JP2018066754A - Thermal flowmeter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a thermal flowmeter having high measurement accuracy.SOLUTION: A thermal flowmeter is obtained by a method which includes the steps of: molding a circuit package 400 for measuring flow rate in a first resin molding process; resin molding a housing 302 having an entrance groove 351, a front-side sub passage groove 332, and an exit groove 353 or the like in a second resin molding process; and surrounding the circuit package 400 manufactured in the first resin molding process with resin in the second resin molding process on the outer peripheral surface of the circuit package and fixing the circuit package to the housing 302.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a thermal flow meter.

  A thermal flow meter that measures the flow rate of gas includes a flow rate detection unit for measuring the flow rate, and performs heat transfer between the flow rate detection unit and the gas to be measured, thereby reducing the flow rate of the gas. It is configured to measure. The flow rate measured by the thermal flow meter is widely used as an important control parameter for various devices. A feature of the thermal flow meter is that it can measure a gas flow rate, for example, a mass flow rate, with relatively high accuracy compared to other types of flow meters.

However, further improvement in gas flow rate measurement accuracy is desired. For example, a vehicle equipped with an internal combustion engine has a very high demand for fuel saving and exhaust gas purification. In order to meet these demands, it is required to measure the intake air amount, which is a main parameter of the internal combustion engine, with high accuracy. A thermal flow meter for measuring the amount of intake air led to an internal combustion engine includes a sub-passage that takes in a part of the intake air amount and a flow rate detector disposed in the sub-passage, and the flow rate detector is a gas to be measured. The state of the gas to be measured flowing through the sub-passage is measured by performing heat transfer between and the electric signal, and an electric signal representing the amount of intake air guided to the internal combustion engine is output. Such a technique is disclosed in, for example, Japanese Patent Application Laid-Open No. 2011-252796 (Patent Document 1).

JP 2011-252796 A

  In order to measure the gas flow rate with high accuracy by the thermal flow meter, the flow detection unit of the thermal flow meter is installed in the sub-passage provided in the thermal flow meter for taking in the gas flowing through the main passage. It is required to position and fix with high accuracy. In the technique described in Patent Document 1, a housing including a sub-passage in which a hole for fitting a flow rate detection unit is formed is manufactured in advance, and a sensor assembly including a flow rate detection unit is manufactured separately from the housing. Then, the sensor assembly is fixed to the housing in a state where the flow rate detection unit is inserted into the hole of the sub passage. The gap between the hole of the sub-passage and the flow rate detection unit and the gap of the fitting part of the sensor assembly to the housing are filled with an elastic adhesive, and the mutual linear expansion difference is absorbed by the elastic force of the adhesive. To do.

  In such a structure, it is difficult to accurately set and fix the positional relationship and the angular relationship between the flow rate detection unit and the auxiliary passage when the sensor assembly is fitted into the housing. That is, there has been a problem that the positional relationship and the angular relationship between the sensor assembly and the sub-passage provided in the housing easily change depending on the state of the adhesive. For this reason, in the conventional thermal type flow meter, it was difficult to further improve the flow rate detection accuracy. In general, thermal flow meters are mass-produced. In this mass production process, when fixing the flow rate detector to the specified position or angle with respect to the sub-passage using an adhesive, the flow rate detector is used during bonding using the adhesive and during the solidification process of the adhesive. It is difficult to determine the positional relationship and angle relationship between the sub-passage and the sub-passage, and it is extremely difficult to maintain and fix these positional relationships with high accuracy. For these reasons, conventionally, it has been difficult to further improve the measurement accuracy of the thermal flow meter.

  An object of the present invention is to provide a thermal flow meter with high measurement accuracy.

  In order to solve the above-described problem, the thermal flow meter of the present invention has a heat transfer surface between a sub-passage for flowing the measurement gas taken from the main passage and the measurement gas flowing through the sub-passage. A thermal flow meter including a flow rate detection unit for measuring a flow rate by performing heat transfer, a circuit package including a connection terminal and the flow rate detection unit, and a sub-passage groove for forming the sub-passage And a housing for fixing the circuit package, and a cover for forming the sub passage by covering the sub passage groove formed in the housing, the circuit package detecting the flow rate And a part of the connection terminal are integrally formed with the first resin by the first resin molding process, and the measurement flow path surface including the heat transfer surface is further formed by the first resin molding process. The housing is molded on the surface of the cage, and in the second resin molding step with the second resin, the housing including the sub-passage groove and a fixing portion for fixing the circuit package is molded, and the first molding step The measurement flow path surface including the heat transfer surface formed on the surface of the circuit package is disposed inside the sub-passage groove by molding the sub-passage groove by the second molding step, and further, the second The circuit package is fixed to the housing by molding the fixing portion of the housing in the molding process.

  According to the present invention, a thermal flow meter with high measurement accuracy can be obtained.

1 is a system diagram showing an embodiment in which a thermal flow meter according to the present invention is used in an internal combustion engine control system. It is a figure which shows the external appearance of a thermal type flow meter, FIG. 2 (A) is a left view, and FIG. 2 (B) is a front view. It is a figure which shows the external appearance of a thermal type flow meter, FIG. 3 (A) is a right view, and FIG. 3 (B) is a rear view. It is a figure which shows the external appearance of a thermal type flow meter, FIG. 4 (A) is a top view, FIG.4 (B) is a bottom view. It is a figure which shows the housing of a thermal type flow meter, FIG. 5 (A) is a left view of a housing, and FIG. 5 (B) is a front view of a housing. It is a figure which shows the housing of a thermal type flow meter, FIG. 6 (A) is a right view of a housing, and FIG. 6 (B) is a rear view of a housing. FIG. 7A is a partially enlarged view showing the state of the flow path surface arranged in the sub-passage, and FIG. 7B is a partially enlarged view showing another embodiment of FIG. 7A. It is a figure which shows the external appearance of a table | surface cover, FIG. 8 (A) is a left view, FIG.8 (B) is a front view, FIG.8 (C) is a top view. It is a figure which shows the external appearance of the back cover 304, FIG. 9 (A) is a left view, FIG.9 (B) is a front view, FIG.9 (C) is a top view. It is the elements on larger scale which show the other Example of the Example shown in FIG. It is a block diagram which shows other Example of the Example shown in FIG. 5 and FIG. It is the elements on larger scale which show a part of BB cross section of FIG. It is the elements on larger scale of a terminal connection part. 14A and 14B are external views of a circuit package, in which FIG. 14A is a left side view, FIG. 14B is a front view, and FIG. 14C is a rear view. It is a figure which shows the state which mounted the circuit components in the frame frame of the circuit package. It is explanatory drawing explaining the communicating path which connects the space | gap and opening inside a diaphragm and a diaphragm. It is a figure which shows the state of the circuit package after a 1st resin mold process. It is a figure which shows the other Example of the circuit package shown in FIG. 14, FIG. 18 (A) is a front view of a circuit package, FIG.18 (B) is a rear view. It is a figure which shows the outline | summary of the manufacturing process of a thermal type flow meter, and is a figure which shows the production process of a circuit package. It is a figure which shows the outline | summary of the manufacturing process of a thermal type flow meter, and is a figure which shows the production process of a thermal type flow meter. It is a figure which shows the outline | summary of the manufacturing process of a thermal type flow meter, and is a figure which shows the other Example of the production process of a thermal type flow meter. It is a circuit diagram which shows the flow volume detection circuit of a thermal type flow meter. It is explanatory drawing explaining the flow volume detection part of a flow volume detection circuit.

  The form for carrying out the invention described below (hereinafter referred to as an embodiment) solves various problems that are demanded as actual products, and particularly as a measuring device for measuring the intake air amount of a vehicle. It solves various problems that are desirable for use, and has various effects. One of the various problems solved by the following embodiment is the contents described in the column of the problem to be solved by the invention described above, and one of the various effects exhibited by the following embodiment is as follows. It is the effect described in the column of the effect of the invention. Various problems solved by the following embodiments, and various effects produced by the following embodiments will be described in the description of the following embodiments. Therefore, the problems and effects solved by the embodiments described in the following embodiments are also described in the contents other than the contents of the problem column to be solved by the invention and the effect column of the invention.

  In the following embodiments, the same reference numerals indicate the same configuration even when the figure numbers are different, and the same effects are achieved. For configurations that have already been described, only the reference numerals are attached to the drawings, and the description may be omitted.

1. FIG. 1 shows an embodiment in which the thermal flow meter according to the present invention is used for an electronic fuel injection internal combustion engine control system. It is a system diagram. Based on the operation of the internal combustion engine 110 including the engine cylinder 112 and the engine piston 114, the intake air is sucked from the air cleaner 122 as the measurement target gas 30 and passes through the main passage 124 such as the intake body, the throttle body 126, and the intake manifold 128. Guided to the combustion chamber of the engine cylinder 112. The flow rate of the gas 30 to be measured, which is the intake air led to the combustion chamber, is measured by the thermal flow meter 300 according to the present invention, and fuel is supplied from the fuel injection valve 152 based on the measured flow rate. The gas to be measured is introduced into the combustion chamber together with a certain gas 30 to be measured. In the present embodiment, the fuel injection valve 152 is provided at the intake port of the internal combustion engine, and the fuel injected into the intake port forms an air-fuel mixture together with the measured gas 30 as intake air, and passes through the intake valve 116. It is guided to the combustion chamber and burns to generate mechanical energy.

  In recent years, as a method excellent in exhaust gas purification and fuel consumption improvement in many vehicles, a method in which a fuel injection valve 152 is attached to a cylinder head of an internal combustion engine and fuel is directly injected into each combustion chamber from the fuel injection valve 152 has been adopted. . The thermal flow meter 300 can be used not only for the method of injecting fuel into the intake port of the internal combustion engine shown in FIG. 1 but also for the method of directly injecting fuel into each combustion chamber. In both types, the basic concept of the control parameter measurement method including the method of using the thermal flow meter 300 and the control method of the internal combustion engine including the fuel supply amount and ignition timing are substantially the same. A method of injecting fuel into the port is shown in FIG.

  The fuel and air guided to the combustion chamber are in a mixed state of fuel and air, and are burned explosively by spark ignition of the spark plug 154 to generate mechanical energy. The combusted gas is guided from the exhaust valve 118 to the exhaust pipe, and exhausted as exhaust 24 from the exhaust pipe to the outside of the vehicle. The flow rate of the gas 30 to be measured, which is the intake air led to the combustion chamber, is controlled by the throttle valve 132 whose opening degree changes based on the operation of the accelerator pedal. The fuel supply amount is controlled based on the flow rate of the intake air guided to the combustion chamber, and the driver controls the flow rate of the intake air guided to the combustion chamber by controlling the opening degree of the throttle valve 132, thereby The mechanical energy generated by the engine can be controlled.

1.1 Outline of Control of Internal Combustion Engine Control System The flow rate and temperature of the measurement target gas 30 that is the intake air that is taken in from the air cleaner 122 and flows through the main passage 124 are measured by the thermal flow meter 300, and An electric signal indicating the flow rate and temperature of the intake air is input to the control device 200. Further, the output of the throttle angle sensor 144 that measures the opening degree of the throttle valve 132 is input to the control device 200, and the positions and states of the engine piston 114, the intake valve 116, and the exhaust valve 118 of the internal combustion engine, and the rotation of the internal combustion engine. In order to measure the speed, the output of the rotation angle sensor 146 is input to the control device 200. The output of the oxygen sensor 148 is input to the control device 200 in order to measure the state of the mixture ratio between the fuel amount and the air amount from the state of the exhaust 24.

The control device 200 calculates the fuel injection amount and the ignition timing based on the flow rate of intake air that is the output of the thermal flow meter 300 and the rotational speed of the internal combustion engine that is measured based on the output of the rotation angle sensor 146. Based on these calculation results, the amount of fuel supplied from the fuel injection valve 152 and the ignition timing ignited by the spark plug 154 are controlled. The fuel supply amount and ignition timing are actually based on the intake air temperature and throttle angle change state measured by the thermal flow meter 300, the engine rotational speed change state, and the air-fuel ratio state measured by the oxygen sensor 148. It is finely controlled. The control device 200 further controls the amount of air that bypasses the throttle valve 132 by the idle air control valve 156 in the idle operation state of the internal combustion engine, thereby controlling the rotational speed of the internal combustion engine in the idle operation state.

1.2 The importance of improving the measurement accuracy of the thermal flow meter and the installation environment of the thermal flow meter Both the fuel supply amount and ignition timing, which are the main controlled variables of the internal combustion engine, are the main parameters of the output of the thermal flow meter 300 Is calculated as Therefore, improvement in measurement accuracy of the thermal flow meter 300, suppression of changes over time, and improvement in reliability are important in terms of improvement in vehicle control accuracy and ensuring reliability. In particular, in recent years, there has been a very high demand for fuel efficiency of vehicles and a very high demand for exhaust gas purification. In order to meet these demands, it is extremely important to improve the measurement accuracy of the flow rate of the measurement target gas 30 that is the intake air measured by the thermal flow meter 300. It is also important that the thermal flow meter 300 maintains high reliability.

The vehicle on which the thermal flow meter 300 is mounted is used in an environment with a large temperature change, and is used in wind and rain or snow. When a vehicle travels on a snowy road, it travels on a road on which an antifreezing agent is sprayed. It is desirable for the thermal flow meter 300 to take into account the response to temperature changes in the environment in which it is used and the response to dust and contaminants. Further, the thermal flow meter 300 is installed in an environment that receives vibrations of the internal combustion engine. It is required to maintain high reliability against vibration.

  The thermal flow meter 300 is attached to an intake pipe that is affected by heat generated from the internal combustion engine. Therefore, heat generated by the internal combustion engine is transmitted to the thermal flow meter 300 via the intake pipe which is the main passage 124. Since the thermal flow meter 300 measures the flow rate of the gas to be measured by performing heat transfer with the gas to be measured, it is important to suppress the influence of heat from the outside as much as possible.

  As described below, the thermal flow meter 300 mounted on the vehicle simply solves the problem described in the column of the problem to be solved by the invention, and exhibits the effect described in the column of the effect of the invention. In addition, as will be described below, the above-described various problems are fully considered, and various problems required as products are solved, and various effects are produced. Specific problems to be solved by the thermal flow meter 300 and specific effects achieved will be described in the description of the following examples.

2. 2. Structure of Thermal Flow Meter 300 2.1 External Structure of Thermal Flow Meter 300 FIGS. 2, 3, and 4 are views showing the external appearance of the thermal flow meter 300, and FIG. 2B is a front view, FIG. 3A is a right side view, FIG. 3B is a rear view, FIG. 4A is a plan view, and FIG. It is a bottom view. The thermal flow meter 300 includes a housing 302, a front cover 303, and a back cover 304. The housing 302 includes a flange 312 for fixing the thermal flow meter 300 to the intake body that is the main passage 124, an external connection portion 305 having an external terminal 306 for electrical connection with an external device, and a flow rate. Etc., a measuring unit 310 is provided. A sub-passage groove for creating a sub-passage is provided inside the measuring unit 310, and a flow rate detection for measuring the flow rate of the gas 30 to be measured flowing through the main passage 124 is provided inside the measuring unit 310. A circuit package 400 including a temperature detection unit 452 for measuring the temperature of the measurement target gas 30 flowing through the unit 602 (see FIG. 20) and the main passage 124 is provided.

