JP2012098173A - Manufacturing method of sensor, and sensor manufactured by the manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a sensor in which a fixing hole can be surely filled up together with a seal member.SOLUTION: A method of manufacturing a rotary angle sensor 100 is provided. The rotary angle sensor 100 is fixed in a fixing hole 31 and an O ring 80 holding an O ring groove 70 sealing the fixing hole 31 and the sensor is formed along a circumferential direction. In a first molding step, a cavity 10a of a first metal die 10 is filled with a PBT resin, thereby molding a columnar resin collar 40 which forms on a tubular surface 41 of an outer circumference a bottom surface 71 and one side surface 72 of the O ring groove 70 and a continuous surface 41a continued in an axial direction from the bottom surface 71 to an end face 42 in the axial direction. In a second molding step after the first molding step, a cavity 20a of a second metal die 20 in which the resin collar 40 is installed is filled with a PBT resin. Thus, another side surface 73 is formed which opposed to the one side surface 72 of the resin collar 40 in the axial direction, and a secondary mold resin 50 is formed which is joined with the resin collar 40.

Description

  The present invention relates to a method of manufacturing a sensor fixed in a cylindrical hole-shaped fixing hole, and the sensor.

  2. Description of the Related Art Conventionally, a sensor having a seal groove that holds a seal member that seals between a fixed hole is known. For example, in the electromagnetic rotation sensor disclosed in Patent Document 1, a seal groove for holding an O-ring is formed on the cylindrical surface of the outer periphery of the main body molding portion fixed in a cylindrical hole-shaped fixing hole formed in the cylinder block. Is formed. The O-ring held in the seal groove is in close contact between the fixing hole of the cylinder block and the main body molding portion, and seals between the fixing hole and the main body molding portion.

Japanese Patent Application Laid-Open No. 08-43415

  Now, when manufacturing the electromagnetic rotation sensor disclosed in Patent Document 1, it is considered that the main body molding portion is molded by a single molding process. Therefore, the main body molding part molded by this one molding process must have both a pair of side surfaces of the seal groove. That is, a continuous surface that is continuous in the axial direction from the bottom surface of the seal groove to the end surface in the axial direction cannot be formed on the outer peripheral surface of the main body molding portion. Therefore, any one side surface becomes obstructive, and the main body molding portion cannot be removed from the molding die along the axial direction. Therefore, the molding die is divided in the radial direction of the main body molding portion.

  Then, in the molding die, the parting surface and the part for molding the bottom surface of the seal groove always intersect. Therefore, burrs may occur on the bottom surface of the seal groove due to the resin protruding from the gap between the molds generated on the mold splitting surface. In this case, the O-ring floats from the bottom surface due to the burr on the bottom surface, and creates a gap between the bottom surface of the seal groove. Then, the O-ring cannot seal between the fixed hole and the main body molding portion.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a sensor capable of reliably closing a fixing hole together with a seal member.

  In order to achieve the above object, according to the first aspect of the present invention, in order to detect a physical phenomenon, a seal groove that is fixed in a cylindrical hole-shaped fixing hole and holds a seal member that seals between the fixing holes is provided. Is a method of manufacturing a sensor formed along the circumferential direction, in which a bottom surface and one side surface of the seal groove are formed, and a continuous surface extending in the axial direction from the bottom surface to the end surface in the axial direction is a cylinder. Forming a columnar primary molded product to be formed on the surface by filling a molding material into the first mold, and forming the other side surface in the axial direction opposite to one side surface of the seal groove And forming a secondary molded product by forming a secondary molded product to be joined to the primary molded product, by placing the primary molded product in the second mold and filling the molding material. A second molding step, and a method for manufacturing the sensor, That.

  According to this invention, the sensor is molded through the first molding process and the second molding process. Therefore, if the secondary molded product that forms the other side surface of the seal groove is molded in the second molding process, the primary molded product molded in the first molding process is axially moved from the bottom surface of the seal groove. A continuous surface that continues in the axial direction up to the end surface of the outer peripheral surface may be formed on the outer cylindrical surface. By forming such a continuous surface on the columnar primary molded product, the primary molded product can be released from the first mold along the axial direction. Therefore, by dividing the first molding die in the axial direction of the primary molded product, a parting surface can be formed while avoiding the portion of the first molding die that forms the bottom surface.

