JP2021139693A - Position sensor and method for manufacturing position sensor - Google Patents

Abstract

To provide means for suppressing variations in the quality of a position sensor.SOLUTION: The position sensor includes: a case; a substrate 4 contained in a case; a print circuit 6 in the substrate 4; and a terminal 8 having a base end part 8a supported by the case and having a top end part 8b pressed against the print circuit 6. The top end part 8b includes: a top end surface 22 of the edge surface of the terminal 8, which is the most distant from the base end part 8a; and a contact part 24 in contact with the print circuit 6, which is closer to the base end part 8a than the top end surface 22.SELECTED DRAWING: Figure 4

Description

The present disclosure relates to a position sensor and a method for manufacturing the position sensor.

For example, as disclosed in Patent Document 1, a position sensor is known as a device for detecting the displacement of a detection object. The position sensor includes a substrate, a circuit formed on the substrate, and terminals pressed against the circuit.

Japanese Unexamined Patent Publication No. 10-227604

However, in the configuration disclosed in Patent Document 1, when a terminal is pressed against a circuit formed on a substrate, a part of the circuit is scraped by sliding of the tip of the terminal, and the conduction resistance of the circuit changes. There is. As a result, the quality of the position sensor may vary.

The present disclosure has been made in view of the above-mentioned problems, and an object of the present disclosure is to provide a position sensor capable of suppressing quality variation.

(1) The position sensor according to at least one embodiment of the present invention is pressure-welded to a case, a substrate housed in the case, a printing circuit formed on the substrate, a base end portion supported by the case, and a printing circuit. It is provided with a terminal having a tip portion to be formed, and the tip portion is located at the tip end surface of the end face of the terminal located farthest from the base end portion and is located closer to the base end portion than the tip end surface and contacts the printing circuit. Includes contact parts and.

(2) In some embodiments, in the configuration described in (1) above, the terminal has a facing surface facing the surface of the substrate on which the printing circuit is formed, and the facing surface of the terminal is the substrate. The first surface extending along the first direction intersecting with the surface of the It may include a second surface that extends along a second direction that intersects.

(3) In some embodiments, in the configuration described in (2) above, the angle θ formed by the second direction with respect to the surface of the substrate may be 3 degrees or more and less than 30 degrees.

(4) In some embodiments, in the configuration described in (2) or (3) above, the second surface may be a plane located between the contact portion and the tip surface.

(5) In the method for manufacturing a position sensor according to at least one embodiment of the present invention, the tip end portion of a terminal whose base end portion is supported by a case is pressed against a printed circuit formed on a substrate of the position sensor. As described above, the step of assembling the board to the case is provided, and in the state of assembling the board to the case, the tip end portion of the terminal is closer to the base end portion than the tip end surface of the terminal end face located farthest from the base end portion. The contact portion located at is in contact with the printing circuit.

(6) In some embodiments, in the manufacturing method described in (5) above, a step of forming a plate material having an outer shape of a terminal by punching and a terminal facing the surface of a substrate on which a printing circuit is formed are formed. A step of face-cutting the plate material may be provided so that a flat surface portion connected to the tip end surface of the terminal is formed as a part of the facing surface of the plate material.

According to the position sensor of the present disclosure, it is possible to suppress variations in quality.

It is a perspective view which shows schematic structure of the position sensor which concerns on one Embodiment of this invention, and shows by disassembling a part of the structure of a position sensor for explanation. It is a perspective view which shows schematic structure of the case which concerns on one Embodiment of this invention. It is a perspective view which shows schematic structure of the substrate and the printing circuit which concerns on one Embodiment of this invention. It is a schematic block diagram which shows schematic structure of the tip part of the terminal which concerns on one Embodiment of this invention. It is a perspective view which shows typically the structure of the tip part of the terminal which concerns on one Embodiment of this invention. It is a reference figure which shows typically the shape of the tip of a terminal. It is a flowchart which shows the manufacturing method of the position sensor which concerns on one Embodiment of this invention. It is a perspective view which shows typically the structure of the position sensor which concerns on another embodiment of this invention.

Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings. However, the dimensions, materials, shapes, relative arrangements, etc. of the components described as embodiments or shown in the drawings are not intended to limit the scope of the present invention to this, but are merely explanatory examples. No.
For example, expressions that represent relative or absolute arrangements such as "in a certain direction", "along a certain direction", "parallel", "orthogonal", "center", "concentric" or "coaxial" are exact. Not only does it represent such an arrangement, but it also represents a state of relative displacement with tolerances or angles and distances to the extent that the same function can be obtained.
For example, expressions such as "same", "equal", and "homogeneous" that indicate that things are in the same state not only represent exactly the same state, but also have tolerances or differences to the extent that the same function can be obtained. It shall also represent the existing state.
For example, an expression representing a shape such as a quadrangular shape or a cylindrical shape not only represents a shape such as a quadrangular shape or a cylindrical shape in a geometrically strict sense, but also an uneven portion or chamfering within a range in which the same effect can be obtained. The shape including the part and the like shall also be represented.
On the other hand, the expressions "equipped", "equipped", "equipped", "included", or "have" one component are not exclusive expressions that exclude the existence of other components.

(Position sensor)
The configuration of the position sensor according to the embodiment of the present invention will be described with reference to FIGS. 1 to 5. In the present disclosure, a throttle position sensor that detects the opening degree of the throttle will be described as an example, but the position sensor may be a position sensor other than the throttle position sensor. For example, the position sensor may be a crank position sensor that detects the rotational position of the crankshaft.

As shown in FIGS. 1 to 3, the position sensor 1 is pressed against the case 2, the substrate 4 (element base), the printing circuit 6, the base end portion 8a supported by the case 2, and the printing circuit 6. A terminal 8 having a tip portion 8b is provided.

As shown in FIG. 2, the case 2 includes a main body portion 2a having a cylindrical shape, and a storage space 3 is formed inside the main body portion 2a. The accommodation space 3 is open toward one side, and in the present disclosure, the direction in which the accommodation space 3 is open will be described as the upward direction. As referred to in FIG. 1, the opening of the accommodation space 3 is closed by the top cover portion 10 which is a plate-shaped member. When the opening of the accommodating space 3 is closed by the top cover portion 10, the projecting portion 11 provided in the accommodating space 3 and projecting toward the opening in the accommodating space 3 penetrates the substrate 4. It penetrates the hole 13.

Further, the case 2 further includes a terminal support portion 2b and a mounting portion 2c. The terminal support portion 2b is attached to the outer peripheral surface of the main body portion 2a. The terminal support portion 2b has a base end portion 8a of the terminal 8 embedded therein, and supports the base end portion 8a of the terminal 8. The mounting portion 2c is mounted on the lower surface of the main body portion 2a, and a communication hole 12 for communicating the accommodation space 3 and the outside is formed. Although not shown, a connecting shaft for connecting the rotor 14 and the throttle shaft housed in the accommodating space 3 is arranged in the communication hole 12. The main body portion 2a, the terminal support portion 2b, and the mounting portion 2c constituting the case 2 are configured as one component as a whole, and may be integrally composed of, for example, resin.

As referred to in FIG. 1, the spring 18 and the brush 20 are housed in the housing space 3. The spring 18 winds around the rotor 14 and is urged to rotate the rotor 14 in a predetermined direction. The brush 20 is attached to the upper surface of the rotor 14 and is arranged so as to be in contact with the printing circuit 6, particularly the low resistance film pattern 6c of the printing circuit 6 described later. In the position sensor 1 having such a configuration, when the opening degree of the throttle, which is the object to be detected, changes, the brush 20 interlocking with the throttle slides on the printing circuit 6 and applies a voltage to the printing circuit 6 via the terminal 8. At the same time as applying the voltage, the voltage corresponding to the position of the brush 20 is acquired to detect the opening degree of the throttle.