2.2 Effects based on the external structure of the thermal flow meter 300 Since the inlet 350 of the thermal flow meter 300 is provided on the distal end side of the measuring unit 310 extending from the flange 312 toward the center of the main passage 124, A portion of the gas that is not near the inner wall surface of the main passage 124 but near the center away from the inner wall surface can be taken into the sub-passage. For this reason, the thermal type flow meter 300 can measure the flow rate and temperature of the gas in the part away from the inner wall surface of the main passage 124, and can suppress a decrease in measurement accuracy due to the influence of heat or the like. In the vicinity of the inner wall surface of the main passage 124, the temperature of the measurement target gas 30 is easily affected by the temperature of the main passage 124 and is different from the original temperature of the gas. It will be different from the state. In particular, when the main passage 124 is an intake body of an engine, it is often maintained at a high temperature under the influence of heat from the engine. For this reason, the gas in the vicinity of the inner wall surface of the main passage 124 is often higher than the original temperature of the main passage 124, which causes a reduction in measurement accuracy.

In the vicinity of the inner wall surface of the main passage 124, the fluid resistance is large, and the flow velocity is lower than the average flow velocity of the main passage 124. For this reason, if the gas in the vicinity of the inner wall surface of the main passage 124 is taken into the sub passage as the gas to be measured 30, a decrease in the flow velocity with respect to the average flow velocity in the main passage 124 may lead to a measurement error. In the thermal flow meter 300 shown in FIGS. 2 to 4, the inlet 350 is provided at the tip of the thin and long measuring unit 310 extending from the flange 312 toward the center of the main passage 124, so that the flow velocity in the vicinity of the inner wall surface is provided. Measurement errors related to the reduction can be reduced. In addition, in the thermal type flow meter 300 shown in FIGS. 2 to 4, not only the inlet 350 is provided at the distal end portion of the measuring unit 310 extending from the flange 312 toward the center of the main passage 124, but also the outlet of the sub passage. Is also provided at the tip of the measurement unit 310, so that measurement errors can be further reduced.

The measurement unit 310 of the thermal flow meter 300 has a shape that extends long from the flange 312 toward the center of the main passage 124, and a portion of the gas to be measured 30 such as intake air is taken into the sub-passage at the tip. There are provided an inlet 350 and an outlet 352 for returning the gas 30 to be measured from the auxiliary passage to the main passage 124. The measuring section 310 has a shape that extends long along the axis from the outer wall of the main passage 124 toward the center, but the width has a narrow shape as shown in FIGS. 2 (A) and 3 (A). doing. That is, the measurement unit 310 of the thermal flow meter 300 has a side surface with a thin width and a substantially rectangular front surface. Thereby, the thermal flow meter 300 can be provided with a sufficiently long sub-passage, and the fluid resistance of the measurement target gas 30 can be suppressed to a small value. For this reason, the thermal type flow meter 300 can measure the flow rate of the measurement target gas 30 with high accuracy while suppressing the fluid resistance to a small value.

2.3 Structure of Temperature Detection Unit 452 As shown in FIGS. 2 and 3, the flow of the measurement target gas 30 is positioned closer to the flange 312 side than the auxiliary passage provided on the distal end side of the measurement unit 310. An inlet 343 opening toward the upstream side is formed, and a temperature detector 452 for measuring the temperature of the measurement target gas 30 is disposed inside the inlet 343. In the central part of the measurement unit 310 where the inlet 343 is provided, the upstream outer wall in the measurement unit 310 constituting the housing 302 is recessed toward the downstream side, and the temperature detection unit 452 extends from the depression-shaped upstream outer wall. Has a shape protruding toward the upstream side. Further, a front cover 303 and a back cover 304 are provided on both side portions of the hollow outer wall, and upstream ends of the front cover 303 and the rear cover 304 are directed upstream from the hollow outer wall. It has a protruding shape. Therefore, an inlet 343 for taking in the measurement target gas 30 is formed by the hollow outer wall and the front cover 303 and the back cover 304 on both sides thereof. The gas 30 to be measured taken from the inlet 343 comes into contact with the temperature detector 452 provided inside the inlet 343, and the temperature is measured by the temperature detector 452. Further, the gas to be measured 30 flows along a portion supporting the temperature detection unit 452 protruding upstream from the outer wall of the housing 302 having a hollow shape, and the front side outlet 344 and the back side outlet 345 provided in the front cover 303 and the back cover 304. Is discharged into the main passage 124.

2.4 Effects related to the temperature detector 452 The temperature of the gas flowing into the inlet 343 from the upstream side in the direction along the flow of the gas 30 to be measured is measured by the temperature detector 452, and the gas further passes through the temperature detector 452. By flowing toward the base portion of the temperature detection unit 452 that is the supporting portion, the temperature of the portion that supports the temperature detection portion 452 is cooled in a direction approaching the temperature of the measurement target gas 30. The temperature of the intake pipe, which is the main passage 124, is normally high, and heat is transmitted from the flange 312 or the heat insulating portion 315 to the portion supporting the temperature detecting portion 452 through the upstream outer wall in the measuring portion 310, and the temperature measurement accuracy There is a risk of affecting. As described above, after the gas to be measured 30 is measured by the temperature detection unit 452, the support portion is cooled by flowing along the support portion of the temperature detection unit 452. Therefore, it is possible to suppress the heat from being transmitted from the flange 312 or the heat insulating portion 315 to the portion supporting the temperature detecting portion 452 through the upstream outer wall in the measuring portion 310.

In particular, the support portion of the temperature detection unit 452 has a shape in which the upstream outer wall in the measurement unit 310 is recessed toward the downstream side (described below with reference to FIGS. 5 and 6). The distance between the upstream outer wall in 310 and the temperature detector 452 can be increased. As the heat conduction distance becomes longer, the distance of the cooling portion by the measurement target gas 30 becomes longer. Accordingly, it is possible to reduce the influence of heat generated from the flange 312 or the heat insulating portion 315. As a result, the measurement accuracy is improved. Since the upstream outer wall has a shape recessed toward the downstream side (described below with reference to FIGS. 5 and 6), the circuit package 400 described below (see FIGS. 5 and 6) is fixed. Becomes easy.

2.5 Structure and effect of upstream side surface and downstream side surface of measurement unit 310 Upstream side protrusion 317 and downstream side projection 318 are provided on the upstream side surface and downstream side surface of measurement unit 310 constituting thermal flow meter 300, respectively. Is provided. The upstream protrusion 317 and the downstream protrusion 318 have a shape that becomes narrower toward the tip with respect to the root, and the fluid resistance of the measurement target gas 30 that is the intake air flowing in the main passage 124 can be reduced. An upstream protrusion 317 is provided between the heat insulating portion 315 and the inlet 343. The upstream protrusion 317 has a large cross-sectional area and large heat conduction from the flange 312 or the heat insulating portion 315, but the upstream protrusion 317 is interrupted before the inlet 343, and further, the upstream protrusion 317 has a temperature detecting portion 452 side. The distance from the temperature detection unit 452 to the temperature detection unit 452 is long due to the depression of the outer wall on the upstream side of the housing 302 as will be described later. For this reason, the heat conduction from the heat insulation part 315 to the support part of the temperature detection part 452 is suppressed.

  In addition, a gap including a terminal connection portion 320 and a terminal connection portion 320 described later is formed between the flange 312 or the heat insulating portion 315 and the temperature detection portion 452. For this reason, the gap between the flange 312 or the heat insulation part 315 and the temperature detection part 452 is long, and the front cover 303 and the back cover 304 are provided in this long part, and this part acts as a cooling surface. Therefore, the influence of the temperature of the wall surface of the main passage 124 on the temperature detection unit 452 can be reduced. In addition, since the gap between the flange 312 or the heat insulating portion 315 and the temperature detecting portion 452 becomes long, the intake portion of the gas 30 to be measured leading to the sub passage can be brought closer to the center of the main passage 124. A decrease in measurement accuracy due to heat transfer from the wall surface of the main passage 124 can be suppressed.

  As shown in FIGS. 2B and 3B, the measurement unit 310 inserted into the main passage 124 has a very narrow side surface, and the downstream protrusion 318 and the upstream protrusion 317 provide air resistance. The tip has a narrow shape with respect to the root to be reduced. For this reason, an increase in fluid resistance due to the insertion of the thermal flow meter 300 into the main passage 124 can be suppressed. Further, in the portion where the downstream protrusion 318 and the upstream protrusion 317 are provided, the upstream protrusion 317 and the downstream protrusion 318 protrude from both sides of the front cover 303 and the back cover 304. . Since the upstream protrusion 317 and the downstream protrusion 318 are made of a resin mold, the upstream protrusion 317 and the downstream cover 304 are easily formed into a shape with low air resistance, while the front cover 303 and the back cover 304 have a shape with a wide cooling surface. For this reason, the thermal flow meter 300 has an effect that air resistance is reduced and the air to be measured that flows through the main passage 124 is easily cooled.

2.6 Structure and Effect of Flange 312 The flange 312 is provided with a plurality of recesses 314 in the lower surface of the flange 312 facing the main passage 124 to reduce the heat transfer surface between the flange 312 and the main passage 124. The thermal flow meter 300 is less susceptible to heat. The screw hole 313 of the flange 312 is for fixing the thermal type flow meter 300 to the main passage 124, and the surface of the screw hole 313 around the screw passage 313 facing the main passage 124 is separated from the main passage 124. A space is formed between the main passage 124 and a surface around the screw hole 313 facing the main passage 124. By doing in this way, it has the structure which can reduce the heat transfer from the main channel | path 124 with respect to the thermal type flowmeter 300, and can prevent the fall of the measurement precision by heat. Furthermore, the recess 314 functions not only to reduce the heat conduction but also to reduce the influence of shrinkage of the resin constituting the flange 312 when the housing 302 is molded.

A heat insulating part 315 is provided on the measurement part 310 side of the flange 312. The measurement part 310 of the thermal type flow meter 300 is inserted into the inside from an attachment hole provided in the main passage 124, and the thermal insulation part 315 faces the inner surface of the attachment hole of the main passage 124. The main passage 124 is, for example, an intake body, and the main passage 124 is often maintained at a high temperature. Conversely, when starting in a cold region, the main passage 124 may be at a very low temperature. If such a high or low temperature state of the main passage 124 affects the temperature detection unit 452 or the flow rate measurement described later, the measurement accuracy decreases. For this reason, a plurality of depressions 316 are provided in the thermal insulation portion 315 adjacent to the inner surface of the hole of the main passage 124, and the width of the thermal insulation portion 315 adjacent to the inner surface of the hole between the adjacent depressions 316 is extremely thin. , Or less than one third of the width of the recess 316 in the fluid flow direction. Thereby, the influence of temperature can be reduced. In addition, the heat insulating portion 315 has a thick resin. During resin molding of the housing 302, volume shrinkage occurs when the resin cools from a high temperature state to a low temperature and cures, and distortion due to the generation of stress occurs. By forming the depression 316 in the heat insulating portion 315, the volume shrinkage can be made more uniform, and the stress concentration can be reduced.

  The measurement unit 310 of the thermal flow meter 300 is inserted into the inside through an attachment hole provided in the main passage 124 and is fixed to the main passage 124 with a screw by the flange 312 of the thermal flow meter 300. It is desirable that the thermal flow meter 300 is fixed in a predetermined positional relationship with respect to the mounting hole provided in the main passage 124. A recess 314 provided in the flange 312 can be used for positioning the main passage 124 and the thermal flow meter 300. By forming the convex portion in the main passage 124, the convex portion and the recess 314 can be formed into a fitting relationship, and the thermal flow meter 300 can be fixed to the main passage 124 at an accurate position.

2.7 Structure and Effect of External Connection Portion 305 and Flange 312 FIG. 4A is a plan view of the thermal flow meter 300. FIG. Four external terminals 306 and a correction terminal 307 are provided in the external connection portion 305. The external terminal 306 is a terminal for outputting a flow rate and temperature as a measurement result of the thermal flow meter 300 and a power supply terminal for supplying DC power for operating the thermal flow meter 300. The correction terminal 307 is used to measure the produced thermal flow meter 300, obtain a correction value related to each thermal flow meter 300, and store the correction value in a memory inside the thermal flow meter 300. In the subsequent measurement operation of the thermal flow meter 300, the correction data representing the correction value stored in the memory is used, and the correction terminal 307 is not used. Therefore, the correction terminal 307 has a shape different from that of the external terminal 306 so that the correction terminal 307 does not get in the way when the external terminal 306 is connected to another external device. In this embodiment, the correction terminal 307 is shorter than the external terminal 306, and even if a connection terminal to an external device connected to the external terminal 306 is inserted into the external connection unit 305, the connection is not hindered. It has become. In addition, a plurality of depressions 308 are provided along the external terminals 306 inside the external connection portion 305, and these depressions 308 concentrate stress due to resin shrinkage when the resin that is the material of the flange 312 cools and hardens. It is for reducing.

  In addition to the external terminal 306 used during the measurement operation of the thermal flow meter 300, a correction terminal 307 is provided to measure the characteristics of each of the thermal flow meter 300 before shipping and to measure product variations. The correction value for reducing the variation can be stored in the memory inside the thermal flow meter 300. After the correction value setting step, the correction terminal 307 is formed in a shape different from that of the external terminal 306 so that the correction terminal 307 does not interfere with the connection between the external terminal 306 and the external device. In this way, the thermal flow meter 300 can reduce the variation of each before shipping and can improve the measurement accuracy.

3. 3.1 Overall Structure of Housing 302 and its Effects 3.1 Structure and Effects of Sub-passage and Flow Rate Detection Unit FIGS. 5 and 6 show the state of the housing 302 with the front cover 303 and the back cover 304 removed from the thermal flow meter 300. FIG. 5A is a left side view of the housing 302, FIG. 5B is a front view of the housing 302, FIG. 6A is a right side view of the housing 302, and FIG. 4 is a rear view of the housing 302. FIG. The housing 302 has a structure in which the measuring unit 310 extends from the flange 312 toward the center of the main passage 124, and a sub-passage groove for forming the sub-passage is provided on the tip side thereof. In this embodiment, the sub-passage grooves are provided on both the front and back surfaces of the housing 302. FIG. 5B shows the front-side sub-passage groove 332, and FIG. 6B shows the back-side sub-passage groove 334. An inlet groove 351 for forming the inlet 350 of the sub-passage and an outlet groove 353 for forming the outlet 352 are provided at the distal end portion of the housing 302, so that the gas in a portion away from the inner wall surface of the main passage 124 In other words, the gas flowing in the portion close to the central portion of the main passage 124 can be taken in from the inlet 350 as the gas 30 to be measured. The gas flowing in the vicinity of the inner wall surface of the main passage 124 is affected by the wall surface temperature of the main passage 124 and often has a temperature different from the average temperature of the gas flowing through the main passage 124 such as intake air. Further, the gas flowing in the vicinity of the inner wall surface of the main passage 124 often exhibits a flow rate that is slower than the average flow velocity of the gas flowing through the main passage 124. Since the thermal flow meter 300 of the embodiment is not easily affected by this, it is possible to suppress a decrease in measurement accuracy.