  As described above, the generation of burrs on the bottom surface of the seal groove is suppressed. In the seal groove in which the other side surface is formed in the second molding step, the seal member comes into close contact with the bottom surface without floating from the bottom surface. As described above, the seal member can exhibit a function of sealing between the fixing hole and the sensor. Therefore, the sensor can reliably block the fixing hole together with the seal member.

  According to the second aspect of the present invention, in the first molding step, the primary molded product that forms the protruding portion protruding from the end surface along the axial direction of the primary molded product is molded, and in the second molding step, the second molding process is performed. The protrusion is once melted by the heat of the molding material filled in the mold.

  According to this invention, since the protrusion part protrudes along the axial direction from the end surface of the primary molded product, it does not hinder the release of the primary molded product from the first mold. Therefore, even if it has a protrusion part, the bottom face of the seal groove without a burr | flash is formed in a primary molded product.

  In addition, the protrusion once melted by the heat of the molding material filled in the second mold is welded to the secondary molded product, and the bonding between the primary molded product and the secondary molded product is further strengthened. Become. As described above, the primary molded product and the secondary molded product are firmly bonded, so that a decrease in the strength of the sensor due to the molding of the sensor through a plurality of molding processes is suppressed.

  According to a third aspect of the present invention, in the first molding step, a primary molded product that forms a projecting portion extending annularly along the outer periphery of the end face is molded.

  According to the present invention, in the second molding step, the projecting portion extending in an annular shape along the outer periphery of the end face is once melted and welded to the secondary molded product, so that the projecting portion becomes the primary molded product and the secondary molded product. Can be sealed. Therefore, the leakage of the liquid or gas existing inside the fixing hole through the gap formed between the primary molded product and the secondary molded product is suppressed in advance by the protrusion.

  According to invention of Claim 4, a 2nd metal mold | die has a gate opened toward the protrusion part of the primary molded object installed in the said 2nd metal mold, The secondary molded product is molded by filling a molding material in the second mold through the second mold.

  According to this invention, the molding material filled in the second molding die through the gate opening toward the protruding portion of the primary molded product installed in the second molding die is directed toward the protruding portion of the primary molded product. Can flow. Therefore, the molding material having high heat just filled in the second mold flows toward the protrusion. As described above, the protrusion is surely welded to the secondary molded product by the heat of the molding material, and the joint between the primary molded product and the secondary molded product becomes strong. As described above, the opening of the gate provided in the second mold is preferably directed to the protruding portion.

  Invention of Claim 5 is a sensor manufactured by the manufacturing method as described in any one of Claims 2-4, Comprising: A protrusion part is welded to a secondary molded object, It is characterized by the above-mentioned. .

  By welding the protrusions to the secondary molded product as in the present invention, the joint between the primary molded product and the secondary molded product can be strong. Therefore, a decrease in the strength of the sensor due to the molding of the sensor by a plurality of molding processes is suppressed.

  According to the invention described in claim 6, in the first molding step, a primary molded product further having a housing portion that is recessed from the end surface along the axial direction is molded, and the primary molded product is positioned on the inner peripheral side of the continuous surface. It further includes an accommodating step of accommodating, in the accommodating portion, an accommodation in which a concave groove extending in the circumferential direction of the outer peripheral wall is provided on the outer peripheral wall fitted to the inner peripheral wall of the accommodating portion.

  According to this invention, the concave surface extending in the circumferential direction is provided on the outer peripheral wall fitted to the inner peripheral wall of the accommodating portion located on the inner peripheral side of the continuous surface in the stored object, so that the continuous surface is the second Due to the pressure of the molding material filled in the mold, it is bent toward the concave groove. Therefore, in the second molding step, the secondary molding forms a convex portion corresponding to the shape of the depression caused by the deflection to the inner peripheral side of the continuous surface in the portion surrounding the outer peripheral side of the continuous surface in the secondary molded product. The object is molded. When this convex part fits into the recess of the continuous surface, the primary molded product is difficult to come off from the secondary molded product along the axial direction of the primary molded product. Therefore, the bonding between the primary molded product and the secondary molded product becomes stronger.

  According to the seventh aspect of the present invention, in the accommodating step, the accommodating portion is configured such that the concave portion extending annularly in the circumferential direction is accommodated in the accommodating portion.

  According to this invention, by providing the annular concave groove extending in the circumferential direction on the outer peripheral wall of the container, in the second molding step, a recess extending annularly in the circumferential direction due to the pressure of the molding material can be generated in the continuous surface. . Therefore, the secondary molding which forms the cyclic | annular convex part extended in the circumferential direction of a continuous surface is shape | molded by a 2nd shaping | molding process.

