin 8. As shown in fig. 1, a pair of ribs 526 are provided on the second housing member 52 so as to sandwich the second opening 82. At the time of molding of the molding resin 8, the metal mold is aligned between the pair of ribs 526.

As shown in fig. 1, 2 and 4, a heat shrinkable tube 9 is provided to prevent liquid or the like from entering the housing 5 and the molded resin 8 from the gaps between the molded resin 8 and the cable 4 into the housing 5 and the molded resin 8. The heat shrinkable tube 9 is formed so as to cover the case 5 and the boundary of the molded resin 8 and the cable 4 when viewed from the outside. The heat shrinkable tube 9 is configured to shrink at least toward the inner peripheral side of the heat shrinkable tube 9 at a predetermined temperature or higher. The heat shrinkable tube 9 covers the molded resin 8 and the end of the case 5 on the sheath 42 side and the end of the sheath 42 on the case 5 side. As shown in fig. 4, in the present embodiment, in the heat shrinkable tube 9, the length in the cable longitudinal direction X of the portion covering the sheath 42 is longer than the length in the cable longitudinal direction X of the portion covering the end portion of the housing 5 and the molded resin 8. And, a part of the heat shrinkable tube 9 enters between the sheath 42 and the housing 5. Further, a hot melt, which is an adhesive material that melts at a predetermined temperature or higher and solidifies again due to a temperature lower than the predetermined temperature, may be provided in the inner peripheral portion of the heat shrinkable tube 9.

(method for manufacturing magnetostrictive torque sensor 10)

Next, an example of a method of manufacturing the magnetostrictive torque sensor 10 will be described.

First, the substrate 2, the four terminals 3 formed integrally with the integrated resin 12, and the cable 4 are assembled to the first housing member 51. This brings the state shown in fig. 7 and 8.

Next, the second housing member 52 integrally formed with the magnetic ring 7 is assembled to the first housing member 51. Thereby, one surface of the substrate planar portion 22 of the substrate 2 is supported by the support portion 522 of the second case member 52.

Next, the terminals 3 are bonded to the substrate flat portion 22 through the window portion 512a of the first housing member 51. The bonding operation of the terminal 3 and the substrate planar portion 22 is performed as follows: a tool, not shown, for forming solder 11 is inserted into the case 5 from the window 512a, and the terminal 3 is bonded to the substrate flat portion 22 using the solder 11. At this time, since the substrate planar portion 22 is supported by the support portion 522, deformation of the substrate planar portion 22 due to pressing by a tool or the like can be suppressed. After the terminal 3 is bonded to the substrate flat portion 22, the window portion 512a is closed by the cover member 6.

Next, a molding resin 8 is formed. Fig. 19 is a sectional view showing a state in which the magnetostrictive torque sensor 10 before the molding resin 8 and the heat shrinkable tube 9 are provided is disposed in the metal mold of the molding resin 8. Fig. 20 is a cross-sectional view showing a state after the resin constituting the molding resin 8 is injected into the metal mold of the molding resin 8.

In forming the mold resin 8, as shown in fig. 19, a magnetostrictive torque sensor 10 in a state where the mold resin 8 and the heat shrinkable tube 9 are not molded is disposed in a mold. The metal mold has at least an upper mold 141 and a lower mold 142 overlapped in the rotation axis direction Z. The lower die 142 has a lower die abutment portion 142a that abuts a portion of the lower surface of the cover member 6, and the upper die 141 has an upper die abutment portion 141a that abuts a portion of the upper surface of the second housing member 52. Thereby, the cover member 6 is pressed to the second case member 52 side, and the intrusion of the molding resin 8 into the interface between the cover member 6 and the window 512a is suppressed. The molding resin 8 is formed by injecting a resin in a molten state into a cavity surrounded by the upper mold 141 and the lower mold 142, and solidifying the resin. At the time of molding of the molding resin 8, the region where the lower die contact portion 142a exists becomes the first opening 81, and the region where the upper die contact portion 141a exists becomes the second opening 82.

Next, the heat shrinkable tube 9 is provided. When the heat shrinkable tube 9 is provided, first, the heat shrinkable tube 9 before heat shrinkage having an outer diameter larger than the outer diameters of the housing 5, the molded resin 8, and the portion of the cable 4 covered with the heat shrinkable tube 9 is arranged so as to surround the housing 5, the molded resin 8, and the predetermined portion of the cable 4 covered with the heat shrinkable tube 9. Then, the heat shrinkable tube 9 is heated to shrink, so that the heat shrinkable tube 9 is closely adhered to the surfaces of the housing 5, the molded resin 8, and the cable 4 directly or via the hot melt in the presence of the hot melt. At this time, a part of the heat shrinkable tube 9 is reduced in diameter so as to enter the space between the sheath 42 and the housing 5.

