JP3207117B2 - Insert conductor, insert resin molded product and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an insert conductor, an insert resin molded product, and a method for manufacturing the same, which are used as components of a rotation sensor for detecting the number of revolutions of a gear-shaped magnetic rotator.

[0002]

FIG. 9 is a side view of a conventional rotation sensor, and FIG.
Reference numeral 0 is a side sectional view of the rotation sensor of FIG. 9. The rotation sensor has a sensor main body 1 and a connector 2 connected to the sensor main body 1. The sensor body 1 is a case 3
And a permanent magnet 4 housed in the case 3, a Hall element 5 serving as a magnetoelectric conversion element, an electric circuit 8, and an O-ring 11 for sealing between the sensor body 1 and the connector 2. I have. The electric circuit 8 is configured by attaching an electronic component 7 to a circuit board 6. The connector 2 has a terminal 9 electrically connected to the electric circuit 8 and a connector body 10 made of an insulating resin in which the terminal 9 is partially embedded.

In this rotation sensor, the rotation of a gear-shaped magnetic rotator 12 which is a magnetic substance provided close to the rotation sensor causes the recess 1 of the magnetic rotator 12 to be formed in the Hall element 5.
The protrusions 2a and the protrusions 12b alternately approach each other, so that the magnetic field from the permanent magnet 4 applied to the Hall element 5 changes. The change in the magnetic field is detected by the Hall element 5 as a change in voltage.
The change in the voltage generated in the Hall element 5 is converted into a pulse wave by the electronic component 7, and then this electric signal is sent to a computer unit (not shown) via the terminal 9 of the connector 2, Is detected.

FIG. 11 is a plan view of an insert conductor which is a component of the rotation sensor. The insert conductor 13 includes a frame portion 22 forming an outer frame, a terminal portion 16 which is cut to become the terminal 9 of the connector 2, and Wiring 27 and electrodes 18a and 18b connected to wiring 27 and to which electronic component 7 is joined by soldering
And a circuit pattern portion 21 having The electrode 18a and the electrode 18b are connected at a first connecting portion 17, the wires 27 are connected at a second connecting portion 23, and the frame portion 22 and the terminal portion 16, and the frame portion 22 and the circuit pattern portion 21 are connected. Are connected to each other at a third connecting portion 29.

FIG. 12 is a plan view of a primary molded body 15 formed by insert-molding a resin on the insert conductor 13 of FIG. 11, and a molded resin portion is formed on a circuit pattern portion 21 of the insert conductor 13. 14
Is provided. In the resin part 14 made of heat-resistant and insulating polyphenylene sulfide, the first connecting part 17 and the wiring 2 are formed in the manufacturing process of the rotation sensor.
A hole 28 is formed for cutting the 7.

Next, a method of manufacturing the rotation sensor will be described. First, insert resin molding is performed on the press-formed insert conductor 13 to form a primary molded body 15 shown in FIG. 12 in which the resin portion 14 is molded on the insert conductor 13.

Thereafter, the terminal portion 16 of the insert conductor 13 is cut to form the terminal 9 by press working, and a part of the frame portion 22 is cut and deleted.

Next, the connector 2 in which the end of the terminal 9 is exposed
Then, insert molding for forming the O-ring groove 19 is performed to produce a secondary molded body 20 which is an insert resin molded body shown in FIG. At the time of the insert molding, the permanent magnet 4 is mounted on the end of the circuit board 6.

Subsequently, the first connecting portion 17 for connecting the adjacent electrodes 18a and 18b is cut by press working to separate the electrodes 18a and 18b from each other and to form a wiring 27.
The second connecting portion 23 for connecting each other is cut off, and the third connecting portion 29 connecting the circuit pattern portion 21 and the frame portion 22 of the insert conductor 13 is cut off to produce an assembly shown in FIG. In this assembly, FIG. 15 is an enlarged view of a portion A in FIG. 14, and FIG. 1 is a cross-sectional view taken along line AA in FIG.
As can be seen from FIG. 6, adjacent electrodes 18a and 18b
A cutting portion 25, which is a through hole, is formed between the two.