  Since the convex part of this secondary molded product can complement the shape of the depression generated on the continuous surface, it can be in close contact with the continuous surface. In addition, the convex portion and the continuous surface are in close contact with each other in the circumferential direction. Therefore, the convex portion and the continuous surface can seal between the primary molded product and the secondary molded product. As described above, leakage of liquid or gas existing inside the fixing hole through the gap formed between the primary molded product and the secondary molded product is suppressed by the convex portion formed in the secondary molded product. .

  According to invention of Claim 8, it is a sensor manufactured by the manufacturing method of Claim 6 or 7, Comprising: A secondary molded object is in the hollow produced in a continuous surface in the surrounding wall part surrounding a continuous surface. It has the convex part to fit, It is characterized by the above-mentioned.

  According to this invention, the primary molded product comes off from the secondary molded product along the axial direction of the primary molded product by fitting the convex portion of the peripheral wall portion of the secondary molded product into the recess formed on the continuous surface. It becomes difficult. Therefore, the bonding between the primary molded product and the secondary molded product becomes stronger.

It is sectional drawing for demonstrating the structure of the rotation angle sensor by one Embodiment of this invention. It is a figure for demonstrating in detail the 1st shaping | molding process among the processes which manufacture a rotation angle sensor, Comprising: (a) shows the 1st metal mold | die before being filled with a molding material, (b) is shaping | molding. A step of filling the material into the first mold is shown, and (c) shows a step of releasing the resin collar from the first die. It is a figure for demonstrating in detail the accommodation process among the processes which manufacture a rotation angle sensor. It is a figure for demonstrating in detail the 2nd shaping | molding process among the processes which manufacture a rotation angle sensor, (a) shows the 2nd metal mold | die in which the result by the accommodation process was installed, (b) Shows the process of filling the molding material with the second mold, and (c) shows the process of releasing the rotation angle sensor from the second mold. It is the figure which expanded the characteristic part of FIG.4 (b).

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

  FIG. 1 is a cross-sectional view for explaining the configuration of a rotation angle sensor 100 manufactured by a manufacturing method according to an embodiment of the present invention. The rotation angle sensor 100 is a sensor for detecting the rotational position of the crankshaft in an internal combustion engine such as a gasoline engine. The rotation angle sensor 100 is inserted into a cylindrical hole 31 provided in a cylinder block 30 of a gasoline engine and is fixed to the fixed hole 31 in order to detect a fluctuation of a magnetic field as a physical phenomenon. The distal end portion of the rotation angle sensor 100 in the insertion direction is attached to a crankshaft (not shown) of the gasoline engine and faces the sensor rotor 35 that rotates integrally with the crankshaft. The sensor rotor 35 is a disk-shaped member made of a magnetic material. A plurality of teeth 36 projecting radially outward are arranged on the outer periphery of the sensor rotor 35 in order to cause fluctuations in the magnetic field.

  An O-ring groove 70 that holds the O-ring 80 is formed in the outer peripheral portion 75 of the rotation angle sensor 100 along the circumferential direction. The O-ring 80 is formed in an annular shape from a highly oil-resistant fluorine rubber or the like. The O-ring groove 70 extends in a ring shape along the outer peripheral portion 75 of the rotation angle sensor 100, and a pair of side surfaces 72, 73 facing the axial direction of the rotation angle sensor 100 and a bottom surface positioned between the side surfaces 72, 73. 71. The O-ring 80 is crushed between the bottom surface 71 of the O-ring groove 70 and the inner peripheral portion 33 of the fixing hole 31, thereby being brought into close contact with the bottom surface 71 and the inner peripheral portion 33 and exhibiting a sealing function. Thereby, the rotation angle sensor 100 closes the fixing hole 31 of the cylinder block 30 together with the O-ring 80 mounted in the O-ring groove 70.

  The rotation angle sensor 100 includes a resin collar 40, an insert portion 60, a secondary molding resin 50, and the like.

  The resin collar 40 is a bottomed cylindrical member formed of a resin material such as polybutylene terephthalate (PBT) resin. The resin collar 40 is inserted into the fixing hole 31 from the bottom 47 side formed at one end of the resin collar 40 in the axial direction. In addition to the bottom surface 71 and the one side surface 72 of the O-ring groove 70 described above, the resin collar 40 is formed with a continuous surface 41a, a protruding portion 43, and a housing portion 45.