As described above, the magnetostrictive torque sensor 10 of the present embodiment can be manufactured.

(action and Effect of the embodiment)

In the magnetostrictive torque sensor 10 of the present embodiment, the case 5 is provided with a window 512a exposing a joint (solder 11) between the substrate 2 and the terminal 3, and the cover member 6 closes the window 512a. The housing 5 and the cover member 6 are covered with a molding resin 8. Thus, the mold resin 8 is suppressed from entering the space where the joint portion of the substrate 2 and the terminal 3 is arranged. This can prevent the molding resin 8 from entering the periphery of the joint between the substrate 2 and the terminal 3, thereby preventing the molding resin 8 from generating stress between the substrate 2 and the terminal 3 and further preventing electrical connectivity between the substrate 2 and the terminal 3.

In this embodiment, since the window 512a is provided in the housing 5 to expose the joint portion between the substrate 2 and the terminal 3, the joint operation between the substrate 2 and the terminal 3 can be performed through the window 512a after the substrate 2 and the terminal 3 are assembled to the housing 5. This can improve the degree of freedom in the manufacturing method of the magnetostrictive torque sensor 10.

The housing 5 includes a first housing member 51 having a window 512a formed therein, and a second housing member 52 covering the substrate 2 and the terminals 3 from the opposite side of the first housing member 51. Therefore, the substrate 2 and the terminals 3 are easily attached to the housing 5.

The cover member 6 has a projection 614 projecting toward the second case member 52, and the insertion hole 222 into which the projection 614 is inserted is formed in the substrate 2. Therefore, the strength of the cover member 6 and the second case member 52 can be ensured by the protruding portion 614. In the present embodiment, the injection pressure of the molding resin 8 is applied to the case 5 and the cover member 6 during the molding of the molding resin 8, but the second case member 52 and the cover member 6 are in contact with each other via the protruding portion 614, so that the deformation of the cover member 6 and the second case member 52 can be suppressed. The cover member 6 and the second case member 52 may not be in contact with each other via the protruding portion 614 before the molding of the molding resin 8, but when the injection pressure of the molding resin 8 acts on the cover member 6 and the second case member 52, the cover member 6 and the second case member 52 are pressed by the injection pressure, and the protruding portion 614 is in contact with the second case member 52 to suppress deformation of the second case member 52 and the cover member 6.

Here, the protruding portion may be provided on the second case member 52 side, and the protruding portion of the second case member 52 may be in contact with the cover member 6, but in this embodiment, the protruding portion 614 is provided on the cover member 6. Therefore, the assembly of the magnetostrictive torque sensor 10 is easy. Unlike this embodiment, when the protruding portion 614 is formed in the second housing member 52, the protruding portion 614 protrudes from the insertion hole 222 of the substrate 2 toward the window 512a side in a state where the first housing member 51, the second housing member 52, the substrate 2, and the terminal 3 are assembled with each other. In this way, when the bonding operation between the substrate 2 and the terminal 3 is performed from the window 512a side, the bonding tool may interfere with the protruding portion 614. On the other hand, in the present embodiment, since the protruding portion 614 is provided in the cover member 6, such a concern is eliminated.

The second housing member 52 is provided with a fitting recess 523 to be fitted with the projection 614. Therefore, when the window 512a is closed by the cover member 6, the protruding portion 614 of the cover member 6 is guided straight to the fitting recess 523, and therefore, the protruding portion 614 can be prevented from interfering with the insertion hole 222 of the substrate 2, and the substrate 2 can be prevented from being deformed, displaced, or the like.

At least a part of the inner peripheral surface 523a of the fitting recess 523 is located on the inner peripheral side with respect to the inner peripheral surface 222a of the insertion hole 222. Therefore, when the protruding portion 614 of the cover member 6 is inserted into the insertion hole 222 of the substrate 2 and the fitting recess 523 of the second housing member 52, the protruding portion 614 interferes with the inner peripheral surface 523a of the fitting recess 523 located on the inner peripheral side than the insertion hole 222, and interference between the protruding portion 614 and the inner peripheral surface 222a of the insertion hole 222 of the substrate 2 can be suppressed.