  The sub passages formed by the front side sub passage groove 332 and the back side sub passage groove 334 described above are connected to the heat insulating portion 315 by the outer wall recess 366, the upstream outer wall 335, and the downstream outer wall 336. The upstream outer wall 335 is provided with an upstream protrusion 317, and the downstream outer wall 336 is provided with a downstream protrusion 318. With such a structure, the thermal flow meter 300 is fixed to the main passage 124 by the flange 312, whereby the measuring unit 310 having the circuit package 400 is fixed to the main passage 124 with high reliability.

In this embodiment, the sub-passage groove for forming the sub-passage is formed in the housing 302, and the sub-passage is completed by the sub-passage groove and the cover by covering the cover with the front and back surfaces of the housing 302. . With such a structure, all the sub-passage grooves can be formed as a part of the housing 302 in the resin molding process of the housing 302. In addition, since molds are provided on both sides of the housing 302 when the housing 302 is molded, by using both molds, both the front side sub-passage groove 332 and the back side sub-passage groove 334 are all part of the housing 302. It becomes possible to mold. By providing the front cover 303 and the back cover 304 on both sides of the housing 302, the secondary passages on both sides of the housing 302 can be completed. By forming the front side secondary passage groove 332 and the back side secondary passage groove 334 on both surfaces of the housing 302 using a mold, the secondary passage can be formed with high accuracy. Moreover, high productivity is obtained.

In FIG. 6B, a part of the measurement target gas 30 flowing through the main passage 124 is taken into the back side sub passage groove 334 from the inlet groove 351 that forms the inlet 350 and flows through the back side sub passage groove 334. The back side sub-passage groove 334 has a shape that becomes deeper as it advances, and as the gas flows along the groove, the measured gas 30 gradually moves in the front side direction. In particular, the back side sub-passage groove 334 is provided with a steeply inclined portion 347 that becomes deeper and deeper at the upstream portion 342 of the circuit package 400, and a part of the air having a small mass moves along the steeply inclined portion 347. The upstream portion 342 flows through the measurement flow path surface 430 shown in FIG. On the other hand, since a foreign substance having a large mass is difficult to change its course rapidly due to inertial force, the foreign substance moves on the measurement channel surface rear surface 431 shown in FIG. Thereafter, it passes through the downstream portion 341 of the circuit package 400 and flows through the measurement channel surface 430 shown in FIG.

  The flow of the measurement target gas 30 in the vicinity of the heat transfer surface exposed portion 436 will be described with reference to FIG. In the front side sub-passage groove 332 illustrated in FIG. 5B, the air that is the measurement target gas 30 that has moved from the upstream portion 342 of the circuit package 400 to the front side sub-passage groove 332 is along the measurement channel surface 430. Then, heat is transferred to and from the flow rate detection unit 602 for measuring the flow rate via the heat transfer surface exposed portion 436 provided on the measurement flow path surface 430, and the flow rate is measured. Both the gas 30 to be measured that has passed through the measurement flow path surface 430 and the air that has flowed from the downstream portion 341 of the circuit package 400 to the front side sub-passage groove 332 flow along the front side sub-passage groove 332 to form the outlet 352. It is discharged from the exit groove 353 to the main passage 124.

  A substance having a large mass such as dust mixed in the measurement target gas 30 has a large inertial force, and along the surface of the portion of the steeply inclined portion 347 shown in FIG. It is difficult to change the course rapidly in the deep direction of the groove. For this reason, the foreign matter having a large mass moves toward the measurement channel surface rear surface 431, and the foreign matter can be prevented from passing near the heat transfer surface exposed portion 436. In this embodiment, since many foreign substances having a large mass other than gas pass through the measurement channel surface rear surface 431 which is the back surface of the measurement channel surface 430, they are caused by foreign matters such as oil, carbon, and dust. The influence of dirt can be reduced, and the decrease in measurement accuracy can be suppressed. That is, since it has a shape in which the path of the gas to be measured 30 is suddenly changed along an axis that crosses the flow axis of the main passage 124, the influence of foreign matter mixed in the gas to be measured 30 can be reduced.

  In this embodiment, the flow path formed by the back side sub-passage groove 334 draws a curve from the front end of the housing 302 toward the flange, and the gas flowing through the sub-passage flows into the main passage 124 at the position closest to the flange. On the other hand, the flow is in the reverse direction, and the sub-passage on the back surface, which is one side in the flow portion in the reverse direction, is connected to the sub-passage formed on the surface side, which is the other side. By doing so, it becomes easy to fix the heat transfer surface exposed portion 436 of the circuit package 400 to the sub-passage, and further, it becomes easy to take in the gas 30 to be measured at a position close to the central portion of the main passage 124.

  In this embodiment, the flow passage surface 430 for measuring the flow rate has a structure that penetrates the back side sub-passage groove 334 and the front side sub-passage groove 332 in the front-rear direction in the flow direction, and the front end side of the circuit package 400 is the housing. In this configuration, the cavity 382 is provided instead of the configuration supported by 302, and the space of the upstream portion 342 of the circuit package 400 and the space of the downstream portion 341 of the circuit package 400 are connected. As a configuration that penetrates the upstream portion 342 of the circuit package 400 and the downstream portion 341 of the circuit package 400, the front side sub passage groove 332 formed on the other surface of the housing 302 from the back side sub passage groove 334 formed on one surface of the housing 302. The sub passage is formed in a shape in which the gas 30 to be measured moves. With such a configuration, the sub-passage grooves can be formed on both surfaces of the housing 302 in a single resin molding step, and the structure connecting the sub-passage grooves on both surfaces can be formed together.

  When molding the housing 302, a structure is formed that penetrates the upstream portion 342 of the circuit package 400 and the downstream portion 341 of the circuit package 400 by clamping both sides of the measurement flow path surface 430 formed in the circuit package 400 with a molding die. In addition, the circuit package 400 can be mounted on the housing 302 simultaneously with resin molding of the housing 302. Thus, by forming the circuit package 400 by inserting it into the molding die of the housing 302, the circuit package 400 and the heat transfer surface exposed portion 436 can be mounted with high accuracy in the sub-passage.

  In this embodiment, the circuit package 400 is configured to penetrate the upstream portion 342 and the downstream portion 341 of the circuit package 400. However, by adopting a configuration that penetrates either the upstream part 342 or the downstream part 341 of the circuit package 400, the shape of the sub-passage that connects the back-side sub-passage groove 334 and the front-side sub-passage groove 332 can be achieved in a single resin molding step. It is also possible to mold.

  A back side sub-passage inner peripheral wall 391 and a back side sub-passage outer peripheral wall 392 are provided on both sides of the back side sub-passage groove 334, and the height-direction tips of the back side sub-passage inner peripheral wall 391 and the back side sub-passage outer peripheral wall 392 The back side sub-passage of the housing 302 is formed by the close contact between the portion and the inner surface of the back cover 304. Further, a front side sub-passage inner peripheral wall 393 and a front side sub-passage outer peripheral wall 394 are provided on both sides of the front side sub-passage groove 332. The front side sub-passage inner peripheral wall 393 and the front-side sub-passage outer peripheral wall 394 and the front end portion in the height direction and the front side. When the inner surface of the cover 303 is in close contact, the front side sub-passage of the housing 302 is formed.

  In this embodiment, the measurement target gas 30 is divided into both the measurement flow path surface 430 and the back surface thereof, and the heat transfer surface exposed portion 436 for measuring the flow rate is provided on one side. Instead of being divided into two passages, only the surface side of the measurement channel surface 430 may be passed. By bending the sub-passage along the second axis in a direction crossing the first axis in the flow direction of the main passage 124, the foreign matter mixed in the measurement target gas 30 can be removed on one side where the second axis is less bent. By providing the measurement flow path surface 430 and the heat transfer surface exposed portion 436 on the side with the larger curvature of the second axis, the influence of foreign matter can be reduced.

  Further, in this embodiment, a measurement flow path surface 430 and a heat transfer surface exposed portion 436 are provided at the connecting portion between the front side sub passage groove 332 and the back side sub passage groove 334. However, it may be provided in the front side sub-passage groove 334 or in the back side sub-passage groove 334 instead of the connecting portion between the front side sub-passage groove 332 and the back side sub-passage groove 334.

A throttle shape is formed in the heat transfer surface exposed portion 436 for measuring the flow rate provided on the measurement flow path surface 430 (described below with reference to FIG. 7). As a result, measurement accuracy is improved. Even if a vortex is generated in the gas flow on the upstream side of the heat transfer surface exposed portion 436, the vortex can be eliminated or reduced by the restriction, and the measurement accuracy is improved.

  5 and 6, the upstream outer wall 335 includes an outer wall recess 366 that has a shape that is recessed downstream at the root of the temperature detector 452. The outer wall recess 366 increases the distance between the temperature detection unit 452 and the outer wall recess 366, thereby reducing the influence of heat transmitted through the upstream outer wall 335.

Further, the circuit package 400 is fixed by wrapping the circuit package 400 in the fixing portion 372. However, by further fixing the circuit package 400 by the outer wall recess portion 366, the force for fixing the circuit package 400 is increased. Can do. The fixed portion 372 includes the circuit package 400 in a direction along the flow axis of the measurement target gas 30. On the other hand, the outer wall recess 366 includes the circuit package 400 in a direction crossing the flow axis of the measurement target gas 30. That is, the circuit package 400 is included in such a manner that the direction in which the fixing portion 372 is included is different. Since the circuit package 400 is included in two different directions, the securing force is increased. Although the outer wall recess 366 is a part of the upstream outer wall 335, the circuit package 400 is arranged in a different direction from the fixing portion 372 on the downstream outer wall 336 instead of the upstream outer wall 335 for increasing the fixing force. May be included. For example, the downstream outer wall 336 may include the plate portion of the circuit package 400, or the downstream outer wall 336 may include a recess recessed in the upstream direction or a protrusion projecting in the upstream direction to include the circuit package 400. good. The inclusion of the circuit package 400 by providing the outer wall recess 366 on the upstream outer wall 335 has the effect of increasing the thermal resistance between the temperature detector 452 and the upstream outer wall 335 in addition to fixing the circuit package 400. This is because they were held.

  The outer wall recess 366 is provided at the base of the temperature detection unit 452, and thereby the influence of heat transmitted from the flange 312 or the heat insulating unit 315 through the upstream outer wall 335 can be reduced. Further, a temperature measurement recess 368 formed by a notch between the upstream protrusion 317 and the temperature detection unit 452 is provided. The temperature measurement depression 368 can reduce the transfer of heat provided to the temperature detector 452 via the upstream protrusion 317. Thereby, the detection accuracy of the temperature detector 452 is improved. In particular, since the upstream protrusion 317 has a large cross-sectional area, heat is easily transmitted, and the function of the temperature measuring recess 368 for preventing heat transfer is important.

3.2 Structure and Effect of Sub-Flow-Flow Detection Unit FIG. 7 is a partially enlarged view showing a state in which the measurement channel surface 430 of the circuit package 400 is arranged inside the sub-passage groove. It is -A sectional drawing. Note that this figure is a conceptual diagram, and the details shown in FIGS. 5 and 6 are omitted and simplified in detail in FIG. 7, and the details are slightly modified. The left portion in FIG. 7 is the end portion of the back side auxiliary passage groove 334, and the right side portion is the starting end portion of the front side auxiliary passage groove 332. Although not clearly shown in FIG. 7, penetrating portions are provided on the left and right sides of the circuit package 400 having the measurement channel surface 430, and the back sides are provided on the left and right sides of the circuit package 400 having the measurement channel surface 430. The sub passage groove 334 and the front side sub passage groove 332 are connected.

The gas to be measured 30 taken from the inlet 350 and flowing through the back side sub-passage formed by the back side sub-passage groove 334 is guided from the left side of FIG. 7, and a part of the gas to be measured 30 is upstream of the circuit package 400. 342 flows through the surface of the measurement channel surface 430 of the circuit package 400 and the channel 386 formed by the protrusion 356 provided on the front cover 303 via the through-hole 342, and the other gas to be measured 30 is used for measurement. It flows in the direction of the flow path 387 formed by the flow path surface back surface 431 and the back cover 304. Thereafter, the gas to be measured 30 that has flowed through the flow path 387 moves toward the front side sub-passage groove 332 through the penetration portion of the downstream portion 341 of the circuit package 400, and merges with the gas to be measured 30 that is flowing through the flow path 386. Then, it flows through the front side auxiliary passage groove 332 and is discharged from the outlet 352 to the main passage 124. As shown in FIG. 7B, a protrusion 358 provided on the back cover 304 may project toward the measurement channel surface rear surface 431 in the channel 387.

  The measured gas 30 led to the flow path 386 from the back side sub-passage groove 334 through the penetration part of the upstream part 342 of the circuit package 400 is bent more than the flow path guided to the flow path 387. Since the sub-passage groove is formed, a substance having a large mass such as dust contained in the gas to be measured 30 gathers in the flow path 387 having a small bend. For this reason, almost no foreign substance flows into the flow path 386.

  In the flow path 386, a structure is formed in which the throttle is formed by the protrusion 356 provided on the front cover 303 projecting gradually toward the measurement flow path surface 430 continuously from the most distal portion of the front side sub-passage groove 332. Is made. A flow path surface for measurement 430 is arranged on one side of the throttle part of the flow path 386, and a heat transfer surface exposed part for allowing the flow rate detection unit 602 to transfer heat to the measurement target gas 30 on the flow path surface for measurement 430. 436 is provided. In order to measure the flow rate detection unit 602 with high accuracy, it is desirable that the measurement target gas 30 is a laminar flow with few vortices in the heat transfer surface exposed portion 436. In addition, the measurement accuracy is improved when the flow velocity is high. For this purpose, the diaphragm is formed by the projection 356 provided on the front cover 303 facing the measurement channel surface 430 smoothly projecting toward the measurement channel surface 430. This restriction acts to reduce the vortex of the measured gas 30 and bring it closer to the laminar flow. Further, the flow velocity is increased in the throttle portion, and since the heat transfer surface exposed portion 436 for measuring the flow rate is arranged in the throttle portion, the flow rate measurement accuracy is improved.

  A projection is formed by projecting the protrusion 356 into the sub-passage groove so as to face the heat transfer surface exposed portion 436 provided on the measurement flow path surface 430, so that the measurement accuracy can be improved. The protrusion 356 for forming the aperture is provided on the cover facing the heat transfer surface exposed portion 436 provided on the measurement flow path surface 430. In FIG. 7, since the cover facing the heat transfer surface exposed portion 436 provided on the measurement flow path surface 430 is the front cover 303, the front cover 303 is provided with a protrusion 356, but the front cover 303 or the back cover 304 is provided. Of these, it may be provided on the cover facing the heat transfer surface exposed portion 436 provided on the measurement flow path surface 430. Depending on which of the measurement flow path surface 430 and the surface on which the heat transfer surface exposed portion 436 is provided in the circuit package 400, which of the covers facing the heat transfer surface exposed portion 436 is changed.