  The bottom surface 71, the side surface 72, and the continuous surface 41 a are formed on the cylindrical surface 41 of the outer peripheral surface of the resin collar 40. The continuous surface 41 a is continuous in the axial direction from the bottom surface 71 to the end surface 42 in the axial direction of the resin collar 40 located on the side opposite to the bottom portion 47. The continuous surface 41a is provided with a draft for facilitating extraction from the first mold 10 (see FIG. 2) in a first molding step described later. Specifically, the outer diameter of the continuous surface 41a gradually decreases from the bottom surface 71 toward the end surface. The protruding portion 43 protrudes from the end surface 42 along the axial direction of the resin collar 40. The protrusion 43 extends in an annular shape along the outer periphery of the end surface 42. The end face 42 is welded to the secondary molding resin 50. The accommodating part 45 forms a cylindrical space in the resin collar 40 by being recessed from the end face along the axial direction. The insert portion 60 is accommodated in the accommodating portion 45.

  The insert portion 60 is configured by combining a main body portion 60a, a coil 65, a terminal 66, a yoke 67, and the like. The insert part 60 is embedded in the rotation angle sensor 100 by being accommodated in the accommodating part 45 of the resin collar 40 and then being covered with the secondary molding resin 50.

  The main body 60a is formed in a cylindrical shape by a resin material such as PBT resin. A fitting wall 61 and a concave groove 63 are formed in the main body 60a. The fitting wall 61 is fitted into the inner peripheral wall 44 of the receiving portion 45 located on the inner peripheral side of the continuous surface 41 a by the insert portion 60 being received in the resin collar 40. The concave groove 63 is provided in the fitting wall 61 and extends annularly in the circumferential direction of the fitting wall 61.

  The coil 65 is formed by winding a conductive wire around a cylindrical bobbin. The coil 65 is accommodated in the accommodating portion 45 in a posture in which the axial direction of the bobbin is aligned with the axial direction of the resin collar 40. The coil 65 is in contact with the bottom 47 of the resin collar 40 when the insert portion 60 is accommodated in the accommodating portion 45.

  The terminal 66 is a plate-like member made of a metal such as brass. A pair of terminals 66 are accommodated in the main body 60a. Each terminal 66 extends along the axial direction of the main body 60a. Of the end portions of each terminal 66 in the extending direction, one end portion 66 a close to the coil 65 is connected to a conductive wire forming the coil 65. The other end 66b of each terminal 66 in the extending direction penetrates the secondary molding resin 50 and is exposed to the outside.

  The yoke 67 is formed in a cylindrical shape by a magnetic material such as soft iron. The yoke 67 is accommodated in the main body 60a. The axial direction of the yoke 67 accommodated in the main body 60a is along the axial direction of the main body 60a. A coil 65 is fitted on the end of the yoke 67 in the axial direction. The main body 60a, the coil 65, and the yoke 67 are arranged coaxially with each other. A permanent magnet 68 is provided on the end surface of the yoke 67 located on the bottom 47 side in the axial direction. According to the above configuration, the fluctuation of the magnetic field caused by the rotation of the sensor rotor 35 is amplified by the yoke 67 and detected by the coil 65. Then, it is output to the outside of the rotation angle sensor 100 through a terminal 66 connected to the coil 65.

  The secondary molding resin 50 is a columnar member molded from a resin material such as PBT resin. The secondary molding resin 50 is exposed to the outside of the cylinder block 30. In the secondary molding resin 50, in addition to the other side surface 73 of the O-ring groove 70 described above, a convex portion 53, a flange 57, and a socket 55 are formed.

  The side surface 72 and the convex portion 53 are formed on the peripheral wall portion 51 surrounding the continuous surface 41 a of the resin collar 40. In the peripheral wall portion 51, the convex portion 53 protrudes from the surface portion facing the continuous surface 41a to the inner peripheral side. The convex portion 53 extends annularly in the circumferential direction. The convex part 53 is bending the continuous surface 41a to the inner peripheral side by urging the continuous surface 41a toward the concave groove 63. The convex portion 53 is formed in a shape that complements the depression 41b formed by the bending generated in the continuous surface 41a.