The substrate 4 has a plate-like shape, and is accommodated in the accommodation space 3 together with the rotor 14, the spring 18, and the brush 20 described above. As shown in FIG. 3, a printing circuit 6 is formed on the surface 5 of the substrate 4. In this embodiment, the printing circuit 6 is formed on the lower surface of the substrate 4.

The printing circuit 6 may include an electrode film pattern 6a, a resistance film pattern 6b, and a low resistance film pattern 6c. The electrode film pattern 6a is formed on the surface 5 of the substrate 4 with, for example, a highly conductive material containing silver. In another embodiment, the electrode film pattern 6a may be formed of a highly conductive material containing something other than silver such as aluminum, gold, and nickel. The resistance film pattern 6b is formed so as to cover a part of the electrode film pattern 6a. The low resistance film pattern 6c is formed of a material having higher conductivity than the resistance film pattern 6b, and covers the rest of the electrode film pattern 6a. In this low resistance film pattern 6c, the tip portion 8b of the terminal 8 is pressure-welded. That is, the low resistance film pattern 6c also functions as a protective film that protects the rest of the electrode film pattern 6a.

The terminal 8 is for taking out the output of the position sensor 1 to the outside, and has a base end portion 8a and a tip end portion 8b as described above. The base end portion 8a of the terminal 8 is supported by the terminal support portion 2b of the case 2, and the tip end portion 8b of the terminal 8 is located in the accommodation space 3 of the case 2. That is, the terminal 8 extends from the terminal support portion 2b toward the accommodation space 3 in the horizontal direction.

The tip portion 8b of the terminal 8 is bent toward the substrate 4 (printing circuit 6) side in a natural state before being pressed against the printing circuit 6. The tip portion 8b of the terminal 8 is pressure-welded to the printing circuit 6 so that the bending amount is smaller than that in the natural state in the pressure-contacting state where the terminal 8 is pressure-welded. That is, the terminal 8 functions as a leaf spring. The terminal 8 is made of a material having springiness and high conductivity, for example, phosphor bronze.

The configuration of the tip portion 8b of the terminal 8 will be described with reference to FIG. As shown in FIG. 4, the tip end portion 8b of the terminal 8 is located at the tip end surface 22 located farthest from the base end portion 8a among the end faces of the terminal 8 and closer to the base end portion 8a than the tip end surface 22. A contact portion 24 that comes into contact with the printing circuit 6 is included.

The terminal 8 has a facing surface 26 facing the surface 5 of the substrate 4 on which the printing circuit 6 is formed. As shown in FIG. 4, the facing surface 26 includes a first surface 28 extending along the first direction D1 intersecting the surface 5 of the substrate 4, and the first surface 28 sandwiching the contact portion 24. May include a second surface 30 that is located on the opposite side, is connected to the tip surface 22 of the terminal 8, and extends along a second direction D2 that intersects the surface 5 of the substrate 4. That is, the contact portion 24 is a portion where the first surface 28 and the second surface 30 intersect.

Further, the terminal 8 may be arranged so that the tip surface 22 of the terminal 8 and the first surface 28 of the terminal 8 intersect with each other in the normal direction of the surface 5 of the substrate 4. At this time, the angle θ formed by the second direction D2 with respect to the surface 5 of the substrate 4 may be 3 degrees or more and less than 30 degrees, for example, the angle θ is 21 degrees. Further, as shown in FIG. 5, the second surface 30 may be a flat surface located between the contact portion 24 and the tip surface 22. The width of the second surface 30 of the second surface 30 decreases from the contact portion 24 side toward the tip end surface 22 side.

