JP5842610B2 - Sensor control apparatus and manufacturing method thereof - Google Patents

Description

  The present invention relates to a sensor control device used for a sensor in which a detection unit such as a temperature sensor or a gas sensor is placed in a high temperature environment, and a manufacturing method thereof.

In recent years, various sensors for detecting changes in driving conditions have been provided for controlling internal combustion engines such as automobile engines in order to further improve fuel consumption and purify combustion exhaust.
For example, Patent Document 1 discloses a gas concentration detection device that detects the concentration of a specific gas component in a gas to be measured. As shown in FIG. 11 of Patent Document 1, such a sensor is accommodated in a case. The sensor control electric circuit board is connected via a signal line, and the electric circuit board is formed with a connector including a terminal for connection to the outside.

In addition, the temperature sensor that measures engine coolant temperature, intake air temperature, combustion exhaust gas temperature, etc., and the exhaust gas such as oxygen sensor, air-fuel ratio sensor, NO x sensor, ammonia sensor, PM sensor, etc. as the gas to be measured A detection unit such as a gas sensor that detects the concentration of a specific component contained in the engine is provided in an environment exposed to a relatively high temperature, such as in an engine room or an exhaust passage, and the sensor control device stabilizes the detection result. Therefore, it is desirable to place it in a relatively stable temperature environment that is not exposed to high temperatures, and it is provided separately from the detection unit and connected to the detection unit via a heat-resistant electric wire.
High heat resistance is required for the electric wires connected to the detection part of the sensor placed in a high temperature environment.For example, a core wire made of a twisted wire made of a highly conductive copper wire and a highly heat resistant stainless steel wire is used. Dissimilar metal materials, such as those covered with a heat-resistant insulating coating, or those in which a highly conductive copper wire is nickel-plated to improve heat resistance and the core wire is covered with a heat-resistant insulating coating A heat-resistant electric wire using a core wire made of is used.

However, when connecting a heat-resistant electric wire using a core wire made of such a dissimilar metal material and the circuit board of the sensor control device, an input terminal portion patterned on the circuit board has a core wire made of a dissimilar metal material. It is difficult to directly bond the terminal portion by soldering or the like because it includes a core wire with poor solder wettability.
For this reason, the connection between the heat-resistant electric wire using the core wire including the dissimilar metal drawn from the sensor used in such a high-temperature environment and the sensor control device is previously connected to the end portion of the core wire including the dissimilar metal material. After crimping a crimp terminal made of a product, the terminal portion of the crimp terminal is inserted into the input terminal portion of the circuit board and joined by soldering or the like.
Stainless steel is made by adding nickel, chromium, etc. to iron, and all the alloys can be said to be made of dissimilar metal materials, but it consists of only a single alloy such as stainless steel and is uniform throughout the core wire. A core wire that exhibits good solder wettability and does not have difficulty in soldering does not correspond to the core wire made of a dissimilar metal material.

  For example, Patent Document 2 accepts a circuit board defined by receiving a sensor signal and generating a sensor characteristic in accordance with the received sensor signal, a main body, and an inner surface of the main body. Including a cavity adapted to the circuit board, the circuit board being placed in the cavity, an input line configured to receive a sensor signal from the sensor, and a unitary structure The first end of the unitary structure is directly coupled to the end of the input line, and the second end of the unitary structure is received in the cavity and directly coupled to the circuit board, so that the first electrical connection with the circuit board A sensor adapter circuit housing assembly is disclosed that comprises a connector for mechanical connection.

  Further, in this type of sensor control device, there is a risk that moisture may enter through a gap formed at the interface between the signal line and the container. In Patent Document 2, a crimp terminal (the first end and the second end of the connector) In the meantime, a curved portion is provided to lengthen the movement path of moisture, thereby suppressing the movement of moisture and trying to suppress failure due to moisture.