  The flange 57 is a bowl-shaped portion that protrudes radially outward from the outer peripheral portion of the secondary molding resin 50. The flange 57 extends annularly in the circumferential direction, and comes into contact with the wall surface of the cylinder block 30 from the outside by fixing the rotation angle sensor 100 to the fixing hole 31. The socket 55 is connected to a plug (not shown) for connecting, for example, a control device for controlling a gasoline engine and the rotation angle sensor 100. Each end 66 b of each terminal 66 is exposed inside the socket 55.

  The first mold 10 and the second mold 20 for manufacturing the rotation angle sensor 100 having the configuration described so far, and a method for manufacturing the rotation angle sensor 100 will be described in detail below with reference to FIGS. .

(First molding process)
In the first molding step shown in FIG. 2, the resin collar 40 is first molded. The first mold 10 used in the first molding step is divided into two in the axial direction of the resin collar 40 (see FIG. 2A). For convenience, among the first mold 10 divided into two, the one having the gate 15 and forming the bottom 47 side of the resin collar 40 is referred to as the split mold 11 and the end face 42 side of the resin collar 40 is formed. This is a split mold 12. In the first mold 10, the split surfaces 14 of the split dies 11 and 12 are orthogonal to the axial direction of the resin collar 40. In addition, the parting surface 14 is provided closer to the bottom 47 than the part forming the side surface 72 of the O-ring groove 70 so that the parting surface 14 and the part forming the bottom surface 71 do not intersect.

  In the first molding step using the first mold 10 described above, the molds 11 and 12 are first closed. Thereafter, the molds 11 and 12 are clamped so that the resin material does not leak from the cavity 10a due to the pressure during filling. Then, the melted resin material is filled into the cavity 10 a in the first mold 10 through the gate 15 at a predetermined pressure. Thereby, the resin collar 40 which forms the bottom surface 71 and the side surface 72 of the O-ring groove 70, the continuous surface 41a, the protruding portion 43, and the like is molded (see FIG. 2B). Then, the molds 11 and 12 are opened after the resin material is solidified. The molded resin collar 40 is released from the split mold 12 along the axial direction (see FIG. 2C).

(Containment process)
The accommodation step shown in FIG. 3 is performed after the first molding step. In the housing step, the assembled insert portion 60 is housed in the housing portion 45 of the resin collar 40. Thereby, the fitting wall 61 of the insert part 60 is fitted to the inner peripheral wall 44 of the resin collar 40.

(Second molding process)
The second molding step shown in FIG. 4 is performed after the housing step. In the second molding step, the secondary molding resin 50 is molded. The second mold 20 used in the second molding step is divided into three split molds 21, 22, and 23 (see FIG. 4A). For convenience, among the second mold 20 divided into three parts, the part in which the resin collar 40 and the insert part 60 are installed is the split part 21, and the part having the part for molding the socket 55 is the split part 22. A part having a part for molding the side surface 73 is referred to as a split mold 23. In the second mold 20, a gate 25 for filling the cavity 20 a with a resin material is formed between the split mold 22 and the split mold 23. The gate 25 opens toward the protrusion 43 of the resin collar 40 installed in the cavity 20a.

  In the second molding process using the second mold 20 described above, the second mold 20 is first opened, and the resultant product including the resin collar 40 and the insert portion 60 obtained by the housing process is installed in the split mold 21. Is done. Then, each of the split molds 21 to 23 is closed in a state where the resultant product is accommodated in the cavity 20a. Thereafter, the molds 21 to 23 are clamped to prevent leakage of the resin material from the cavity 20a due to the pressure during filling and to fix the installed product.

  Then, the melted resin material is filled into the cavity 20a in the second mold 20 through the gate 25 at a pressure of, for example, about 30 MPa (see FIG. 4B). Thus, the other side surface 73 of the O-ring groove 70 and the like are formed, and the secondary molding resin 50 that covers the insert portion 60 and is joined to the resin collar 40 is molded. After the filled resin material is solidified, each of the split molds 21 to 23 is opened. Then, the rotation detection sensor 100 having the molded secondary molding resin 50 is released from the cavity 20a in the second mold 20 (see FIG. 4C).

  As shown in FIG. 5, the resin material filled in the second mold 20 through the gate 25 flows toward the protrusion 43 of the resin collar 40. The high heat resin material just filled in the second mold 20 flows toward the protrusion 43, and once the protrusion 43 is melted by heat, the resin material is solidified. Thus, the protrusion 43 is welded to the secondary molding resin 50.