  The distribution of the gas 30 to be measured between the flow path 386 and the flow path 387 is also related to high-accuracy measurement. As shown in FIG. 7B, the projection 358 provided on the back cover 304 is connected to the flow path 387. It is also possible to adjust the distribution of the gas 30 to be measured between the flow path 386 and the flow path 387 by projecting to the flow path. Further, by providing a throttle portion in the flow path 387, the flow rate is increased, and foreign substances such as dust are drawn into the flow path 387. In the embodiment shown in FIG. 7B, the diaphragm 358 is used as one of various adjustment means for the flow path 386 and the flow path 387. However, the measurement flow path surface back surface 431 and the back cover 304 are used. The distribution of the flow rate between the flow channel 386 and the flow channel 387 described above may be adjusted by adjusting the width between the channels. In this case, as shown in FIG. 7A, the protrusion 358 provided on the back cover 304 is not necessary.

  In FIG. 5 and FIG. 6, the trace of the mold used in the resin molding process of the circuit package 400 is applied to the measurement channel surface rear surface 431 which is the back surface of the heat transfer surface exposed portion 436 provided on the measurement channel surface 430. 442 remains. The press mark 442 does not particularly hinder measurement of the flow rate, and there is no problem even if the press mark 442 remains as it is. As will be described later, when the circuit package 400 is molded with a resin mold, it is important to protect the semiconductor diaphragm of the flow rate detection unit 602. For this reason, it is important to hold the back surface of the heat transfer surface exposed portion 436. It is also important that the resin that covers the circuit package 400 does not flow into the heat transfer surface exposed portion 436. From this point of view, the measurement flow path surface 430 including the heat transfer surface exposed portion 436 is surrounded by a mold, and the back surface of the heat transfer surface exposed portion 436 is pressed by another mold to prevent the inflow of resin. Since the circuit package 400 is made by transfer molding, the pressure of the resin is high, and it is important to press the heat transfer surface exposed portion 436 from the back surface. Further, a semiconductor diaphragm is used for the flow rate detection unit 602, and it is desirable to form a ventilation passage formed by the semiconductor diaphragm. In order to hold and fix a plate or the like for forming the ventilation passage, it is important to press the heat transfer surface exposed portion 436 from the back surface.

3.3 Shapes and Effects of Table Cover 303 and Back Cover 304 FIG. 8 is a view showing the appearance of the table cover 303, FIG. 8 (A) is a left side view, FIG. 8 (B) is a front view, and FIG. C) is a plan view. FIG. 9 is a view showing the appearance of the back cover 304. FIG.
FIG. 9A is a left side view, FIG. 9B is a front view, and FIG. 9C is a plan view. In FIGS. 8 and 9, the front cover 303 and the back cover 304 are used to make a secondary passage by closing the secondary passage groove of the housing 302. In addition, the projection 356 is provided and used to provide a restriction in the flow path. For this reason, it is desirable that the molding accuracy be high. Since the front cover 303 and the back cover 304 are made by a resin molding process in which a thermoplastic resin is injected into a mold, the front cover 303 and the back cover 304 can be made with high molding accuracy. Further, the front cover 303 and the back cover 304 are formed with a protrusion 380 and a protrusion 381, and the circuit package shown in FIGS. 5B and 6B when the housing 302 is fitted. The gap of the cavity portion 382 on the front end side of 400 is filled, and at the same time, the front end portion of the circuit package 400 is covered.

  A front protection part 322 and a rear protection part 325 are formed on the front cover 303 and the rear cover 304 shown in FIGS. As shown in FIGS. 2 and 3, a front protection part 322 provided on the front cover 303 is disposed on the front side surface of the inlet 343, and a back protection part 325 provided on the back cover 304 is provided on the rear side surface of the inlet 343. Has been placed. The temperature detection unit 452 disposed inside the entrance 343 is protected by the front protection unit 322 and the back protection unit 325, and the machine of the temperature detection unit 452 due to a collision with the temperature detection unit 452 during production or when mounted on a vehicle. Damage can be prevented.

A protrusion 356 is provided on the inner side surface of the front cover 303. As shown in the example of FIG. 7, the protrusion 356 is disposed opposite to the measurement flow path surface 430 and extends in a direction along the axis of the flow path of the sub-passage. It has a long shape. The cross-sectional shape of the protrusion 356 may be inclined toward the downstream side with the apex of the protrusion as a boundary as shown in FIG. The measurement channel surface 430 and the projections 356 form a throttle in the above-described channel 386 to reduce the vortices generated in the measurement target gas 30 and cause a laminar flow. In this embodiment, the sub-passage having the throttle portion is divided into a groove portion and a lid portion that closes the groove and completes the flow path having the throttle, and the groove portion is the first part for molding the housing 302. Next, the front cover 303 having the projections 356 is formed by another resin molding process, and the front cover 303 is used as a lid of the groove to cover the groove. In the second resin molding step for molding the housing 302, the circuit package 400 having the measurement flow path surface 430 is also fixed to the housing 302. In this way, by forming a complicated groove in the resin molding process and providing the projection 356 for drawing on the front cover 303, the flow path 386 shown in FIG. 7 can be formed with high accuracy. In addition, since the positional relationship between the groove and the measurement flow path surface 430 and the heat transfer surface exposed portion 436 can be maintained with high accuracy, the variation in mass-produced products can be reduced, resulting in high measurement results. Productivity is also improved.

  The same applies to the formation of the channel 387 by the back cover 304 and the measurement channel surface rear surface 431. The flow path 387 is formed by dividing the flow path 387 into a groove portion and a lid portion, creating the groove portion by a second resin molding step of molding the housing 302, and covering the groove with the back cover 304. By making the flow path 387 in this way, the flow path 387 can be made with high accuracy, and productivity is improved. In this embodiment, a restriction is provided in the flow path 386, but it is also possible to use a flow path 387 having a restriction by providing a projection 358 as shown in FIG. 7B.

3.4 Another Example of the Example Shown in FIG. 7 FIG. 10 is an enlarged view showing another example of the flow rate measurement portion shown in FIG. 7, and corresponds to the AA cross section of FIG. 6 (B). It is another Example of a part. As in FIG. 7, the gas to be measured 30 taken in from the inlet groove (not shown) flows in the sub-passage provided on the tip side of the measuring unit 310 not shown in FIG. 10 as indicated by the dashed arrow, and on the left side of the figure It is led to the passage 386 from the groove located on the terminal side of the rear side sub passage groove. In this passage 386, the flow rate is measured by the heat transfer surface exposed portion 436 provided on the measurement channel surface 430. After that, it is guided to the front side sub-passage groove and flows again through the sub-passage provided on the tip side of the measuring unit 310 not shown in FIG. 10 as indicated by the dashed arrow, and from the outlet 352 shown in FIG. Is discharged.

  The back side of the measurement flow path surface 430 provided in the circuit package 400 is embedded in a resin portion 359 for forming the sub-passage. The back side of the measurement flow path surface 430 of the circuit package 400 is embedded in the resin portion 359 for forming the sub-passage, whereby the measurement package formed in the circuit package 400 along the inner surface of the groove of the back-side sub-passage groove 334. The measurement target gas 30 flows along the inner surface of the back side sub-passage groove 334 and the measurement channel surface 430, and the heat transfer surface exposed portion 436 provided on the measurement channel surface 430 is arranged so that the channel surface 430 is continuous. The flow rate is measured. Although not shown, the sub passage groove formed on the back surface of the measuring unit 310 is covered with the back cover 304 to form a sub passage.

  The front cover 303 at a position facing the heat transfer surface exposed portion 436 provided on the measurement flow path surface 430 is provided with a protrusion 356 protruding inside the flow path 386, and the protrusion 356 and the measurement flow A diaphragm is formed by the road surface 430. Similar to the flow path 386 shown in FIG. 7, by forming a restriction in the flow path 386, the vortex of the measured gas 30 flowing through the flow path 386 is reduced, and the measured gas 30 approaches a laminar flow. Therefore, the measurement accuracy of the flow rate measured by the flow rate detection unit 602 is improved. Further, the restriction provided in the passage channel 386 increases the flow velocity of the flow rate measurement portion, leading to improvement in accuracy of flow rate measurement.

  The major difference from the structure shown in FIG. 7 is that, in FIG. 7, the sub-passage is formed on both sides of the measurement channel surface 430 formed on the circuit package 400 and the measurement channel surface back surface 431 on the back surface thereof. On the other hand, in FIG. 10, the auxiliary passage is formed only on the measurement flow path surface 430. The structure shown in FIG. 10 has an effect of increasing the flow rate of the measured gas 30 to be measured because the flow rate flowing along the measurement channel surface 430 increases.

  In FIG. 10, the circuit package 400 is fixed to the housing 302 so that the measurement channel surface 430 is continuous with the back side sub-passage groove. Accordingly, the protrusion 356 is provided on the front cover 303. Therefore, no projection is required on the back cover 304. However, the circuit package 400 may be fixed to the housing 302 so that the measurement channel surface 430 is continuous with the front side sub-passage groove. In this case, the protrusion 356 is provided on the back cover 304, and the front cover 303 does not require a protrusion.

3.5 Still another embodiment of the embodiment shown in FIGS. 5 and 6 FIG. 11 is a block diagram showing another embodiment of the embodiment shown in FIGS. 5 and 6, and the main passage shown in FIGS. A portion for forming a sub-passage groove corresponding to the distal end side of the measurement unit 310 inserted into 124 is shown. Note that the flange 312 and the external connection portion 305 are omitted. In the embodiment shown in FIGS. 5 and 6, a sub-passage groove for molding both the front and back sub-passages of the housing 302 of the thermal flow meter 300 is provided. FIG. 11 shows a structure in which the auxiliary passage is provided on either the front surface or the back surface of the housing 302 and has a simple structure. The technical contents are substantially the same regardless of whether the front surface or the back surface of the housing 302 is provided with a secondary passage. FIG. 11 is an example in which a secondary passage is provided on the front surface. FIG.

A cover is provided on the front side provided with the sub-passage, and no cover is provided on the back side because no passage is formed. That is, the back side of the housing 302 covers the back side with resin forming the housing 302 instead of the cover. The cover is formed of a thermoplastic resin by a resin molding process as in the embodiments of FIGS.

  The sub-passage is made of a sub-passage groove and a resin cover that covers the groove, and an inlet groove 351 for forming the inlet 350 is formed on the upstream side in the flow direction of the gas 30 to be measured, and on the downstream side. An outlet groove 353 for forming the outlet 352 is formed. The gas to be measured 30 taken in from the inlet groove 351 is guided to the front side sub-passage groove 332, approaches the circuit package 400, flows along the surface of the measurement channel surface 430, and is provided on the measurement channel surface 430. The flow rate is measured by the exposed heat transfer surface exposed portion 436 and is discharged from the outlet groove 353 to the main passage 124 after the flow rate is measured.

  The circuit package 400 made in the first resin molding process is fixed to the housing 302 in the second resin molding process, and at the same time, the front side auxiliary passage groove 332, the outer wall recess 366, the upstream side outer wall 335, the downstream side outer wall 336, FIG. A housing 302 including a flange 312 and an external connection portion 305 not shown is molded in the second resin molding step. The effects associated with this are as described above with reference to FIGS.

  12 is a cross-sectional view taken along the line AA in FIG. The entire back surface of the housing 302 is covered with a resin portion 359, and the measurement flow channel surface back surface 431 and the side surface of the measurement package flow surface 430 of the circuit package 400 are embedded and fixed in the resin portion 359. A sub-passage for allowing the measurement target gas 30 to flow is formed by the front cover 303 covering the front-side sub-passage groove 332, and following the sub-passage formed in the front-side sub-passage groove 332, the measurement channel surface 430 and the position facing this A flow path 386 having a protrusion 356 provided on the surface is formed. Note that the protrusion 356 is provided on the front cover 303, which is a cover at a position facing the heat transfer surface exposed portion 436. A throttle shape is formed by the measurement flow path surface 430 and the protrusion 356, and a heat transfer surface exposed portion 436 is provided at a position where the throttle shape is formed. Therefore, as described with reference to FIGS. 7 and 10, the measurement target gas 30 measured by the heat transfer surface exposed portion 436 becomes a substantially laminar flow with few vortices, and the measurement accuracy is improved due to the throttle shape. Moreover, the flow rate of the gas 30 to be measured is increased by the throttle shape, which leads to improvement in measurement accuracy for measuring the flow rate.

3.6 Fixing Structure and Effect of Circuit Package 400 by Housing 302 Next, referring to FIGS. 5 and 6 again, fixing of the circuit package 400 to the housing 302 by a resin molding process will be described. In the embodiment shown in FIGS. 5 and 6, for example, in the embodiment shown in FIG. 5 and FIG. 6, the surface of the circuit package 400 is formed on the connecting portion of the front side sub passage groove 332 and the back side sub passage groove 334. The circuit package 400 is arranged and fixed to the housing 302 so that the measurement flow path surface 430 is arranged. A portion for embedding and fixing the circuit package 400 in the housing 302 with a resin mold is provided as a fixing portion 372 for embedding and fixing the circuit package 400 in the housing 302 on the flange 312 side slightly from the sub-passage groove. The fixing portion 372 is embedded so as to cover the outer periphery of the circuit package 400 formed by the first resin molding process.

  As shown in FIG. 5B, the circuit package 400 is fixed by a fixing portion 372. The fixing portion 372 includes the circuit package 400 by a surface having a height in contact with the front cover 303 and a thin portion 376. By reducing the thickness of the resin covering the portion 376, the shrinkage when the temperature of the resin cools when the fixing portion 372 is molded can be reduced, and the concentration of stress applied to the circuit package 400 can be reduced. is there. As shown in FIG. 6B, when the back side of the circuit package 400 is also shaped as described above, more effects can be obtained.

  Further, the entire surface of the circuit package 400 is not covered with the resin for molding the housing 302, but a portion where the outer wall of the circuit package 400 is exposed is provided on the flange 312 side of the fixing portion 372. 5 and 6, the area of the outer peripheral surface of the circuit package 400 that is included in the resin of the housing 302 is exposed from the resin of the housing 302 without being included in the resin of the housing 302. The area is wider. Further, the part of the measurement flow path surface 430 of the circuit package 400 is also exposed from the resin forming the housing 302.

  By thinning a part of the fixing portion 372 that covers the outer wall of the circuit package 400 in a strip shape over the entire circumference, the periphery of the circuit package 400 is included in the second resin molding step for molding the housing 302. Thus, excessive stress concentration due to volume shrinkage in the process of hardening the fixing portion 372 is reduced. Excessive stress concentration may also adversely affect the circuit package 400.

  In addition, in order to more securely fix the circuit package 400 with a small area by reducing the area of the outer surface of the circuit package 400 included in the resin of the housing 302, the circuit package 400 in the fixing portion 372 can be fixed more firmly. It is desirable to improve the adhesion with the outer wall of the. When a thermoplastic resin is used for the purpose of molding the housing 302, the thermoplastic resin enters the fine irregularities of the outer wall of the circuit package 400 in a state where the viscosity of the thermoplastic resin is low, and the thermoplastic resin enters the fine irregularities of the outer wall. It is desirable for the resin to cure. In the resin molding process for molding the housing 302, it is desirable to provide an inlet for the thermoplastic resin at or near the fixed portion 372. The thermoplastic resin increases in viscosity based on a decrease in temperature and hardens. Accordingly, by pouring the high temperature thermoplastic resin into or from the fixing portion 372, the low viscosity thermoplastic resin can be brought into close contact with the outer wall of the circuit package 400 and cured. This suppresses the temperature drop of the thermoplastic resin, prolongs the low-viscosity state, and improves the adhesion between the circuit package 400 and the fixing portion 372.