(Action / effect)
The operation and effect of the position sensor 1 according to the embodiment of the present invention will be described. According to the findings of the present inventors, an unintended interference portion may be formed on the tip surface 22 of the terminal 8. For example, as shown in the reference drawing of FIG. 6, when the tip surface 22 of the terminal 8 is formed by punching, the tip surface 22 of the terminal 8 has a sagging 50 (interference portion), a shear surface 52, and a fracture surface. 54 and 56 burrs are included. Therefore, when the terminal 8 is pressed against the printing circuit 6 formed on the substrate 4 in order to assemble the substrate 4 to the case 2, a part of the printing circuit 6 is scraped by the sagging 50, and the conduction resistance of the printing circuit 6 is reduced. May change and the quality of the position sensor 1 may vary. Further, it is not easy to adjust the position, shape, size, etc. of the sagging 50.

However, according to the present embodiment, the contact portion 24 in contact with the printing circuit 6 is located closer to the base end portion 8a than the tip end surface 22. Therefore, it is possible to prevent or suppress the interference of the tip surface 22 of the terminal 8 with the printing circuit 6 when the terminal 8 is slid to press the tip 8b of the terminal 8 against the printing circuit 6. can. That is, it is possible to prevent a part of the printing circuit 6 from being scraped by the sagging 50. Therefore, it is possible to suppress variations in the quality of the position sensor 1.

Further, according to the present embodiment, the terminal 8 in the natural state is pressed against the substrate 4 so as to bend in the direction opposite to the printing circuit 6 side, so that the continuity between the terminal 8 and the printing circuit 6 can be ensured. can. Therefore, the terminal 8 can be made simpler than the case where the terminal 8 is made up of a joint of a plurality of parts, and the cost can be suppressed.

Further, according to the present embodiment, the contact portion 24 is located at a boundary portion between the first surface 28 and the second surface 30 of the facing surfaces 26 facing the surface 5 of the substrate 4 on which the printing circuit 6 is formed. .. Therefore, even if the sagging 50 is formed on the tip surface 22, the sagging 50 interferes with the printing circuit 6 when the terminal 8 is slid to press the tip 8b of the terminal 8 against the printing circuit 6. It can be deterred or suppressed.

Further, according to the present embodiment, since the angle θ is 3 degrees or more, even if the tip portion 8b of the terminal 8 is in a natural state before being pressed against the printing circuit 6, the printing circuit 6 and the contact portion 24 It is possible to secure the grounding of.

Further, according to the present embodiment, since the second surface 30 is a flat surface located between the contact portion 24 and the tip surface 22, the tip surface 22 of the punched terminal 8 can be processed to form the tip surface. It is possible to prevent or suppress the sagging 50 formed on the surface 22 from interfering with the printing circuit 6. Further, as a processing method of the tip surface 22, for example, a relatively easy processing method of forming the second surface 30 by face-to-face processing on the sagging 50 is easily performed, and the quality of the position sensor 1 can be easily varied. It can be suppressed.

(Manufacturing method of position sensor)
A method of manufacturing a position sensor according to an embodiment of the present invention will be described with reference to FIG. 7. In the following, the case of manufacturing the position sensor 1 described above will be described as an example, and the same reference numerals will be given to the constituent members of the position sensor 1, and the detailed description thereof will be omitted.

As shown in FIG. 7, the manufacturing method of the position sensor 1 includes a substrate assembly step S3. In the board assembly step S3, the board 4 is assembled to the case 2 so that the tip 8b of the terminal 8 is pressed against the printing circuit 6 formed on the board 4 of the position sensor 1. At this time, in the state where the substrate 4 is assembled to the case 2, the tip portion 8b of the terminal 8 comes into contact with the printing circuit 6 at the contact portion 24 located closer to the base end portion 8a than the tip surface 22 of the terminal 8. ..

Further, as shown in FIG. 7, the manufacturing method of the position sensor 1 may further include a plate material forming step S1 and a face-to-face processing step S2. The plate material forming step S1 and the face-to-face processing step S2 are steps performed prior to the substrate assembly step S3.