  In addition, in the insert portion 60, the concave wall 63 is provided in the fitting wall 61 located on the inner peripheral side of the continuous surface 41a, so that the continuous surface 41a is recessed by the pressure of the resin material filled in the cavity 20a. Deflection toward the groove 63. Therefore, the convex part 53 is formed in the surrounding wall part 51 of the secondary shaping | molding resin 50 so that it may respond | correspond to the shape of the hollow 41b produced by the bending to the inner peripheral side of the continuous surface 41a. This convex part 53 fits into the dent 41b of the continuous surface 41a.

  Furthermore, when the convex part 53 presses the continuous surface 41 a toward the inner peripheral side, the inner peripheral wall 44 of the resin collar 40 is deformed so as to contact the bottom surface of the concave groove 63 provided in the fitting wall 61. Thereby, the corner | angular part 63a between the fitting wall 61 and the ditch | groove 63 comes to contact the inner peripheral wall 44 with high surface pressure.

  The rotation angle sensor 100 is manufactured by molding the secondary molding resin 50 by the second molding step as described above and taking it out from the second mold 20 (see FIG. 4C).

  In the present embodiment described so far, the rotation angle sensor 100 is molded through the first molding process and the second molding process. Therefore, by forming the side surface 73 of the O-ring groove 70 in the second molding step, a continuous surface 41 a that continues from the bottom surface 71 to the end surface 42 of the O-ring groove 70 is formed on the cylindrical surface 41 in the resin collar 40. Can be done. By forming the continuous surface 41a on the resin collar 40 in this way, the resin collar 40 is released from the first mold 10 along the axial direction. Therefore, by dividing the first mold 10 in the axial direction of the resin collar 40, the parting surface 14 is formed while avoiding the portion of the first mold 10 where the bottom surface 71 is molded.

  As described above, a situation in which burrs are generated on the bottom surface 71 of the O-ring groove 70 due to the resin protruding from the gap of the mold dividing surface 14 is suppressed. Therefore, the O-ring 80 attached to the O-ring groove 70 comes into close contact with the bottom surface 71 without floating from the bottom surface 71. As described above, the O-ring 80 can exhibit a function of sealing between the fixed hole 31 and the rotation angle sensor 100. Therefore, the rotation angle sensor 100 can reliably close the fixing hole 31 together with the O-ring 80.

  In addition, in this embodiment, by directing the opening of the gate 25 provided in the second mold 20 to the protruding portion 43 of the resin collar 40, the protruding portion 43 is reliably melted by the heat of the resin material, and is subjected to secondary molding. It can be welded to the resin 50. The protrusion 43 welded to the secondary molding resin 50 further strengthens the bonding between the resin collar 40 and the secondary molding resin 50. In addition, the annular protrusion 43 can seal between the resin collar 40 and the secondary molding resin 50. Therefore, leakage of the engine oil existing inside the fixing hole 31 through the gap generated between the resin collar 40 and the secondary molding resin 50 is suppressed by the protrusion 43.

  Moreover, in this embodiment, since the protrusion part 43 which exhibits an effect | action as mentioned above protrudes along the axial direction from the end surface 42 of the resin collar 40, when the resin collar 40 is released from the 1st metal mold | die 10, it is. It won't interfere. Therefore, even if the protruding portion 43 is provided, the resin collar 40 is formed with the bottom surface 71 of the O-ring groove 70 having no burr.

  Furthermore, in this embodiment, the convex part 53 which complements the shape of the hollow 41b of the continuous surface 41a is formed in the surrounding wall part 51 of the secondary molding resin 50 in a 2nd shaping | molding process. When the convex portion 53 is fitted into the recess of the continuous surface 41 a, the resin collar 40 is difficult to come off from the secondary molding resin 50 along the axial direction of the resin collar 40. Therefore, the joint between the resin collar 40 and the secondary molding resin 50 becomes stronger.

  In addition, in this embodiment, the convex part 53 and the continuous surface 41a can be reliably adhered to each other. In addition, the convex portion 53 and the continuous surface 41a are in close contact with each other in an annular shape. Therefore, the convex portion 53 and the continuous surface 41 a can seal between the resin collar 40 and the secondary molding resin 50. Furthermore, the corner | angular part 63a of the fitting wall 61 and the inner peripheral wall 44 are contacting with high surface pressure. Therefore, even if the engine oil leaked from between the resin collar 40 and the secondary molding resin 50 tries to enter between the inner peripheral wall 44 and the fitting wall 61, the engine oil is not supplied to the corner 63a. And damming between the inner peripheral walls 44. As described above, the situation in which engine oil adheres to the coil 65, the terminal 66, and the like housed in the housing portion 45 can be suppressed. Therefore, the rotation angle sensor 100 can output a correct detection result over a long period of time.