However, as disclosed in Patent Document 2, in order to accommodate the input line and the circuit board via the input connector and accommodate the output connector to the circuit board in the accommodating body, FIG. As shown in the flowchart shown in FIG. 8, the terminal end of the input connector is connected to the terminal end of the input line in advance, the terminal end of the input line connected to the input connector is accommodated in the mold together with the output connector, and the circuit board is mounted. After forming the housing body by so-called insert molding that forms the housing body having the cavity to be disposed, the circuit board is housed in the cavity, and the resin is filled and sealed.
For this reason, it is necessary to hold the output connector so that it is possible to connect the input connector in a state where it is coupled to the input line to the mold for forming the container and the circuit board after molding the container, Since it is necessary to prevent damage to the input lines and connectors when opening and closing the molds divided into multiple parts, the structure of the molds may be complicated and automation may be difficult. .

On the other hand, in sensor control devices installed in environments exposed to external vibrations and shocks such as automobile engines, it is necessary to prevent instantaneous interruption of signals even when subjected to vibrations and shocks. Since the fitting clearance with the mating connector is small, the output connector is required to have extremely high dimensional accuracy.
However, as described in Patent Document 2, when the output connector is held in the housing at the same time as the housing is formed by insert molding, the output connector is deformed by the resin filling pressure when forming the housing. May occur.

Furthermore, as disclosed in Patent Document 2, when the signal line is directly accommodated in the container by insert molding, the resin constituting the container shrinks after the insert molding, and there is a gap at the interface with the signal line. Formed and will allow moisture ingress.
In such a situation, when a curved portion is provided in the connector, it is considered that the moving speed can be suppressed as long as the invading moisture moves on the surface of the connector.
However, it is difficult to drain the moisture once it has entered the container, and evaporation and condensation are repeated in the container due to changes in the temperature of the environment, and moisture moves to an arbitrary position, forming a control circuit. Corrosion such as rust may occur on metal parts such as parts and connection terminals, and the reliability of the control device may be significantly reduced.

  Further, as described in Patent Document 1 and Patent Document 2, when the sensor control device and the connector are integrated, the magnitude, frequency, input / output voltage, and current of the electric signal input / output via the connector are integrated. It is difficult to standardize because it is necessary to change the shape, position, size, etc. of the connector according to the size, etc., or according to the mating connector, increasing the design cost and manufacturing cost. It is also a cause.

  Therefore, in view of such circumstances, the present invention uses a dissimilar metal material that is difficult to directly connect with a terminal pattern formed on a circuit board as an input line that connects a sensor detection unit and a control unit in a sensor control device. Even if a heat-resistant conductor is used, a crimp terminal is not required for connection between the circuit board and the input signal line, and there is no output structure with a direct connector on the circuit board. As with the connection of the input signal line, the output structure is designed to be connected to the outside via the output signal line without using crimp terminal fittings, and standardization and automation are easy. It is an object of the present invention to provide a highly reliable sensor control device and its manufacturing method.

In the first aspect of the invention, the sensor having a detection unit whose electrical characteristics change according to the physical quantity of the detection target in a high temperature environment is connected via an input line having a heat-resistant conductor containing a different metal as a core. A sensor control device in which a control circuit for controlling the sensor and outputting the detection result to the outside is enclosed in a housing, wherein the housing has a substantially cylindrical peripheral wall having at least both ends open. And a lid portion that seals both or both ends of the peripheral wall portion of the casing, and a flat terminal base that bridges part of the opposing side surfaces of the peripheral wall portion of the casing The input pedestal portion is press-fitted and fixed, one end is exposed in a direction parallel to the plate surface of the terminal pedestal portion , and the input wire is fixed by welding, and the other end is the terminal the control was exposed in a direction perpendicular to the plate surface of the base portion Comprising an input terminal and an input-side insertion end portion connected to the road.

  According to a second aspect of the present invention, the terminal base portion includes a terminal fixing groove that opens toward one of the opening directions of the housing.