In the plate material forming step S1, a plate material having the outer shape of the terminal 8 is formed by punching. That is, this plate material has a tip surface 22 of the terminal 8 as shown in the reference drawing of FIG.

In the face-to-face processing step S2, a flat surface portion (second surface 30) connected to the tip surface 22 of the terminal 8 is formed as a part of the facing surface 26 of the terminal 8 facing the surface 5 of the substrate 4 on which the printing circuit 6 is formed. The plate material formed in the plate material forming step S1 is faced so that it is formed. Specifically, the tip surface 22 of the terminal 8 on which the sagging 50 is formed is faced, and the sagging 50 of the tip surface 22 is expanded to form the second surface 30.

According to such a method, the sagging 50 formed on the tip surface 22 of the terminal 8 can be eliminated, so that the sagging 50 can be prevented from interfering with the printing circuit 6 or can be suppressed. Therefore, it is possible to suppress variations in the quality of the position sensor 1. Further, according to such a method, it is possible to easily suppress the variation in the quality of the position sensor 1 only by performing a relatively simple step of the face-to-face processing step S2.

Although the position sensor according to the embodiment of the present invention and the method for manufacturing the position sensor have been described above, the present invention is not limited to the above-described embodiment, and various types within a range not deviating from the object of the present invention. It can be changed. For example, as shown in FIG. 8, the present invention can be applied to the linear motion sensor 100 (1). The substrate 104 (4) of the linear motion sensor 100 is housed in the accommodation space 103 (3) in an upright state. The bending amount of the tip 108b (8b) of the terminal 108 (8) of the linear motion sensor 100 is smaller than that in the natural state in the pressure welding state in which the tip portion 108b (8b) is pressure-welded to the printing circuit 106 (6) formed on the substrate 104. As described above, it is pressure-welded to the printing circuit 106.

1 Position sensor 2 Case 4 Board 5 Board surface 6 Printed circuit 8 Terminal 8a Terminal base end 8b Terminal tip 22 Tip surface 24 Contact 26 Facing surface 28 First surface 30 Second surface

D1 1st direction D2 2nd direction S1 Plate material forming step S2 Face-casting step S3 Substrate assembly step

Claims (6)

With the case
The substrate housed in the case and
The printing circuit formed on the substrate and
A base end portion supported by the case and a terminal having a tip end portion pressed against the printing circuit are provided.
The tip is
Of the end faces of the terminals, the tip surface located farthest from the base end portion,
A position sensor including a contact portion located closer to the base end portion than the tip surface and in contact with the printing circuit. The terminal has a facing surface facing the surface of the substrate on which the printing circuit is formed.
The facing surface of the terminal is
A first surface extending along a first direction intersecting the surface of the substrate,
A second surface located on the opposite side of the contact portion from the first surface, connected to the tip surface of the terminal, and extending along a second direction intersecting the surface of the substrate. The position sensor according to claim 1, wherein the position sensor includes. The position sensor according to claim 2, wherein the angle θ formed by the second direction with respect to the surface of the substrate is 3 degrees or more and less than 30 degrees. The position sensor according to claim 2 or 3, wherein the second surface is a plane located between the contact portion and the tip surface. A step of assembling the board to the case is provided so that the tip of the terminal whose base end is supported by the case is pressed against the printing circuit formed on the board of the position sensor.
In the state of assembling the substrate to the case, the tip end portion of the terminal is a contact portion located closer to the base end portion than the tip end surface located farthest from the base end portion of the end face of the terminal. A method for manufacturing a position sensor that comes into contact with the printing circuit. A step of forming a plate material having the outer shape of the terminal by punching, and
The plate material is faced so that a flat surface portion connected to the tip surface of the terminal is formed as a part of the facing surface of the terminal facing the surface of the substrate on which the printing circuit is formed. The method for manufacturing a position sensor according to claim 5, further comprising a step to be performed.

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