Next, the electronic components 7 are applied to the electrodes 18a and 18b.
The Hall element 5 is joined by soldering to form a sensor assembly. Thereafter, the sensor assembly is fitted into the case 3 and the distal end portion 24 of the case 3 is thermally caulked, whereby the case 3 and the sensor assembly are completely integrated.

[0011]

In manufacturing a conventional rotation sensor, the primary molded body 15 and the secondary molded body 20 are made by insert molding. In order to prevent the entire insert conductor 13 from being deformed by the applied resin pressure, the insert conductor 13 has a first connecting portion 17, a second connecting portion 23 and a third connecting portion 29, The first joint portion 17 and the third joint portion 29 are cut after the secondary molded body 20 is formed.

However, when the electronic component 7 is joined to the adjacent electrodes 18a and 18b by soldering after the first connecting portion 17 is cut, FIG. 17 (the electronic component 7 is omitted). )), The solder flows into the cut portion 25 after the first joint portion 17 has been cut to form the connecting portion 26, and the electrodes 18a and 18b are short-circuited. There is a problem in that the connecting portion 26 must be found by performing a visual inspection, and a troublesome operation of removing the connecting portion 26 must be performed.

SUMMARY OF THE INVENTION An object of the present invention is to solve such a problem, and an insert conductor, an insert resin molded article and an insert resin molded article which do not form a connecting portion for short-circuiting between electrodes. The purpose is to obtain a manufacturing method.

[0014]

An insert conductor according to the present invention comprises a plurality of wirings, a plurality of electrodes connected to these wirings to which an electronic component is joined, and a wiring between the wirings except for a region between adjacent electrodes. And a connecting portion for preventing the overall shape from being deformed by the resin injection pressure at the time of insert resin molding.

Further, the insert resin molded article of the present invention comprises: an insert conductor having a plurality of wirings, a plurality of electrodes connected to these wirings to which electronic components are joined, and a connecting portion connected between the wirings; A resin portion having an inter-electrode resin portion in which the electrodes are electrically insulated by a resin interposed between adjacent electrodes, which is formed by insert resin molding on the conductor.

Further, polyphenylene sulfide is used as the resin.

Further, the method of manufacturing an insert resin molded article includes a step of insert-molding a resin on an insert conductor, a step of cutting a connecting portion connected between the electrodes, and a step of cutting the connecting portion between the electrodes. And forming a resin portion between the electrodes by insert molding of a resin.

[0018]

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiment 1 FIG. FIG. 1 is a plan view of an insert conductor according to an embodiment of the present invention.
The frame portion 22 forming the outer frame, the terminal portion 16 which is cut to be the terminal 9 of the connector 2, the plurality of wires 27, and the electrodes 18 a and 18 b connected to these wires 27 and to which the electronic components 7 are joined by soldering And a circuit pattern portion 21. The wires 27 are connected to each other at a second connecting portion 23, and the frame portion 22 and the terminal portion 16 are connected to each other, and the frame portion 22 and the circuit pattern portion 21 are connected to each other at a third connecting portion 29.

FIG. 2 is a plan view of a primary molded body 30 formed by insert-molding a resin on the insert conductor 40 of FIG. 1. The molded resin part is formed on the circuit pattern portion 21 of the insert conductor 40. 14 are provided. In the resin sensor 14, a hole 28 for cutting the second joint 23 is formed in the manufacturing process of the rotation sensor.
Are formed. In addition, polyphenylene sulfide excellent in insulation and heat resistance is used as the resin.