  By roughening the outer wall surface of the circuit package 400, the adhesion between the circuit package 400 and the fixing portion 372 can be improved. As a method for roughening the outer wall surface of the circuit package 400, a roughening method for forming fine irregularities on the surface of the circuit package 400 after the circuit package 400 is formed in the first resin molding step, for example, a treatment method called matte treatment. There is. As a roughening method for applying fine irregularities to the surface of the circuit package 400, for example, it can be roughened by sandblasting. Further, it can be roughened by laser processing.

  As another roughening method, a sheet with irregularities is attached to the inner surface of a mold used in the first resin molding step, and the resin is press-fitted into a mold provided with the sheet on the surface. In this way, fine irregularities can be formed on the surface of the circuit package 400 to be roughened. Further, the surface of the circuit package 400 can be roughened by providing irregularities inside the mold for molding the circuit package 400. The surface portion of the circuit package 400 that performs such roughening is a portion where at least the fixing portion 372 is provided. In addition, the degree of adhesion is further increased by roughening the surface portion of the circuit package 400 in which the outer wall recess 366 is provided.

  Further, the depth of the groove depends on the thickness of the sheet when the surface of the circuit package 400 is processed by using the above-described sheet. When the thickness of the sheet is increased, molding in the first resin molding process becomes difficult, so there is a limit to the thickness of the sheet, and when the thickness of the sheet is thin, there is a limit to the depth of unevenness provided in advance in the sheet. Out. For this reason, when using the said sheet | seat, it is desirable that the depth of the unevenness | corrugation between the bottom and the vertex of an unevenness | corrugation is 10 micrometers or more and 20 micrometers or less. At a depth of less than 10 μm, the adhesion effect is weak. A depth greater than 20 μm is difficult due to the thickness of the sheet.

In the case of the roughening method other than the sheet, since the resin thickness in the first resin molding process for forming the circuit package 400 is desirably 2 mm or less, It is difficult to make the depth of the unevenness between 1 mm and 1 mm or more. Conceptually, when the depth of the unevenness between the bottom and apex of the unevenness on the surface of the circuit package 400 is increased, the degree of adhesion between the resin that covers the circuit package 400 and the resin that forms the housing 302 increases. However, for the above reason, the depth of the unevenness between the bottom and the top of the unevenness is preferably 1 mm or less. That is, it is desirable to increase the degree of adhesion between the resin that covers the circuit package 400 and the resin that molds the housing 302 by providing irregularities in the range of 10 μm or more and 1 mm or less on the surface of the circuit package 400.

  There is a difference in the thermal expansion coefficient between the thermosetting resin that forms the circuit package 400 and the thermoplastic resin that forms the housing 302 including the fixing portion 372, and an excessive stress generated based on the difference in the thermal expansion coefficient causes the circuit package. It is desirable not to join 400.

Furthermore, by making the shape of the fixing portion 372 including the outer periphery of the circuit package 400 into a band shape and narrowing the width of the band, the stress due to the difference in thermal expansion coefficient applied to the circuit package 400 can be reduced. It is desirable that the width of the band of the fixing portion 372 is 10 mm or less, preferably 8 mm or less. In the present embodiment, not only the fixing portion 372 but also the outer wall recess 366 that is a part of the upstream outer wall 335 of the housing 302 includes the circuit package 400 and fixes the circuit package 400. The width of the band 372 can be further reduced. For example, if there is a width of 3 mm or more, the circuit package 400 can be fixed.

The surface of the circuit package 400 is provided with a portion covered with the resin for molding the housing 302 and a portion exposed without being covered for the purpose of reducing stress due to the difference in thermal expansion coefficient. A plurality of portions where the surface of the circuit package 400 is exposed from the resin of the housing 302 are provided, one of which is the measurement flow path surface 430 having the heat transfer surface exposed portion 436 described above. A portion exposed to the flange 312 side from the fixing portion 372 is provided. Further, an outer wall recess 366 is formed, and a portion upstream of the outer wall recess 366 is exposed, and this exposed portion is used as a support for supporting the temperature detector 452. The portion of the outer surface of the circuit package 400 closer to the flange 312 than the fixing portion 372 extends from the outer periphery, particularly from the downstream side of the circuit package 400 to the side facing the flange 312, and further to the upstream side of the portion close to the terminal of the circuit package 400. The air gap is formed so as to surround the circuit package 400. Since the gap is formed around the portion where the surface of the circuit package 400 is exposed in this way, the amount of heat transferred from the main passage 124 to the circuit package 400 via the flange 312 can be reduced, and measurement due to the influence of heat. The decrease in accuracy is suppressed.

  A gap is formed between the circuit package 400 and the flange 312, and this gap portion functions as the terminal connection portion 320. At the terminal connection portion 320, the connection terminal 412 of the circuit package 400 and the external terminal inner end 361 located on the housing 302 side of the external terminal 306 are electrically connected by spot welding or laser welding, respectively. As described above, the gap of the terminal connection portion 320 has an effect of suppressing heat transfer from the housing 302 to the circuit package 400, and the connection work between the connection terminal 412 of the circuit package 400 and the external terminal inner end 361 of the external terminal 306. Is reserved as usable space for.

3.7 Structure and Effect of Terminal Connection Part 320 FIG. 13 is an enlarged view of the terminal connection part 320 of the housing 302 shown in FIGS. 5 and 6. However, the following points are a little different. 5 and FIG. 6 is different from the description of FIG. 5 and FIG. 6 in that each external terminal inner end 361 is cut off, whereas in FIG. 13, the state before each external terminal inner end 361 is cut off. In the figure, the external terminal inner ends 361 are connected by connecting portions 365, respectively. In the second molding step, the external terminal inner ends 361 projecting to the circuit package 400 side of the external terminals 306 overlap with the corresponding connection terminals 412 or in the vicinity of the corresponding connection terminals 412. The external terminal 306 is fixed to the housing 302 by resin molding. In order to prevent deformation and displacement of the external terminals 306, as an example, a resin molding process (second resin mold) for molding the housing 302 in a state where the external terminal inner ends 361 are connected to each other by a connecting portion 365. The external terminal 306 is fixed to the housing 302 by the process. However, the connection terminal 412 and the external terminal inner end 361 may be fixed first, and then the external terminal 306 may be fixed to the housing 302 by the second molding step.

3.8 Inspection of Finished Product by First Resin Molding Process In the embodiment shown in FIG. 13, the circuit package 400 has a larger number of terminals than the number of external terminal inner ends 361. Of the terminals included in the circuit package 400, the connection terminal 412 is connected to the external terminal inner end 361, and the terminal 414 is not connected to the external terminal inner end 361. That is, the terminal 414 is a terminal that is provided in the circuit package 400 but is not connected to the external terminal inner end 361.

In FIG. 13, in addition to the connection terminal 412 connected to the external terminal inner end 361, a terminal 414 not connected to the external terminal inner end 361 is provided. After the circuit package 400 is produced in the first resin molding process, it is inspected whether the circuit package 400 operates correctly or whether an abnormality has occurred in electrical connection in the first resin molding process. By doing so, high reliability can be maintained for each circuit package 400. The terminal 414 that is not connected to the external terminal inner end 361 is used for such inspection of the circuit package 400. Since the terminals 414 are not used after the inspection work, these unused terminals 414 may be cut at the base of the circuit package 400 after the inspection, or the inside of the resin that is the terminal side fixing portion 362 as shown in FIG. It may be buried in. Thus, by providing the terminal 414 that is not connected to the external terminal inner end 361, it is possible to inspect whether or not an abnormality has occurred in the circuit package 400 produced in the first resin molding process, and high reliability can be maintained.

3.9 Structure and effect of communication between the gap inside the housing 302 and the outside of the thermal flow meter 300 As shown in the partially enlarged view of FIG. 13, the housing 302 is provided with a hole 364. The hole 364 is connected to an opening 309 provided inside the external connection portion 305 shown in FIG. In the embodiment, both sides of the housing 302 are sealed with a front cover 303 and a back cover 304. If the hole 364 is not provided, a difference occurs between the atmospheric pressure in the air gap and the external air pressure due to the temperature change of the air in the air gap including the terminal connection portion 320. Such a pressure difference is desirably as small as possible. Therefore, a hole 364 connected to the opening 309 provided in the external connection portion 305 is provided in the gap of the housing 302. The external connection part 305 has a structure that is not adversely affected by water or the like in order to improve the reliability of electrical connection, and by providing the opening 309 in the external connection part 305, water can be prevented from entering from the opening 309. Furthermore, it is possible to prevent foreign substances such as dust and dirt from entering.

3.10 Housing 302 Molding and Effects by Second Resin Molding Process In the housing 302 shown in FIGS. 5 and 6 described above, the circuit package 400 including the flow rate detection unit 602 and the processing unit 604 is manufactured by the first resin molding process. Next, the housing 302 having, for example, the front side sub-passage groove 332 and the back side sub-passage groove 334 for forming the sub-passage through which the measurement target gas 30 flows is manufactured in the second resin molding process. In the second resin molding step, the circuit package 400 is built in the resin of the housing 302 and fixed in the housing 302 by a resin mold. By doing so, the heat transfer surface exposed portion 436 and the sub-passage, for example, the front-side sub-passage groove 332 and the back-side sub-passage for the heat-flow detecting unit 602 to perform heat transfer with the measurement target gas 30 and measure the flow rate. It becomes possible to maintain the relationship with the shape of the passage groove 334, for example, the positional relationship and the direction relationship, with extremely high accuracy. It is possible to suppress errors and variations occurring in each circuit package 400 to a very small value. As a result, the measurement accuracy of the circuit package 400 can be greatly improved. For example, the measurement accuracy can be improved by a factor of two or more compared to a conventional method of fixing using an adhesive. The thermal flow meter 300 is often produced by mass production, and the method of adhering with an adhesive while strictly measuring here has a limit in improving measurement accuracy. However, as in the present embodiment, the circuit package 400 is manufactured by the first resin molding process, and then the sub-passage is formed in the second resin molding process in which the sub-passage for flowing the measurement target gas 30 is formed. By fixing the auxiliary passage, variation in measurement accuracy can be greatly reduced, and the measurement accuracy of each thermal flow meter 300 can be greatly improved. This applies not only to the embodiment shown in FIGS. 5 and 6, but also to the embodiment shown in FIG. 7 or FIG.

For example, in the embodiment shown in FIG. 5 and FIG. 6, the relationship among the front side sub-passage groove 332, the back side sub-passage groove 334, and the heat transfer surface exposed portion 436 is set with high accuracy so as to be a prescribed relationship. The circuit package 400 can be fixed to the housing 302. As a result, in the mass production type thermal flow meter 300, the positional relationship between the heat transfer surface exposed portion 436 of each circuit package 400 and the sub-passage, such as the positional relationship and shape, are constantly obtained with very high accuracy. It becomes possible. Since the sub-passage groove, for example, the front-side sub-passage groove 332 and the back-side sub-passage groove 334, to which the heat transfer surface exposed portion 436 of the circuit package 400 is fixed can be formed with very high accuracy, the sub-passage is formed from the sub-passage groove. The work is a work of covering both surfaces of the housing 302 with the front cover 303 and the back cover 304. This work is very simple and is a work process with few factors that reduce the measurement accuracy. The front cover 303 and the back cover 304 are produced by a resin molding process with high molding accuracy. Accordingly, it is possible to complete the sub-passage provided in a defined relationship with the heat transfer surface exposed portion 436 of the circuit package 400 with high accuracy. By such a method, in addition to improvement of measurement accuracy, high productivity can be obtained.

  On the other hand, in the past, a thermal flow meter was produced by manufacturing a sub-passage and then adhering a measuring unit to the sub-passage with an adhesive. As described above, the method of using the adhesive has a large variation in the thickness of the adhesive, and the bonding position and the bonding angle vary from product to product. For this reason, there was a limit to increasing the measurement accuracy. Furthermore, when performing these operations in a mass production process, it is very difficult to improve measurement accuracy.

  In the embodiment according to the present invention, first, the circuit package 400 including the flow rate detecting unit 602 is produced by the first resin mold, and then the circuit package 400 is fixed by the resin mold and at the same time, the auxiliary passage is formed by the resin mold. For this purpose, a secondary passage groove is formed by the second resin mold. By doing in this way, the flow volume detection part 602 can be fixed to the shape of the sub passage groove and the sub passage groove with extremely high accuracy.

  A portion related to the measurement of the flow rate, for example, the measurement flow path surface 430 to which the heat transfer surface exposed portion 436 and the heat transfer surface exposed portion 436 of the flow rate detection unit 602 are attached is formed on the surface of the circuit package 400. Thereafter, the measurement channel surface 430 and the heat transfer surface exposed portion 436 are exposed from the resin for molding the housing 302. That is, the heat transfer surface exposed portion 436 and the measurement flow path surface 430 around the heat transfer surface exposed portion 436 are not covered with the resin for molding the housing 302. The flow passage surface 430 for measurement and the heat transfer surface exposed portion 436 formed by the resin mold of the circuit package 400 or the temperature detection portion 452 are also used as they are after the resin molding of the housing 302 to measure the flow rate of the thermal flow meter 300. Used for temperature measurement. By doing so, the measurement accuracy is improved.

In the embodiment according to the present invention, the circuit package 400 is fixed to the housing 302 with a small fixed area because the circuit package 400 is fixed to the housing 302 having the sub passage by integrally forming the circuit package 400 with the housing 302. it can. That is, the surface area of the circuit package 400 that is not in contact with the housing 302 can be increased. The surface of the circuit package 400 that is not in contact with the housing 302 is exposed to a gap, for example. The heat of the intake pipe is transmitted to the housing 302 and is transmitted from the housing 302 to the circuit package 400. The housing 302 does not include the entire surface or most of the circuit package 400, but the circuit package 400 can be maintained with high accuracy and high reliability even when the contact area between the housing 302 and the circuit package 400 is reduced. It can be fixed to the housing 302. For this reason, heat transfer from the housing 302 to the circuit package 400 can be suppressed to a low level, and a decrease in measurement accuracy can be suppressed.

  In the embodiment shown in FIGS. 5 and 6, the area A of the exposed surface of the circuit package 400 may be equal to the area B covered with the molding material of the housing 302 or the area A may be larger than the area B. Is possible. In the embodiment, the area A is larger than the area B. By doing so, heat transfer from the housing 302 to the circuit package 400 can be suppressed. Further, the stress due to the difference between the thermal expansion coefficient of the thermosetting resin forming the circuit package 400 and the expansion coefficient of the thermoplastic resin forming the housing 302 can be reduced.

4). External appearance of circuit package 400 4.1 Molding of measurement flow path surface 430 including heat transfer surface exposed portion 436 FIG. 14 shows an external appearance of the circuit package 400 produced in the first resin molding step. The hatched portion described on the exterior of the circuit package 400 is used in the second resin molding process when the housing 302 is molded in the second resin molding process after the circuit package 400 is manufactured in the first resin molding process. The fixing surface 432 where the circuit package 400 is covered with the resin to be shown is shown. 14A is a left side view of the circuit package 400, FIG. 14B is a front view of the circuit package 400, and FIG. 14C is a rear view of the circuit package 400. The circuit package 400 incorporates a flow rate detection unit 602 and a processing unit 604, which will be described later, and these are molded with a thermosetting resin and integrally molded.