  In the present embodiment, the first mold 10 corresponds to the “first mold” in the claims, the second mold 20 corresponds to the “second mold” in the claims, and the resin The collar 40 corresponds to the “primary molded product” in the claims, the secondary molding resin 50 corresponds to the “secondary molded product” in the claims, and the insert portion 60 corresponds to the “container” in the claims. The fitting wall 61 corresponds to the “outer peripheral wall” in the claims, the O-ring groove 70 corresponds to the “seal groove” in the claims, and the O-ring 80 corresponds to the “outer wall” in the claims. The side surface 72 corresponds to “one side surface” of the claims, the side surface 73 corresponds to “other side surface” of the claims, and the rotation angle sensor 100 corresponds to the “sealing member”. Corresponds to the range “sensor”.

(Other embodiments)
As mentioned above, although one embodiment by the present invention was described, the present invention is not interpreted limited to the above-mentioned embodiment, and can be applied to various embodiments within the range which does not deviate from the gist.

  In the above embodiment, the end face 42 of the resin collar 40 is formed with an annular protrusion 43 that is welded to the secondary molding resin 50, and the protrusion 43 is connected to the resin collar 40 and the secondary molding resin 50. The function of sealing the gap was demonstrated. However, the end face of the resin collar may have a flat shape where no protrusion is formed as long as leakage of gas or liquid passing between the resin collar 40 and the secondary molding resin 50 can be suppressed. Or the shape of a protrusion part may be circular arc shape extended in the circumferential direction instead of cyclic | annular form.

  In the above embodiment, the gate 25 provided in the second mold 20 opens toward the protrusion 43 provided in the cavity 20a in order to melt the protrusion 43 reliably in the second molding step. However, the position where the gate 25 of the second mold 20 opens is not limited to the above-described form. As long as the protrusion 43 can be melted by the heat of the resin material, the position of the gate 25 may be changed as appropriate.

  In the above embodiment, the convex portion 53 is formed on the peripheral wall portion 51 of the secondary molding resin 50 by forming the concave groove 63 in the fitting wall 61 of the insert portion 60. However, when sealing between the resin collar 40 and the secondary molding resin 50 and between the resin collar 40 and the insert portion 60 is easy, the configuration corresponding to the concave groove is omitted from the fitting wall of the insert portion. Also good. Or the some convex part formed intermittently in the circumferential direction may be provided in a surrounding wall part by forming in the fitting wall the several recessed groove | channel divided | segmented in the circumferential direction.

  In the embodiment described above, the inner peripheral wall 44 of the resin collar 40 is deformed so as to come into contact with the bottom surface of the concave groove 63 provided in the fitting wall 61 due to the bending generated in the continuous surface 41a. However, the depth of the groove may be adjusted so that the inner peripheral wall does not contact the bottom surface of the groove.

  In the above embodiment, PBT resin is used as a molding material for the resin collar 40 and the secondary molding resin 50. However, the resin collar and the secondary molding resin may be molded of a material other than the PBT resin, for example, a resin material such as nylon and polytrimethylene terephthalate. Further, the resin collar and the secondary molding resin may be formed of different materials. However, in order to firmly bond the resin collar and the secondary molding resin to each other, it is desirable that the resin collar and the secondary molding resin are molded from the same material.

  In the said embodiment, PBT resin which is a molding material was filled in the cavity 20a of the 2nd metal mold | die 20 by the molding pressure of about 30 MPa. However, the pressure when filling the cavity 20a is not limited to the above pressure, and may be appropriately changed according to the shape of the secondary molding resin, the characteristics of the material used as the molding material, and the like. Similarly, the pressure when the molding material is filled in the cavity 10a of the first mold 10 may be appropriately changed according to the shape of the resin collar and the characteristics of the material used as the molding material.