According to a third aspect of the present invention, an output in which an output wire is press-fitted and fixed to the terminal pedestal portion, one end is exposed in a direction parallel to the plate surface of the terminal pedestal portion , and an external connection line is fixed by welding. An output terminal having a wire weld portion and an output side insertion end portion, the other end of which is exposed in a direction perpendicular to the plate surface of the terminal pedestal portion and connected to the control circuit;

  According to a fourth aspect of the present invention, at least the housing includes an input line holding part that holds the input line, and a sealing member made of an elastic member is interposed between the input line holding part and the input line. Disguise.

  According to a fifth aspect of the present invention, there is provided a method for manufacturing the sensor control device according to any one of the first to fourth aspects, wherein at least the casing peripheral wall portion and the terminal pedestal portion are integrally formed using a thermoplastic resin. The terminal pedestal portion is formed by utilizing the housing molding step to be formed, the terminal press-fitting step for press-fitting the input terminal into the terminal fixing groove formed in the terminal pedestal portion, and the openings on the upper and lower surfaces of the housing. A terminal welding step of welding the input terminal exposed from the terminal and the terminal portion of the input line.

  In the invention of claim 6, the welding means used in the terminal welding process for welding the input terminal and the terminal portion of the input line is any one of laser welding, ultrasonic welding, and resistance welding.

According to the present invention, there is provided a heat-resistant conductor containing a dissimilar metal material that is difficult to directly connect to a terminal pattern formed on a circuit board as an input line that connects a detection unit and a control unit of a sensor in a sensor control device. Even if it is used, since both ends of the housing are open, the terminal portion of the input line is connected to the input wire welded portion exposed in a direction parallel to the plate surface of the terminal pedestal from the opening. Can be easily welded.
Furthermore, the terminal portion of the output line can be easily welded to the output terminal welding portion exposed in the direction parallel to the plate surface of the terminal pedestal portion.
Therefore, a crimp terminal is not required for the connection between the circuit board and the input signal line, and the output structure in which the connector is directly provided on the circuit board is not used, and the connection between the circuit board and the output signal line is connected to the input signal line. No crimping terminal fittings are required as well as connection, so the output structure that connects to the outside via the output signal line is easy to standardize and automate, and also suppresses intrusion of moisture and is reliable. High sensor control device can be realized.

BRIEF DESCRIPTION OF THE DRAWINGS The outline | summary of the sensor control apparatus in the 1st Embodiment of this invention is shown, (a) is a transparent top view, B direction arrow view, and a top view of a sensor, (b) is this figure (a). Sectional drawing along AA, (c) is a perspective bottom view. The outline | summary of the housing | casing and terminal base part which are the principal parts of the sensor control apparatus shown in FIG. 1 is shown, (a) is a top view, (b) is sectional drawing, (c) is a bottom view, (d). FIG. 3 is a perspective view showing a terminal pedestal and terminal fittings. Sectional drawing which shows the order of the process of (a)-(c) about the principal part of the manufacturing method of the sensor control apparatus shown in FIG. The outline | summary of the housing | casing and terminal base part which are the principal parts of the sensor control apparatus in the 2nd Embodiment of this invention is shown, (a) is a top view, (b) is sectional drawing, (c) is a bottom view. (D) is a perspective view which shows a terminal base part. Sectional drawing which shows the order of the process of (a)-(c) about the principal part of the manufacturing method of the sensor control apparatus in the Example shown in FIG. The expansion | deployment perspective view which shows the outline | summary of the sensor control measure in the 3rd Embodiment of this invention. The outline | summary of the sensor control apparatus in the 4th Embodiment of this invention is shown, (a) is a perspective top view, (b) is a perspective bottom view. The principal part sectional drawing which shows the outline | summary of the resistance welding which can be applied to this invention.