  On the surface of the circuit package 400 shown in FIG. 11B, a measurement channel surface 430 that functions as a surface for flowing the measurement target gas 30 is formed in a shape extending in the flow direction of the measurement target gas 30. In this embodiment, the measurement channel surface 430 has a rectangular shape extending in the flow direction of the measurement target gas 30. As shown in FIG. 14A, the measurement channel surface 430 is made thinner than other portions, and a heat transfer surface exposed portion 436 is provided in a part thereof. The built-in flow rate detection unit 602 performs heat transfer with the measurement target gas 30 via the heat transfer surface exposure unit 436, measures the state of the measurement target gas 30, for example, the flow velocity of the measurement target gas 30, and the main passage 124. An electric signal representing the flow rate flowing through the is output.

In order for the built-in flow rate detector 602 (see FIG. 20) to measure the state of the gas 30 to be measured with high accuracy, the gas flowing in the vicinity of the heat transfer surface exposed part 436 is laminar and has little turbulence. desirable. For this reason, it is preferable that there is no step between the side surface of the heat transfer surface exposed portion 436 and the surface of the measurement channel surface 430 that guides the gas. With such a configuration, it is possible to suppress uneven stress and distortion from acting on the flow rate detection unit 602 while maintaining high accuracy in flow rate measurement. The step may be provided as long as it does not affect the flow rate measurement accuracy.

  As shown in FIG. 14C, the back surface of the measurement flow path surface 430 having the heat transfer surface exposed portion 436 has a pressing mark 442 for pressing the mold that supports the internal substrate or plate when the circuit package 400 is molded with resin. Remains. The heat transfer surface exposed part 436 is a place used for exchanging heat with the gas to be measured 30. In order to accurately measure the state of the gas to be measured 30, the flow detection part 602 and the object to be measured are used. It is desirable that heat transfer with the measurement gas 30 be performed satisfactorily. For this reason, it is necessary to avoid that the heat transfer surface exposed portion 436 is covered with the resin in the first resin molding step. A mold is applied to both the heat transfer surface exposed portion 436 and the measurement flow path surface back surface 431 which is the back surface thereof, and the mold prevents the resin from flowing into the heat transfer surface exposed portion 436. A recessed trace 442 is formed on the back surface of the heat transfer surface exposed portion 436. In this portion, elements constituting the flow rate detection unit 602 and the like are arranged close to each other, and it is desirable to dissipate heat generated by these elements to the outside as much as possible. The molded recess has an effect of being easy to dissipate heat with little influence of the resin.

  A semiconductor diaphragm corresponding to the heat transfer surface exposed portion 436 is formed in a flow rate detection unit (flow rate detection element) 602 formed of a semiconductor element, and the semiconductor diaphragm forms a gap on the back surface of the flow rate detection element 602. It can be obtained by When the gap is sealed, the semiconductor diaphragm is deformed due to a change in pressure in the gap due to a temperature change, and the measurement accuracy is lowered. Therefore, in this embodiment, an opening 438 communicating with the gap on the back surface of the semiconductor diaphragm is provided on the surface of the circuit package 400, and a communication path connecting the gap on the back surface of the semiconductor diaphragm and the opening 438 is provided inside the circuit package 400. Note that the opening 438 is provided in a portion where the hatched lines shown in FIG. 14 are not described so that the opening 438 is not blocked by the resin in the second resin molding step.

  It is necessary to mold the opening 438 in the first resin molding step. A mold is applied to the opening 438 and the back surface thereof, and both the front and back surfaces are pressed with the mold, so that the resin to the opening 438 can be formed. Inflow is blocked and opening 438 is formed. The formation of the communication path that connects the opening 438 and the gap on the back surface of the semiconductor diaphragm and the opening 438 will be described later.

4.2 Molding and Effect of Temperature Detection Unit 452 and Projection 424 The temperature detection unit 452 provided in the circuit package 400 is a projection that extends in the upstream direction of the gas to be measured 30 to support the temperature detection unit 452. A tip 424 is also provided, and has a function of detecting the temperature of the measurement target gas 30. In order to detect the temperature of the gas to be measured 30 with high accuracy, it is desirable to reduce the heat transfer with the portion other than the gas to be measured 30 as much as possible. The protrusion 424 that supports the temperature detection unit 452 has a tip that is narrower than the base, and the temperature detection unit 452 is provided at the tip. With such a shape, the influence of heat from the base portion of the protruding portion 424 on the temperature detecting portion 452 is reduced.

  In addition, after the temperature of the measurement target gas 30 is detected by the temperature detection unit 452, the measurement target gas 30 flows along the protrusion 424, and acts to bring the temperature of the protrusion 424 close to the temperature of the measurement target gas 30. As a result, the influence of the temperature of the base portion of the protrusion 424 on the temperature detection unit 452 is suppressed. In particular, in this embodiment, the vicinity of the protruding portion 424 including the temperature detecting portion 452 is thin, and becomes thicker toward the root of the protruding portion 424. For this reason, the measurement target gas 30 flows along the shape of the protruding portion 424, and the protruding portion 424 is efficiently cooled.

  A hatched portion at the base portion of the protruding portion 424 is a fixed surface 432 covered with a resin for forming the housing 302 in the second resin molding step. A depression is provided in the shaded portion at the base of the protrusion 424. This indicates that a hollow portion that is not covered with the resin of the housing 302 is provided. In this way, by forming a hollow-shaped portion that is not covered with the resin of the housing 302 at the base of the protrusion 424, the protrusion 424 is further easily cooled by the measurement target gas 30.

4.3 Terminals of the circuit package 400 The circuit package 400 is connected to supply power for operating the built-in flow rate detection unit 602 and processing unit 604, and to output flow rate measurement values and temperature measurement values. A terminal 412 is provided. Further, a terminal 414 is provided to inspect whether the circuit package 400 operates correctly and whether an abnormality has occurred in the circuit components or their connections. In this embodiment, the circuit package 400 is made by transfer molding the flow rate detection unit 602 and the processing unit 604 using a thermosetting resin in the first resin molding step. By performing transfer molding, the dimensional accuracy of the circuit package 400 can be improved. However, in the transfer molding process, a high-temperature pressure is applied to the inside of the sealed mold containing the flow rate detection unit 602 and the processing unit 604. Since the resin is injected, it is desirable to inspect the completed circuit package 400 for damage to the flow rate detection unit 602, the processing unit 604, and their wiring relationship. In this embodiment, a terminal 414 for inspection is provided, and each circuit package 400 produced is inspected. Since the inspection terminal 414 is not used for measurement, the terminal 414 is not connected to the external terminal inner end 361 as described above. Each connection terminal 412 is provided with a bending portion 416 in order to increase mechanical elastic force. By giving each connection terminal 412 a mechanical elastic force, it is possible to absorb stress generated due to a difference in thermal expansion coefficient between the resin in the first resin molding process and the resin in the second resin molding process. That is, each connection terminal 412 is affected by thermal expansion due to the first resin molding process, and the external terminal inner end 361 connected to each connection terminal 412 is affected by resin due to the second resin molding process. Generation | occurrence | production of the stress resulting from these resin differences can be absorbed.

4.4 Fixation of Circuit Package 400 by Second Resin Molding Process and its Effect In FIG. 14, the hatched portion is the second resin molding process in order to fix circuit package 400 to housing 302 in the second resin molding process. The fixing surface 432 for covering the circuit package 400 with the thermoplastic resin to be used is shown. As described with reference to FIG. 5 and FIG. 6, the relationship between the measurement channel surface 430 and the heat transfer surface exposed portion 436 provided on the measurement channel surface 430 and the shape of the sub-passage is a prescribed relationship. As such, it is important to be maintained with high accuracy. In the second resin molding step, since the circuit package 400 is fixed to the housing 302 that simultaneously molds the sub-passage and molds the sub-passage, the relationship between the sub-passage, the measurement flow path surface 430 and the heat transfer surface exposed portion 436 It can be maintained with extremely high accuracy. That is, since the circuit package 400 is fixed to the housing 302 in the second resin molding step, the circuit package 400 can be positioned and fixed with high accuracy in a mold for forming the housing 302 having the sub-passage. It becomes possible. By injecting a high-temperature thermoplastic resin into the mold, the sub-passage is molded with high accuracy, and the circuit package 400 is fixed with high accuracy.

  In this embodiment, the entire surface of the circuit package 400 is not the fixing surface 432 that is covered with the resin for molding the housing 302, but the surface is exposed to the connection terminal 412 side of the circuit package 400, that is, the housing is covered with the resin for the housing 302. The part which is not broken is provided. In the embodiment shown in FIG. 14, the area of the surface of the circuit package 400 that is not included in the resin of the housing 302 and exposed from the resin of the housing 302 is larger than the area of the fixing surface 432 included in the resin for the housing 302. Is wider.

  There is a difference in the thermal expansion coefficient between the thermosetting resin that forms the circuit package 400 and the thermoplastic resin that forms the housing 302 including the fixing portion 372, and stress based on this difference in thermal expansion coefficient is not applied to the circuit package 400 as much as possible. It is desirable to do so. By reducing the fixed surface 432 on the surface of the circuit package 400, the influence based on the difference in thermal expansion coefficient can be reduced. For example, the fixed surface 432 on the surface of the circuit package 400 can be reduced by forming a belt with a width L.

  Further, by providing the fixing surface 432 at the base of the protruding portion 424, the mechanical strength of the protruding portion 424 can be increased. On the surface of the circuit package 400, by providing a band-shaped fixed surface in a direction along the axis through which the measured gas 30 flows, and further providing a fixed surface in a direction intersecting with the axis through which the measured gas 30 flows, the circuit package is more firmly provided 400 and the housing 302 can be fixed to each other. In the fixed surface 432, a portion surrounding the circuit package 400 in a band shape with a width L along the measurement flow path surface 430 is a fixed surface in the direction along the flow axis of the measurement target gas 30 described above, and the root of the protrusion 424. The portion that covers is a fixed surface in the direction crossing the flow axis of the measurement target gas 30.

5. Mounting of Circuit Components on Circuit Package 5.1 Frame Frame of Circuit Package FIG. 15 shows a frame state of the circuit package 400 and a chip mounting state of the circuit component 516 mounted on the frame frame 512. A broken line portion 508 indicates a portion covered with a mold used when the circuit package 400 is molded. A lead 514 is mechanically connected to the frame frame 512, a plate 532 is mounted at the center of the frame frame 512, and a chip-shaped flow rate detection unit 602 and a processing unit 604 made as an LSI are mounted on the plate 532. Has been. The flow rate detection unit 602 is provided with a diaphragm 672, which corresponds to the heat transfer surface exposed portion 436 described above by the molding described above. Further, each terminal of the flow rate detection unit 602 described below and the processing unit 604 are electrically connected by wires 542. Further, each terminal of the processing unit 604 and the corresponding lead 514 are connected by a wire 543. The lead 514 located between the portion serving as the connection terminal of the circuit package 400 and the plate 532 has a chip-like circuit component 516 connected between them.

  In this way, when the circuit package 400 is completed, the flow rate detection unit 602 having the diaphragm 672 is disposed at the most distal end side, and the processing unit 604 is in an LSI state to be a connection terminal with respect to the flow rate detection unit 602. Further, a connection wire 543 is disposed on the terminal side of the processing unit 604. In this manner, the flow rate detection unit 602, the processing unit 604, the wire 543, the circuit component 516, and the connection lead 514 are arranged in order from the front end side of the circuit package 400 to the connection terminal, thereby simplifying the entire configuration. Is a concise arrangement.

Leads are provided to support the plate 532, and the leads are fixed to the frame 512 by leads 556 and leads 558. Note that a lower surface of the plate 532 is provided with a lead surface (not shown) having an area equivalent to that of the plate 532 connected to the lead, and the plate 532 is mounted on the lead surface. These lead surfaces are grounded. Thus, noise can be suppressed by performing grounding in the circuits of the flow rate detection unit 602 and the processing unit 604 via the lead surface in common, and the measurement accuracy of the measurement target gas 30 is improved. Further, a lead 544 is provided so as to protrude from the plate 532 toward the upstream side of the flow path, that is, along the axis in a direction crossing the axis of the flow rate detection unit 602, the processing unit 604, and the circuit component 516 described above. Yes. A temperature detection element 518, for example, a chip-like thermistor is connected to the lead 544. Furthermore, a lead 548 is provided near the processing portion 604 that is the base of the protruding portion, and the lead 544 and the lead 548 are electrically connected by a thin wire 546 such as an Au wire. When the lead 548 and the lead 544 are directly connected, heat is transmitted to the temperature detection element 518 through the lead 548 and the lead 544, and the temperature of the measurement target gas 30 cannot be measured accurately. For this reason, the thermal resistance between the lead 548 and the lead 544 can be increased by connecting with a line having a small cross-sectional area and a large thermal resistance. Thereby, the influence of heat does not reach the temperature detection element 518, and the measurement accuracy of the temperature of the measurement target gas 30 is improved.

  The lead 548 is fixed to the frame 512 by a lead 552 and a lead 554. The connecting portion between the lead 552 and the lead 554 and the frame 512 is fixed to the frame 512 in an inclined state with respect to the protruding direction of the protruding temperature detecting element 518, and the mold is also disposed obliquely at this portion. It becomes. As the molding resin flows along this oblique state in the first resin molding step, the molding resin in the first resin molding step flows smoothly to the tip portion where the temperature detection element 518 is provided, and reliability is improved. improves.

  FIG. 15 shows an arrow 592 indicating the resin press-fitting direction. The lead frame on which the circuit components are mounted is covered with a mold, and a press-fitting hole 590 for injecting resin is provided in the position of the circle, and a thermosetting resin is injected into the mold from the direction of the arrow 592. In the direction of the arrow 592 from the press-fitting hole 590, there are a circuit component 516 and a temperature detection element 518, and a lead 544 for holding the temperature detection element 518. Further, a plate 532, a processing unit 604, and a flow rate detection unit 602 are provided in a direction close to the direction of the arrow 592. By arranging in this way, the resin flows smoothly in the first resin molding step. In the first resin molding step, a thermosetting resin is used, and it is important to spread the resin throughout before curing. For this reason, the relationship between the arrangement of circuit components and wiring in the lead 514 and the press-fitting hole 590 and the press-fitting direction is very important.

5.2 Structure for Connecting Gap and Opening on Back of Diaphragm FIG. 16 is a diagram showing a part of the CC cross section of FIG. 15, and is provided inside diaphragm 672 and flow rate detection unit (flow rate detection element) 602. It is explanatory drawing explaining the communicating hole 676 which connects the gap | interval 674 and the hole 520. FIG.