The protruding portion 614 is plate-shaped, which is long in the longitudinal direction of the cover member 6. Thus, the rigidity of the cover member 6 can be improved. In this embodiment, even if the injection pressure of the molding resin 8 acts on the second case member 52 and the cover member 6 during the molding of the molding resin 8, the protrusion 614 of the cover member 6 is brought into contact with the second case member 52 in a long range in the cable longitudinal direction X, and thus deformation of the second case member 52 and the cover member 6 is further suppressed.

A plurality of terminal holes 221 into which the terminals 3 are inserted are formed in the substrate 2, and the insertion holes 222 are provided at positions sandwiched between at least one pair of the terminal holes 221 of the plurality of terminal holes 221. In the substrate 2, the dead space is likely to be formed between the terminal holes 221, but according to the present embodiment, the dead space can be effectively utilized, and the substrate 2 can be prevented from being enlarged.

The second case member 52 has a support portion 522 for supporting one surface of the substrate 2. Therefore, in a state where the substrate 2 and the terminals 3 are assembled in the housing 5, the substrate 2 is supported by the support portions 522, and deformation and displacement of the substrate 2 are suppressed. In this embodiment, when the bonding operation of the substrate 2 and the terminals 3 is performed from the window 512a side, the substrate 2 is prevented from being pressed by a tool for the bonding operation, and the substrate 2 is prevented from being deformed or displaced.

The cover member 6 has a clamp portion 615 for clamping the substrate 2 with the support portion 522. Therefore, deformation and displacement of the substrate 2 can be suppressed.

The case 5 has a frame portion 512e protruding toward the side (i.e., the lower side) where the window portion 512a is opened, and is formed in a ring shape so as to surround the window portion 512a at a position apart from the window portion 512a, and the cover member 6 is fitted inside the frame portion 512e. Therefore, the shape of the interface between the cover member 6 and the second housing member 52 can be made complex, and the intrusion of the molding resin 8 into the housing 5 from the interface between the cover member 6 and the second housing member 52 can be suppressed during the molding of the molding resin 8.

A tip receiving recess 612a in which the tip of the terminal 3 is disposed is formed in the inner surface (upper surface) of the cover member 6. Thus, interference between the tip of the terminal 3 and the cover member 6 can be suppressed. Further, a protruding portion 612b protruding downward L is provided on the outer surface (lower surface) of the cover member 6 at a position overlapping the front end accommodating recess 612a in the thickness direction (i.e., the rotation axis direction Z) of the cover member 6. If the cover member 6 is not specifically designed, the thickness of the portion where the tip receiving recess 612a is formed is likely to be reduced, and there is a concern that the strength of the cover member 6 is reduced or that the forming of the cover member 6 is defective.

The molded resin 8 is formed with a first opening 81 that opens in the cover member 6. The first opening 81 is an opening formed by the metal mold abutting against the cover member 6 during molding of the molding resin 8. Therefore, at the time of molding the molding resin 8, the cover member 6 is pressed against the second case member 52 side by the mold clamping force of the mold, and the formation of a gap between the cover member 6 and the second case member 52 is suppressed. Thus, the intrusion of the molding resin 8 into the case 5 and the cover member 6 is suppressed.

As described above, according to the present embodiment, it is possible to provide an electrical device capable of improving electrical connectivity between a substrate and a terminal.

(summary of embodiments)

Next, the technical ideas grasped from the above-described embodiments will be described with reference to the symbols and the like in the embodiments. Note that the symbols and the like in the following description do not limit the constituent elements in the claims to the components and the like specifically shown in the embodiments.

[1] An electrical device 1 is provided with: a substrate 2; a terminal 3 bonded to the substrate 2; a case 5 that houses the substrate 2 and the terminals 3 and that has a window 512a for exposing a joint 11 between the substrate 2 and the terminals 3; a cover member 6 for closing the window 512a; and a molding resin 8 covering the housing 5 and the cover member 6.

[2] The electric device 1 according to [1], wherein the case 5 has a first case member 51 formed with the window 512a and a second case member 52 covering the substrate 2 and the terminals 3 from a side opposite to the first case member 51.

[3] The electrical device 1 according to [2], wherein one of the cover member 6 and the second case member 52 has a projection 614 projecting toward the other side, and an insertion hole 222 into which the projection 614 is inserted is formed in the substrate 2.

[4] The electric device 1 according to [3], wherein the protruding portion 614 is provided to the cover member 6.

[5] The electric device 1 according to [4], wherein the second case member 52 is provided with a fitting recess 523 to be fitted with the protruding portion 614.

[6] The electric device 1 according to [5], wherein at least a part of the inner peripheral surface 523a of the fitting recess 523 is located on the inner peripheral side with respect to the inner peripheral surface 222a of the insertion hole 222.