Next, a method of manufacturing the rotation sensor will be described. First, the press-formed insert conductor 40
To form a primary molded body 30 in which the resin portion 14 is molded on the insert conductor 40. In addition, this primary molded article 3
0, the inter-electrode resin part 31 is interposed between the adjacent electrodes 18a and 18b,
b is not electrically connected. Thereafter, as shown in FIG. 3, the terminal portion 16 of the insert conductor 40 is cut to form the terminal 9 by press working, and a part of the frame portion 22 is cut and deleted.

Next, the connector 2 with the end of the terminal 9 exposed
Then, insert resin molding for forming the O-ring groove 19 is performed to produce a secondary molded body 34 as an insert resin molded body shown in FIG. At the time of this insert molding, the permanent magnet 4 is attached to the circuit board 6.
Attached to the end.

Subsequently, the third connecting portion 29 connecting the circuit pattern portion 21 and the frame portion 22 of the insert conductor 40 is cut by press working, and the second connecting portion 23 connecting the wires 27 is cut off. Then, the wirings 27 are separated from each other to form an assembly shown in FIG. Next, the electrodes 18a, 18
b, the electronic component 7 and the Hall element 5 are joined by soldering to form a sensor assembly. The adjacent electrodes 18a,
When the electronic component 7 is joined to the electrode 18b, the inter-electrode resin part 31 is interposed between the electrode 18a and the electrode 18b, and the adjacent electrodes 18a and 18b are not connected by solder.

Thereafter, the sensor assembly is fitted into the case 3 and the tip 24 of the case 3 is caulked by heat, so that the case 3 and the sensor assembly are completely integrated.

Embodiment 2 FIG. FIG. 6 is a plan view of a secondary molded body which is an insert resin molded body showing another embodiment of the present invention, FIG. 7 is an enlarged view of a portion B in FIG. 6, and FIG. FIG. 4 is a cross-sectional view taken along line -B. In the secondary molded body 35, an inter-electrode resin portion 36 is interposed between adjacent electrodes 18a and 18b.
Therefore, when the electronic component 7 is joined to the electrodes 18a and 18b, the adjacent electrodes 18a and 18b are not connected by solder.

Next, a method of manufacturing the secondary molded body 35 will be described. The manufacturing process up to the primary molded body 15 shown in FIG. 12 shown in the conventional example is the same as that of the conventional example, and in the conventional example, the electrode 18a and the electrode 18b are thereafter connected with the first joint 17. Although the secondary molded body 20 is formed, in this embodiment, after the primary molded body 15 is formed, the first joint portion 17 is cut. Then, the connector 2 and the O-ring groove 19 are inserted into the secondary molded body 3 by insert resin molding.
5 at the same time, adjacent electrodes 18a and 18b
Also, the resin is filled in the cut portion 25 between them, and the inter-electrode resin portion 36 is formed.

Thereafter, the procedure for manufacturing a rotation sensor from the secondary molded body 35 is the same as in the first embodiment, and a description thereof will be omitted.

In the above embodiment, the insert conductor 40 used as a component of the rotation sensor, the secondary molded articles 34, 3
5 has been described, but it goes without saying that the present invention can be used for components other than the components of the rotation sensor.

[0028]

As described above, according to the insert conductor of the present invention, a plurality of wirings, a plurality of electrodes connected to these wirings and joined to an electronic component, and a region between adjacent electrodes are removed. And a connecting portion that is connected between the wires to prevent the overall shape from being deformed by the resin injection pressure during insert resin molding, so that when the resin is inserted into the insert conductor, Is filled with resin, and no short circuit occurs between the electrodes.

Further, according to the insert resin molded article of the present invention, since the inter-electrode resin portion which is electrically insulated between the electrodes is provided, there is no short circuit between the electrodes.

When polyphenylene sulfide is used as the resin, it is possible to provide an insert resin molded article having excellent insulation and heat resistance.

Further, according to the method of manufacturing an insert resin molded article, a step of insert molding a resin on an insert conductor, a step of cutting a connecting portion connected between the electrodes, and a step of cutting the connecting portion after cutting the connecting portion are performed. A step of insert-molding a resin between the electrodes to form a resin part between the electrodes, so that the resin part between the electrodes electrically insulated between the electrodes can be easily manufactured.