As will be described later, a diaphragm 672 is provided in the flow rate detection unit 602 that measures the flow rate of the gas 30 to be measured, and a gap 674 is provided on the back surface of the diaphragm 672. Although not shown in the drawing, the diaphragm 672 is provided with an element for exchanging heat with the measurement target gas 30 and thereby measuring the flow rate. If heat is transmitted between the elements via the diaphragm 672 separately from the exchange of heat with the gas to be measured 30 between the elements formed in the diaphragm 672, it is difficult to accurately measure the flow rate. For this reason, the diaphragm 672 needs to increase the thermal resistance, and the diaphragm 672 is made as thin as possible.

  The flow rate detection unit (flow rate detection element) 602 is embedded and fixed in the first resin of the circuit package 400 formed by the first resin molding process so that the heat transfer surface 437 of the diaphragm 672 is exposed. The surface of the diaphragm 672 is provided with the above-described elements (the heating element 608 shown in FIG. 21, the resistor 652 that is the upstream resistance temperature detector, the resistor 654 and the resistor 656 that is the downstream resistance temperature detector, the resistor 658, etc.). . The element transmits heat to the measurement target gas 30 (not shown) through the heat transfer surface 437 on the element surface in the heat transfer surface exposed portion 436 corresponding to the diaphragm 672. The heat transfer surface 437 may be constituted by the surface of each element, or a thin protective film may be provided thereon. It is desirable that the heat transfer between the element and the measurement target gas 30 is performed smoothly, while the direct heat transfer between the elements is as small as possible.

  The portion of the flow rate detection unit (flow rate detection element) 602 where the element is provided is disposed in the heat transfer surface exposed portion 436 of the measurement flow channel surface 430, and the heat transfer surface 437 forms the measurement flow channel surface 430. Exposed from the resin. The outer peripheral portion of the flow rate detecting element 602 is covered with the thermosetting resin used in the first resin molding step for forming the measurement flow path surface 430. If only the side surface of the flow rate detection element 602 is covered with the thermosetting resin, and the surface side of the outer peripheral portion of the flow rate detection element 602 (that is, the region around the diaphragm 672) is not covered with the thermosetting resin, The stress generated in the resin molding the measurement flow path surface 430 is received only by the side surface of the flow rate detection element 602, so that the diaphragm 672 may be distorted and the characteristics may be deteriorated. As shown in FIG. 16, the distortion of the diaphragm 672 is reduced by setting the outer peripheral portion on the front side of the flow rate detection element 602 to be covered with the thermosetting resin. On the other hand, if the level difference between the heat transfer surface 437 and the measurement flow path surface 430 through which the measurement target gas 30 flows is large, the flow of the measurement target gas 30 is disturbed, and the measurement accuracy decreases. Therefore, it is desirable that the step W between the heat transfer surface 437 and the measurement flow path surface 430 through which the measurement target gas 30 flows is small.

The diaphragm 672 is made very thin in order to suppress heat transfer between the elements, and is thinned by forming a gap 674 on the back surface of the flow rate detecting element 602. When the gap 674 is sealed, the pressure of the gap 674 formed on the back surface of the diaphragm 672 changes based on the temperature due to a temperature change. When the pressure difference between the gap 674 and the surface of the diaphragm 672 becomes large, the diaphragm 672 receives a pressure to cause distortion, and high-precision measurement becomes difficult. For this reason, the plate 532 is provided with a hole 520 that is connected to the opening 438 that opens to the outside, and a communication hole 676 that connects the hole 520 and the gap 674. The communication hole 676 is made of two plates, for example, a first plate 532 and a second plate 536. The first plate 532 is provided with a hole 520 and a hole 521, and further a groove for forming a communication hole 676. The communication hole 676 is formed by closing the groove and the hole 520 and the hole 521 with the second plate 536. By the communication hole 676 and the hole 520, the air pressure acting on the front surface and the back surface of the diaphragm 672 becomes substantially equal, and the measurement accuracy is improved.

  As described above, the communication hole 676 can be formed by closing the groove and the hole 520 and the hole 521 with the second plate 536. Alternatively, the lead frame can be used as the second plate 536. As illustrated in FIG. 15, an LSI that operates as a diaphragm 672 and a processing unit 604 is provided on the plate 532. A lead frame for supporting a plate 532 on which the diaphragm 672 and the processing unit 604 are mounted is provided below these. Therefore, the structure becomes simpler by using this lead frame. The lead frame can be used as a ground electrode. Thus, the role of the second plate 536 is given to the lead frame, and the lead frame is used to close the hole 520 and the hole 521 formed in the first plate 534 and to form the groove formed in the first plate 534. By forming the communication hole 676 by covering the lead frame so as to cover the lead frame, the entire structure is simplified, and the lead frame acts as a ground electrode, so that the diaphragm 672 and the processing unit 604 are externally connected. The influence of noise can be reduced.

  In the circuit package 400, the pressing trace 442 remains on the back surface of the circuit package 400 where the heat transfer surface exposed portion 436 is formed. In the first resin molding step, in order to prevent the resin from flowing into the heat transfer surface exposed portion 436, a mold, for example, a insert piece is applied to the heat transfer surface exposed portion 436, and the pressing trace 442 on the opposite surface is further formed. A mold is applied to the portion, and both molds prevent the resin from flowing into the heat transfer surface exposed portion 436. By forming the heat transfer surface exposed portion 436 in this manner, the flow rate of the measurement target gas 30 can be measured with extremely high accuracy.

  FIG. 17 shows a state in which the frame shown in FIG. 15 is molded with a thermosetting resin and covered with the thermosetting resin in the first resin molding step. By this molding, the measurement flow path surface 430 is formed on the surface of the circuit package 400, and the heat transfer surface exposed portion 436 is provided on the measurement flow path surface 430. Further, a gap 674 on the back surface of the diaphragm 672 corresponding to the heat transfer surface exposed portion 436 is configured to be connected to the opening 438. A temperature detection unit 452 for measuring the temperature of the measurement target gas 30 is provided at the tip of the protrusion 424, and a temperature detection element 518 is incorporated therein. Inside the protruding portion 424, in order to suppress heat transfer, a lead for taking out an electric signal of the temperature detection element 518 is divided, and a connection line 546 having a large thermal resistance is disposed. Thereby, the heat transfer from the base of the protrusion part 424 to the temperature detection part 452 is suppressed, and the influence by heat is suppressed.

Further, an inclined portion 594 and an inclined portion 596 are formed at the base of the protruding portion 424. While the flow of the resin in the first resin molding step is smooth, the measurement target gas 30 measured by the temperature detection unit 452 is measured by the inclined portion 594 and the inclined portion 596 in a state where the resin is mounted on the vehicle and operating. The projection flows smoothly from the protrusion 424 toward the root, the root of the protrusion 424 is cooled, and the effect of heat on the temperature detector 452 can be reduced. After the state shown in FIG. 17, the lead 514 is disconnected for each terminal to become the connection terminal 412 and the terminal 414.

  In the first resin molding step, it is necessary to prevent the resin from flowing into the heat transfer surface exposed portion 436 and the opening 438. For this reason, in the first resin molding step, the resin flow is blocked at the position of the heat transfer surface exposed portion 436 and the opening 438, for example, a piece larger than the diaphragm 672 is applied, and the back surface is pressed and sandwiched from both sides. . In FIG. 14C, there are pressing marks 442 and pressing marks 441 on the heat transfer surface exposed portion 436 and opening 438 in FIG. 17 or the back surface corresponding to the heat transfer surface exposed portion 436 and opening 438 in FIG. Remaining.

In FIG. 17, the cut surface of the lead separated from the frame 512 is exposed from the resin surface, and thus moisture or the like may enter the inside from the cut surface of the lead during use. It is important to prevent this from the viewpoint of improving durability and improving reliability. For example, the lead cutting portions of the inclined portion 594 and the inclined portion 596 are covered with resin in the second resin molding step, and the cutting surfaces of the leads 552 and the leads 554 shown in FIG. 15 with the frame 512 are covered with the resin. This prevents corrosion of the cut surfaces of the lead 552 and the lead 554 and intrusion of water from the cut portion. The cut surfaces of the lead 552 and the lead 554 are close to an important lead portion that transmits an electrical signal of the temperature detection unit 452. Therefore, it is desirable to cover the cut surface with the second resin molding process.

5.3 Another Example of Circuit Package 400 FIG. 18 shows another example of the circuit package 400. The same reference numerals as those shown in other figures are the same. In the embodiment shown in FIG. 14 described above, the circuit package 400 includes the connection terminal 412 and the terminal 414 provided on the same side of the circuit package 400. On the other hand, in the embodiment shown in FIG. 18, the connection terminal 412 and the terminal 414 are provided on different sides. The terminal 414 is a terminal that is not connected to an external connection terminal of the thermal flow meter 300. As described above, by providing the connection terminal 412 connected to the outside and the terminal 414 not connected to the outside in the thermal flow meter 300 in different directions, the space between the terminals of the connection terminal 412 can be widened, and the workability thereafter is improved. To do. Further, by extending the terminal 414 in a direction different from that of the connection terminal 412, it is possible to reduce the concentration of the leads in the frame 512 to a part, and the arrangement of the leads in the frame 512 is facilitated. In particular, a chip capacitor, which is a circuit component 516, is connected to a lead portion corresponding to the connection terminal 412. In order to provide these circuit components 516, a slightly large space is required. The embodiment of FIG. 18 has an effect of easily securing a lead space corresponding to the connection terminal 412.

  The description of the opening 438, the heat transfer surface exposed portion 436, the measurement flow path surface 430, the pressing trace 441, and the pressing trace 442 in FIG. 18 is substantially the same as the above-described content, and has the same effects. A specific description will be omitted because it will be repeated.

6). Production Process of Thermal Flow Meter 300 6.1 Production Process of Circuit Package 400 FIGS. 19A to 19C show the production process of thermal flow meter 300, FIG. 19A shows the production process of circuit package 400, and FIG. FIG. 19C shows another embodiment of the production process of the thermal flow meter. In FIG. 19A, step 1 shows the process of producing the frame shown in FIG. This frame is made by, for example, press working.

  In step 2, the plate 532 is first mounted on the frame frame formed in step 1, and the flow rate detection unit 602 and the processing unit 604 are further mounted on the plate 532, and circuit components such as a temperature detection element 518 and a chip capacitor are further mounted. Mount. In step 2, electrical wiring is performed between circuit components, between circuit components and leads, and between leads. In step 2, the lead 544 and the lead 548 are connected by a connection line 546 for increasing the thermal resistance. In step 2, the circuit components shown in FIG. 15 are mounted on the frame frame 512, and an electric circuit in which electrical connection is further made is produced.

  Next, in step 3, it is molded with a thermosetting resin by a first resin molding process. This state is shown in FIG. In step 3, the connected leads are separated from the frame frame 512, and the leads are also separated, thereby completing the circuit package 400 shown in FIG. In the circuit package 400, as shown in FIG. 14, a measurement flow path surface 430 and a heat transfer surface exposed portion 436 are formed.

In step 4, the appearance inspection and operation inspection of the completed circuit package 400 are performed. In the first resin molding process of Step 3, the electric circuit made in Step 2 is fixed in the mold, and high temperature resin is injected into the mold at a high pressure, so that there is an abnormality in the electrical components and electrical wiring. It is desirable to check for this. For this inspection, a terminal 414 is used in addition to the connection terminal 412 shown in FIGS. Since the terminal 414 is not used thereafter, the terminal 414 may be cut from the root after this inspection. For example, in FIG. 18, the used terminal 414 is cut at the root.

6.2 Production Process of Thermal Flow Meter 300 and Correction of Characteristics In the process shown in FIG. 19B, the circuit package 400 and the external terminal 306 produced according to FIG. 19A are used. 302 is created. The housing 302 is formed with a resin-made sub passage groove, a flange 312 and an external connection portion 305, and the hatched portion of the circuit package 400 shown in FIG. 302 is fixed. The combination of the production of the circuit package 400 by the first resin molding process (step 3) and the molding of the housing 302 of the thermal flow meter 300 by the second resin molding process significantly improves the flow rate detection accuracy. In step 6, each external terminal inner end 361 shown in FIG. 13 is disconnected, and connection terminal 412 and external terminal inner end 361 are connected in step 7.

  When the housing 302 is completed in step 7, next, in step 8, the front cover 303 and the back cover 304 are attached to the housing 302, the inside of the housing 302 is sealed with the front cover 303 and the back cover 304, and the measured gas 30 A sub-passage for the flow is completed. Further, the diaphragm structure described with reference to FIGS. 7, 10, and 12 is formed by the protrusions 356 provided on the front cover 303 or the back cover 304. The front cover 303 is made by molding in step 10, and the back cover 304 is made by molding in step 11. Further, the front cover 303 and the back cover 304 are made in different processes, and are made by molding with different molds.

  In step 9, the gas is actually introduced into the sub-passage and the characteristics are tested. As described above, since the relationship between the sub passage and the flow rate detection unit is maintained with high accuracy, very high measurement accuracy can be obtained by performing characteristic correction by a characteristic test. In addition, since the positioning and shape-related molding that affects the relationship between the sub-passage and the flow rate detection unit are performed in the first resin molding process and the second resin molding process, there is little change in characteristics even with long-term use, and high accuracy. In addition, high reliability is ensured.

6.3 Another Embodiment of Thermal Flow Meter 300 Production Process and Characteristic Correction In FIG. 19C, the circuit package 400 and the external terminal 306 produced according to FIG. 19A are used, and before the second resin molding process. In step 12, the connection terminal 412 and the external terminal inner end 361 are connected. At this time, or before the step 12, the external terminal inner ends 361 shown in FIG. In step 13, the housing 302 is formed by the second resin molding process. The housing 302 is formed with a resin-made sub passage groove, a flange 312 and an external connection portion 305, and the hatched portion of the circuit package 400 shown in FIG. 302 is fixed. Production of circuit package 400 by the first resin molding process (Step 3)
) And the molding of the housing 302 of the thermal flow meter 300 in the second resin molding step, the flow rate detection accuracy is greatly improved.

  When the housing 302 is completed in step 13, next, in step 8, the front cover 303 and the back cover 304 are attached to the housing 302, the inside of the housing 302 is sealed with the front cover 303 and the back cover 304, and the gas to be measured A sub-passage for flowing 30 is completed. Further, the diaphragm structure described with reference to FIGS. 7, 10, and 12 is formed by the protrusions 356 provided on the front cover 303 or the back cover 304. The front cover 303 is made by molding in step 10, and the back cover 304 is made by molding in step 11. Further, the front cover 303 and the back cover 304 are made in different processes, and are made by molding with different molds.

  In step 9, the gas is actually introduced into the sub-passage and the characteristics are tested. As described above, since the relationship between the sub passage and the flow rate detection unit is maintained with high accuracy, very high measurement accuracy can be obtained by performing characteristic correction by a characteristic test. In addition, positioning and shape-related molding that influences the relationship between the sub-passage and the flow rate detection unit are performed in the first resin molding process and the second resin molding process, so there is little change in characteristics even when used for a long period of time and high accuracy. In addition, high reliability is ensured.