[7] The electric device 1 according to any one of [3] to [6], wherein the protruding portion 614 has a plate shape longer in the longitudinal direction of the cover member 6.

[8] The electrical device 1 according to any one of [3] to [7], wherein a plurality of terminal holes 221 into which the terminals 3 are inserted are formed in the substrate 2, and the insertion holes 222 are provided at positions sandwiched between at least one pair of the terminal holes 221 of the plurality of terminal holes 221.

[9] The electric device 1 according to any one of [2] to [8], wherein the second case member 52 has a support portion 522 that supports one surface of the substrate 2.

[10] The electric device 1 according to [9], wherein the cover member 6 has a holding portion 615 for holding the substrate 2 between the cover member and the support portion 522.

[11] The electric device 1 according to any one of [1] to [10], wherein the case 5 has a frame portion 512e protruding toward a side where the window portion 512a is opened and formed in a ring shape so as to surround the window portion 512a at a position apart from the window portion 512a, and the cover member 6 is fitted inside the frame portion 512e.

[12] The electrical device 1 according to any one of [1] to [11], wherein a tip receiving recess 612a in which the tips of the terminals 3 are disposed is formed on the inner surface of the cover member 6, and a ridge 612b that protrudes outward is provided on the outer surface of the cover member 6 at a position overlapping the tip receiving recess 612a in the thickness direction of the cover member 6.

[13] The electric device 1 according to any one of [1] to [12], wherein an opening 81 that opens in the cover member 6 is formed in the molded resin 8.

[14] The electrical device 1 according to any one of [1] to [13], wherein the electrical device 1 is used as the magnetostrictive torque sensor 10.

(additionally remembered)

The embodiments of the present invention have been described above, but the above embodiments do not limit the invention of the claims. Further, it should be noted that a combination of all the features described in the embodiments is not necessarily essential to the solution to the problem of the invention. The present invention can be implemented by appropriately modifying the present invention within a range not departing from the gist thereof.

Claims (14)

1. An electrical device, comprising:

a substrate;

a terminal bonded to the substrate;

a housing that houses the substrate and the terminals and that has a window portion that exposes a joint portion between the substrate and the terminals;

a cover member that closes the window; and

and a molding resin covering the housing and the cover member.

2. The electrical device of claim 1, wherein the electrical device comprises a plurality of conductors,

the housing includes a first housing member having the window and a second housing member covering the substrate and the terminal from a side opposite to the first housing member.

3. An electrical device according to claim 2, wherein,

one of the cover members and the second housing member has a projection projecting toward the other side,

the substrate is formed with an insertion hole into which the protruding portion is inserted.

4. An electrical device according to claim 3, wherein,

the protruding portion is provided on the cover member.

5. The electrical device of claim 4, wherein the electrical device comprises a plurality of conductors,

the second housing member is provided with a fitting recess to be fitted with the protruding portion.

6. The electrical device of claim 5, wherein the electrical device comprises a plurality of conductors,

at least a part of the inner peripheral surface of the fitting recess is located on the inner peripheral side with respect to the inner peripheral surface of the insertion hole.

7. An electrical device according to any one of claims 3 to 6, wherein,

the protruding portion has a plate shape that is long in the longitudinal direction of the cover member.

8. An electrical device according to any one of claims 3 to 7, wherein,

a plurality of terminal holes for inserting the terminals are formed in the substrate,

the insertion hole is provided at a position sandwiched between at least one pair of the plurality of terminal holes.

9. An electrical device according to any one of claims 2 to 8, wherein,

the second housing member has a support portion for supporting one surface of the substrate.

10. The electrical device of claim 9, wherein the electrical device comprises a plurality of conductors,

the cover member has a holding portion for holding the substrate between the cover member and the support portion.

11. The electrical device according to any one of claims 1 to 10, wherein,

the housing has a frame portion protruding toward a side where the window portion is opened and formed in a ring shape so as to surround the window portion at a position separated from the window portion,

the cover member is fitted inside the frame.

12. The electrical device of any one of claims 1 to 11, wherein,

a front end receiving recess for disposing the front ends of the terminals is formed on the inner surface of the cover member,

a bulge part is provided on the outer surface of the cover member at a position overlapping the front end accommodating recess part in the thickness direction of the cover member.

13. The electrical device of any one of claims 1 to 12, wherein,

the molded resin is formed with an opening portion that opens the cover member.

14. The electrical device of any one of claims 1 to 13, wherein,

the above-described electrical device is used as a magnetostrictive torque sensor.

Images