[Brief description of the drawings]

FIG. 1 is a plan view of an insert conductor according to an embodiment of the present invention.

FIG. 2 is a plan view of a primary molded body molded by insert resin molding on the insert conductor of FIG. 1;

FIG. 3 is a plan view before the primary molded body of FIG. 2 is subjected to insert molding.

FIG. 4 is a plan view of a secondary molded article showing one embodiment of the present invention.

FIG. 5 is a plan view of the secondary molded body of FIG. 4 after cutting a joint portion.

FIG. 6 is a plan view of a secondary molded article showing another embodiment of the present invention.

FIG. 7 is an enlarged view of a location B in FIG. 6;

FIG. 8 is a sectional view taken along the line BB of FIG. 7;

FIG. 9 is a side view of a conventional rotation sensor.

FIG. 10 is a side sectional view of the rotation sensor of FIG. 9;

FIG. 11 is a plan view of a conventional insert conductor.

FIG. 12 is a plan view of a primary molded article obtained by insert resin molding on the insert conductor of FIG. 11;

13 is a plan view of a secondary molded body in which the primary molded body of FIG. 12 is subjected to insert resin molding.

FIG. 14 is a plan view of the secondary molded body of FIG. 13 after cutting a joint portion.

FIG. 15 is an enlarged view of a portion A in FIG. 14;

16 is a sectional view taken along the line AA in FIG.

17 is an enlarged plan view of FIG. 14 when electrodes are short-circuited.

[Explanation of symbols]

18a, 18b electrode, 20 secondary molded body (insert resin molded body), 23 second connecting part, 27 wiring, 29 third connecting part, 30 primary molded body, 31 resin part between electrodes, 34 2 Secondary molded product (insert resin molded product), 35 Secondary molded product (insert resin molded product), 3
6 Resin between electrodes, 40 insert conductor.

Continued on the front page (72) Inventor Wataru Fukui 2-3-2 Marunouchi, Chiyoda-ku, Tokyo Mitsubishi Electric Corporation (72) Inventor Yutaka Ohashi 2-3-2 Marunouchi, Chiyoda-ku, Tokyo Mitsubishi Electric Corporation (72) Inventor Hiroshi Sakanoue 2-3-2 Marunouchi, Chiyoda-ku, Tokyo Inside Mitsubishi Electric Corporation (56) References JP-A-5-302932 (JP, A) (58) Fields investigated (Int. ⁷ , DB name) G01D 5/00-5/62 G01P 1/00-3/80 G01B 7/00-7/32

Claims (4)

(57) [Claims] 1. A plurality of wirings, a plurality of electrodes connected to these wirings to which an electronic component is joined, and a resin injected during insert resin molding connected between the wirings except for a region between the adjacent electrodes. An insert conductor having a connecting portion for preventing the entire shape from being deformed by pressure. 2. An insert conductor having a plurality of wirings, a plurality of electrodes connected to these wirings to which an electronic component is joined, and a connecting portion connected between the wirings, and an insert resin molded and adjacent to the insert conductor. A resin part having an inter-electrode resin part in which the electrodes are electrically insulated by the resin interposed between the electrodes. 3. The insert resin molded article according to claim 2, wherein the resin is polyphenylene sulfide. 4. An insert conductor having a plurality of wirings, a plurality of electrodes connected to these wirings to which an electronic component is joined, and a connecting portion connected between the wirings, and an insert resin molded and adjacent to the insert conductors A resin part having an inter-electrode resin part in which the electrodes are electrically insulated by a resin interposed between the electrodes, the method comprising the steps of: A step of cutting a connecting portion connected between the electrodes; and a step of insert-molding a resin between the electrodes after cutting the connecting portion to form the inter-electrode resin portion. A method for manufacturing an insert resin molded article.