7). Circuit configuration of thermal flow meter 300 7.1 Overall circuit configuration of thermal flow meter 300 FIG. 20 is a circuit diagram showing a flow rate detection circuit 601 of the thermal flow meter 300. Note that a measurement circuit related to the temperature detection unit 452 described above in the embodiment is also provided in the thermal flow meter 300, but is omitted in FIG. The flow rate detection circuit 601 of the thermal type flow meter 300 includes a flow rate detection unit 602 having a heating element 608 and a processing unit 604. The processing unit 604 controls the amount of heat generated by the heating element 608 of the flow rate detection unit 602 and outputs a signal indicating the flow rate based on the output of the flow rate detection unit 602 via the terminal 662. In order to perform the processing, the processing unit 604 includes a central processing unit (hereinafter referred to as a CPU) 612, an input circuit 614, and an output circuit 61.
6. A memory 618 that holds data representing a relationship between a correction value or a measured value and a flow rate, and a power supply circuit 622 that supplies a certain voltage to a necessary circuit, respectively. The power supply circuit 622 is supplied with DC power from an external power source such as an in-vehicle battery via a terminal 664 and a ground terminal (not shown).

  The flow rate detector 602 is provided with a heating element 608 for heating the measurement target gas 30. The voltage V1 is supplied from the power supply circuit 622 to the collector of the transistor 606 constituting the current supply circuit of the heating element 608, and a control signal is applied from the CPU 612 to the base of the transistor 606 via the output circuit 616. Accordingly, a current is supplied from the transistor 606 to the heating element 608 through the terminal 624. The amount of current supplied to the heating element 608 is controlled by a control signal applied from the CPU 612 to the transistor 606 constituting the current supply circuit of the heating element 608 via the output circuit 616. The processing unit 604 controls the amount of heat generated by the heating element 608 so that the temperature of the measurement target gas 30 is higher than the initial temperature by a predetermined temperature, for example, 100 ° C., when heated by the heating element 608.

The flow rate detection unit 602 includes a heat generation control bridge 640 for controlling the amount of heat generated by the heating element 608 and a flow rate detection bridge 650 for measuring the flow rate. One end of the heat generation control bridge 640 is supplied with a constant voltage V3 from the power supply circuit 622 via a terminal 626, and the other end of the heat generation control bridge 640 is connected to the ground terminal 630. A constant voltage V2 is supplied from one end of the flow rate detection bridge 650 from the power supply circuit 622 via a terminal 625, and the other end of the flow rate detection bridge 650 is connected to the ground terminal 630.

  The heat generation control bridge 640 includes a resistor 642 that is a resistance temperature detector whose resistance value changes based on the temperature of the heated measurement target gas 30. The resistor 642, the resistor 644, the resistor 646, and the resistor 648 are bridges. The circuit is configured. The potential difference between the intersection A of the resistor 642 and the resistor 646 and the potential B at the intersection B of the resistor 644 and 648 is input to the input circuit 614 via the terminal 627 and the terminal 628, and the CPU 612 has a predetermined potential difference between the intersection A and the intersection B. In this embodiment, the amount of heat generated by the heating element 608 is controlled by controlling the current supplied from the transistor 606 so as to be zero volts. The flow rate detection circuit 601 illustrated in FIG. 20 heats the measurement gas 30 with the heating element 608 so as to be higher than the original temperature of the measurement gas 30 by a constant temperature, for example, 100 ° C. at all times. In order to perform this heating control with high accuracy, when the temperature of the gas 30 to be measured heated by the heating element 608 becomes a constant temperature, for example, 100 ° C., always higher than the initial temperature, the intersection A and the intersection A The resistance value of each resistor constituting the heat generation control bridge 640 is set so that the potential difference between B becomes zero volts. Therefore, in the flow rate detection circuit 601 shown in FIG. 20, the CPU 612 controls the current supplied to the heating element 608 so that the potential difference between the intersection A and the intersection B becomes zero volts.

  The flow rate detection bridge 650 includes four resistance temperature detectors, a resistor 652, a resistor 654, a resistor 656, and a resistor 658. These four resistance temperature detectors are arranged along the flow of the gas to be measured 30, and the resistor 652 and the resistor 654 are arranged upstream of the heating element 608 in the flow path of the gas to be measured 30, and the resistor 656. And the resistor 658 are arranged on the downstream side in the flow path of the measurement target gas 30 with respect to the heating element 608. In order to increase the measurement accuracy, the resistor 652 and the resistor 654 are arranged so that the distance to the heating element 608 is substantially the same, and the resistor 656 and the resistor 658 are substantially the same distance to the heating element 608. Has been placed.

  A potential difference between an intersection C of the resistor 652 and the resistor 656 and an intersection D of the resistor 654 and the resistor 658 is input to the input circuit 614 through the terminal 631 and the terminal 632. In order to improve the measurement accuracy, for example, each resistance of the flow rate detection bridge 650 is set so that the potential difference between the intersection C and the intersection D becomes zero when the flow of the measurement target gas 30 is zero. Therefore, when the potential difference between the intersection point C and the intersection point D is, for example, zero volts, the CPU 612 generates an electric signal indicating that the flow rate of the main passage 124 is zero based on the measurement result that the flow rate of the measurement target gas 30 is zero. Output from the terminal 662.

  When the measured gas 30 flows in the direction of the arrow in FIG. 20, the resistor 652 and the resistor 654 arranged on the upstream side are cooled by the measured gas 30 and arranged on the downstream side of the measured gas 30. The resistors 656 and 658 are heated by the measurement target gas 30 heated by the heating element 608, and the temperatures of the resistors 656 and 658 are increased. Therefore, a potential difference is generated between the intersection C and the intersection D of the flow rate detection bridge 650, and this potential difference is input to the input circuit 614 via the terminal 631 and the terminal 632. The CPU 612 retrieves data representing the relationship between the potential difference stored in the memory 618 and the flow rate of the main passage 124 based on the potential difference between the intersection C and the intersection D of the flow rate detection bridge 650, and Find the flow rate. An electrical signal representing the flow rate of the main passage 124 obtained in this way is output via the terminal 662. Note that although reference numerals are newly described for the terminal 664 and the terminal 662 shown in FIG. 20, they are included in the connection terminal 412 shown in FIG. 5, FIG. 6, or FIG.

  The memory 618 stores data representing the relationship between the potential difference between the intersection C and the intersection D and the flow rate of the main passage 124, and is obtained based on the actual measured value of gas after the circuit package 400 is produced. In addition, correction data for reducing measurement errors such as variations is stored. Note that the actual measurement of the gas after production of the circuit package 400 and the writing of the correction value based on it into the memory 618 are performed using the external terminal 306 and the correction terminal 307 shown in FIG. In the present embodiment, the arrangement relationship between the sub-passage through which the measurement target gas 30 flows and the measurement flow path surface 430 and the arrangement relationship between the sub-passage through which the measurement target gas 30 flows and the heat transfer surface exposed portion 436 are highly accurate. Since the circuit package 400 is produced in a state where there is little variation, the measurement result with extremely high accuracy can be obtained by the correction using the correction value.

7.2 Configuration of Flow Rate Detection Circuit 601 FIG. 21 is a circuit configuration diagram showing a circuit arrangement of the flow rate detection circuit 601 of FIG. 20 described above. The flow rate detection circuit 601 is made as a rectangular semiconductor chip, and the measured gas 30 flows in the direction of the arrow from the left side to the right side of the flow rate detection circuit 601 shown in FIG.

A rectangular diaphragm 672 in which the thickness of the semiconductor chip is reduced is formed in the flow rate detection unit (flow rate detection element) 602 formed of a semiconductor chip. The diaphragm 672 includes a thin region (that is, the above-described thin area). Heat transfer surface) 603 is provided. The above-described gap is formed on the back surface side of the thin region 603. The gap communicates with the opening 438 shown in FIGS. 14 and 5, and the pressure in the gap depends on the pressure introduced from the opening 438. .

  By reducing the thickness of the diaphragm 672, the thermal conductivity is lowered, and the diaphragm 672 to the resistor 652, the resistor 654, the resistor 658, and the resistor 656 provided in the thin region (heat transfer surface) 603 of the diaphragm 672 is reduced. The heat transfer through is suppressed, and the temperature of these resistors is substantially determined by the heat transfer with the gas 30 to be measured.

  A heating element 608 is provided at the center of the thin region 603 of the diaphragm 672, and a resistor 642 constituting the heating control bridge 640 is provided around the heating element 608. Resistors 644, 646, and 648 constituting the heat generation control bridge 640 are provided outside the thin region 603. The resistors 642, 644, 646, and 648 formed in this way constitute a heat generation control bridge 640.

  In addition, a resistor 652 and a resistor 654 which are upstream temperature measuring resistors and a resistor 656 and a resistor 658 which are downstream temperature measuring resistors are arranged so as to sandwich the heating element 608, and the gas to be measured is placed on the heating element 608. An upstream resistance temperature detector 652 and a resistance 654 are arranged on the upstream side in the direction of the arrow through which 30 flows, and a downstream resistance temperature detector on the downstream side in the direction of the arrow in which the measured gas 30 flows with respect to the heating element 608. A certain resistor 656 and resistor 658 are arranged. In this manner, the flow rate detection bridge 650 is formed by the resistor 652, the resistor 654, the resistor 656, and the resistor 658 arranged in the thin region 603.

  Further, both end portions of the heating element 608 are connected to terminals 624 and 629 described on the lower side of FIG. Here, as shown in FIG. 20, a current supplied from the transistor 606 to the heating element 608 is applied to the terminal 624, and the terminal 629 is grounded as a ground.

The resistor 642, the resistor 644, the resistor 646, and the resistor 648 that constitute the heat generation control bridge 640 are connected to the terminals 626 and 630, respectively. As shown in FIG. 20, a constant voltage V3 is supplied from the power supply circuit 622 to the terminal 626, and the terminal 630 is grounded. A connection point between the resistor 642 and the resistor 646 and between the resistor 646 and the resistor 648 is connected to a terminal 627 and a terminal 628. As shown in FIG. 21, the terminal 627 outputs the potential at the intersection A between the resistor 642 and the resistor 646, and the terminal 627 outputs the potential at the intersection B between the resistor 644 and the resistor 648. As shown in FIG. 20, a constant voltage V2 is supplied from the power supply circuit 622 to the terminal 625, and the terminal 630 is grounded as a ground terminal. The connection point between the resistor 654 and the resistor 658 is connected to the terminal 631, and the terminal 631 outputs the potential at the point B in FIG. A connection point between the resistor 652 and the resistor 656 is connected to a terminal 632, and the terminal 632 outputs a potential at the intersection C shown in FIG.

As shown in FIG. 21, since the resistor 642 constituting the heat generation control bridge 640 is formed in the vicinity of the heat generating body 608, the temperature of the gas warmed by the heat generated from the heat generating body 608 can be accurately measured. it can. On the other hand, resistors 644 and 646 that constitute the heat generation control bridge 640.
, 648 are arranged away from the heating element 608, and thus are not easily affected by the heat generated by the heating element 608. The resistor 642 is configured to react sensitively to the temperature of the gas heated by the heating element 608, and the resistor 644, the resistance 646, and the resistance 648 are configured not to be affected by the heating element 608. For this reason, the detection accuracy of the measurement target gas 30 by the heat generation control bridge 640 is high, and the control for increasing the measurement target gas 30 by a predetermined temperature with respect to the initial temperature can be performed with high accuracy.

  In this embodiment, an air gap is formed on the back surface side of the diaphragm 672, and this air space communicates with the opening 438 shown in FIGS. 14 and 5, and the pressure on the back surface side air gap of the diaphragm 672 and the front side of the diaphragm 672 The difference from the pressure is not increased. Distortion of the diaphragm 672 due to this pressure difference can be suppressed. This leads to an improvement in flow rate measurement accuracy.

  As described above, the diaphragm 672 is formed with the thin region 603, and the thickness of the portion including the thin region 603 is very thin, and heat conduction through the diaphragm 672 is suppressed as much as possible. Therefore, the flow rate detection bridge 650 and the heat generation control bridge 640 are less affected by heat conduction through the diaphragm 672, and the tendency to operate depending on the temperature of the measurement target gas 30 is further increased, and the measurement operation is improved. For this reason, high measurement accuracy is obtained.

  The present invention can be applied to the above-described measuring device for measuring the gas flow rate.

300 Thermal Flowmeter 302 Housing 303 Front Cover 304 Back Cover 305 External Connection Portion 306 External Terminal 307 Correction Terminal 310 Measurement Unit 320 Terminal Connection Portion 332 Front Side Secondary Passage Groove 334 Back Side Secondary Passage Groove 356, 358 Protrusion 359 Resin 361 External terminal inner end 365 Connecting portion 372 Fixed portion 400 Circuit package 412 Connection terminal 414 Terminal 424 Projection portion 430 Measurement flow channel surface 432 Fixed surface 436 Heat transfer surface exposed portion 438 Opening 452 Temperature detection portion 590 Press-fit holes 594, 596 Inclined portion 601 Flow rate detection circuit 602 Flow rate detection unit 604 Processing unit 608 Heating element 640 Heat generation control bridge 650 Flow rate detection bridge 672 Diaphragm

In order to solve the above problems, the thermal flow meter of the present invention performs heat transfer between a sub-passage for taking in and flowing the gas to be measured flowing through the main passage and the gas to be measured flowing through the sub-passage. A circuit package having a flow rate measurement circuit for measuring a flow rate and a first resin for sealing the flow rate measurement circuit, and for storing the circuit package and connecting to an external device And a housing made of a second resin having a thermal expansion coefficient different from that of the first resin, wherein the circuit package outputs at least a measurement result of the flow rate measurement circuit. It has a measurement terminal and an inspection terminal for inspecting the flow rate measurement circuit after the resin molding. The circuit package has a shape having a plurality of sides, and the measurement terminal and the inspection terminal of the circuit package are provided on different sides.

Claims (7)

A sub-passage for taking in and flowing the gas to be measured flowing through the main passage;
A flow rate measuring circuit for measuring a flow rate by performing heat transfer with the gas to be measured flowing through the sub passage;
A circuit package having a first resin for sealing the flow rate measurement circuit;
A housing made of a second resin that houses the circuit package and has an external connection part for connecting to an external device, and having a coefficient of thermal expansion different from that of the first resin,
The circuit package is at least
A measurement terminal for outputting a measurement result of the flow rate measurement circuit;
Inspection terminals for inspecting the flow measurement circuit after the resin molding,
Have
The circuit package has a shape having a plurality of sides in appearance.
The thermal flow meter, wherein the measurement terminal and the inspection terminal of the circuit package are provided on different sides. The thermal flow meter according to claim 1,
The circuit package further includes a correction terminal for reading adjustment data from the outside after the circuit package is accommodated in the case. The thermal flow meter according to claim 1,
A case having the housing and a cover;
The housing includes a sub-passage groove for forming the external terminal and the sub-passage,
A thermal flow meter in which the sub passage is formed by covering the housing with the cover so that the sub passage groove is covered with the cover. The thermal flow meter according to claim 2,
An end of the external terminal on the side connected to the external device and an end of the correction terminal on the side connected to the external device are different thermal flow meters. The thermal flow meter according to claim 2,
The measurement terminal and the correction terminal are thermal flow meters having bent portions. The thermal flow meter according to claim 2,
The thermal flow meter in which the inspection terminal has a shape shorter than the measurement terminal and the correction terminal. The thermal flow meter according to claim 2,
An electrical connection between the measurement terminal and the external terminal is a thermal flowmeter covered with the second resin.

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