  In the said embodiment, the other side surface 73 shape | molded in a 2nd shaping | molding process was located in the direction opposite to an insertion direction rather than the O-ring 80. FIG. However, the side surface positioned in the insertion direction with respect to the O-ring 80 may be formed in the second molding step. However, the side surface 72 molded in the second molding step is preferably positioned in the direction opposite to the insertion direction for the following reason. The reason is that, in the above embodiment, the joint surface between the resin collar 40 and the secondary molding resin 50 is located outside the O-ring 80 and is not always exposed to engine oil. Therefore, it is difficult for engine oil to leak.

  In the above embodiment, the example in which the present invention is applied to the rotation angle sensor 100 has been described. However, the application target of the present invention is not limited to the rotation angle sensor 100. Other sensors, for example, a temperature sensor that is fixed to a fixed hole formed in the container and detects the temperature in the container, a flow rate sensor that is fixed to a fixed hole formed in the pipe and detects the flow rate of the fluid flowing in the pipe, and the container The present invention can be applied to a liquid level detection sensor or the like that detects the liquid level of a liquid that is fixed in a formed fixing hole and stored in a container.

10 First mold (first mold), 10a cavity, 11, 12, split mold, 14 split surface, 15 gate, 20 Second mold (second mold), 20a cavity, 21, 22, 23 split Mold, 25 Gate, 30 Cylinder block, 31 Fixed hole, 33 Inner circumference, 35 Sensor rotor, 36 Teeth, 40 Resin collar (primary molded product), 41 Cylindrical surface, 41a Continuous surface, 41b Depression, 42 End surface, 43 Projection, 44 Inner wall, 45 Housing, 47 Bottom, 50 Secondary molding resin (secondary molding), 51 Perimeter wall, 53 Convex, 55 Socket, 57 Flange, 60 Insert (housing), 60a Body Part, 61 fitting wall (outer peripheral wall), 63 concave groove, 63a corner part, 65 coil, 66 terminal, 66a, 66b end part, 67 yoke, 68 permanent magnet, 7 0 O-ring groove (seal groove), 71 bottom surface, 72 side surface (one side surface), 72 side surface (other side surface), 75 outer periphery, 80 O-ring (seal member), 100 rotation angle sensor (sensor)

Claims (8)

A method of manufacturing a sensor in which a seal groove is formed along a circumferential direction, which is fixed in a cylindrical hole-shaped fixing hole to detect a physical phenomenon, and holds a sealing member that seals between the fixing hole. There,
A columnar primary molded product that forms a bottom surface and one side surface of the seal groove, and forms a continuous surface in the axial direction from the bottom surface to the end surface in the axial direction on the cylindrical surface. A first molding step of molding by filling a molding material;
A second molding step of forming a second molded product formed by forming the other side of the seal groove opposite to the one side in the axial direction, and molding the secondary molded product joined to the primary molded product, A second molding step of molding the secondary molded product by installing the primary molded product and filling a molding material with the primary molded product,
The manufacturing method of the sensor characterized by including. In the first molding step, the primary molded product that forms a protruding portion protruding from the end surface along the axial direction of the primary molded product is molded,
2. The sensor manufacturing method according to claim 1, wherein, in the second molding step, the protrusion is temporarily melted by heat of the molding material filled in the second mold. 3.   3. The sensor manufacturing method according to claim 2, wherein, in the first molding step, the primary molded product that forms the projecting portion extending annularly along the outer periphery of the end surface is molded. The second mold has a gate that opens toward the protruding portion of the primary molded product installed in the second mold,
The sensor production according to claim 2 or 3, wherein, in the second molding step, the secondary molding is molded by filling the second molding die with the molding material through the gate. Method. A sensor manufactured by the manufacturing method according to any one of claims 2 to 4,
The sensor is characterized in that the protrusion is welded to the secondary molded product. In the first molding step, the primary molded product further having a housing portion that is recessed from the end surface along the axial direction,
In the primary molded product, an accommodation object in which a concave groove extending in a circumferential direction of the outer peripheral wall is provided in the outer peripheral wall fitted to the inner peripheral wall of the accommodating part located on the inner peripheral side of the continuous surface is provided in the accommodating part. A housing process for housing;
The method for manufacturing a sensor according to claim 1, further comprising:   The method for manufacturing a sensor according to claim 6, wherein in the housing step, the housing portion includes a housing in which the concave groove extending annularly in the circumferential direction is provided on the outer circumferential wall. A sensor manufactured by the manufacturing method according to claim 6 or 7,
The secondary molded product has a convex portion that fits into a recess formed in the continuous surface at a peripheral wall portion surrounding the continuous surface.

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