With reference to FIG. 1, the sensor control apparatus 1 in the 1st Embodiment of this invention is demonstrated. The sensor control device 1 according to the present invention includes an input line 21 having a heat-resistant conductor containing a dissimilar metal as a core wire 210 in a sensor 2 having a detection unit whose electrical characteristics change according to a physical quantity of a detection target in a high-temperature environment. And a control circuit 12 that controls the sensor 2 and outputs the detection result to the outside.
The casing 10 which is a main part of the present invention seals at least the substantially cylindrical casing peripheral wall portion 100 whose both ends are open, both ends of the casing peripheral wall portion 100, or only one of the surfaces. It consists of the lower surface side cover part 104 or the upper surface side cover part 105, and the flat-plate-shaped terminal base part 11 which bridge | crosslinks a part of side surface which the housing surrounding wall part 100 opposes. Here, the axial direction of the cylinder serving as the casing peripheral wall portion 100 is referred to as the vertical direction, and for convenience, the lower lid portion 104 is a lower lid portion and the upper lid portion is a lower lid portion 104 in FIG. Is the upper surface side lid portion 105.
Furthermore, the sensor control device 1 of the present invention is press-fitted and fixed to the terminal pedestal 11 placed horizontally, and one end is exposed from the terminal pedestal 11 in the horizontal direction , that is, in the direction parallel to the plate surface. An input line welding portion 411 to which the wire 21 is fixed by welding, and an input side insertion end portion 412 having the other end exposed in a direction perpendicular to the plate surface of the terminal base portion 11 and connected to the control circuit 12 are provided. An input terminal 41 is provided. Hereinafter, a direction parallel to the plate surface of the terminal pedestal 11 is referred to as a horizontal direction for convenience.

The sensor control device 1 of the present invention includes, for example, a temperature sensor, a gas sensor (oxygen sensor, NOx sensor, hydrogen sensor, CH sensor), particulate matter (PM) sensor, pressure sensor, speed sensor, acceleration sensor, position sensor, crank It can be suitably employed for control of a sensor that detects a physical quantity to be measured by detecting a change in electrical characteristics such as current, voltage, resistance value, capacitance, inductance, impedance, etc. of an angular sensor.
The sensor control device 1 does not limit the type of physical quantity to be detected by the sensor. The detection unit 20 of the sensor 2 is disposed in a high temperature environment, and at least an input connecting the sensor 2 and the sensor control device 1. As long as the wire 21 is required to have high heat resistance, a heat-resistant electric wire is used, and direct connection with a circuit board is difficult, it is suitable for any sensor.
In order to facilitate understanding of the features of the present invention, in the following description, a temperature sensor will be described as an example of the sensor 2.

In the sensor 2, a detection unit 20 is provided at the distal end of a substantially cylindrical housing 22, and a temperature sensitive element such as a thermistor is built in the detection unit 20, and a pair of signal lines are on the proximal end side of the housing 22. Is connected to the sensor control device 1 as an input line 21 that transmits an input from the sensor 2 to the sensor control device 1.
The input line 21, for example, a twisted Ri wire and the core wire of the high conductivity copper and high heat resistance stainless steel wires, for example, fluorine rubber or silicone rubber, polyimide, glass fibers, heat-resistant insulation etc. For core wires made of dissimilar metal materials, such as those covered with a coating, or a core wire made of a highly conductive copper wire with nickel plating or the like for improving heat resistance covered with a heat resistant insulation coating The heat-resistant electric wire used is used.

In the sensor control device 1, a control circuit 12 for controlling the sensor 2 is accommodated in a housing 10.
A space around the control circuit 12 is filled with a sealing member 15 made of a thermosetting resin such as an epoxy resin, for example.

The control circuit 12 has a predetermined circuit pattern formed by, for example, a circuit board 120 such as a printed board, an alumina board, or a lead frame, and an active element 13 such as an IC or a CPU and a passive element such as a resistor, a capacitor, or a coil. 14 is arranged so that the electrical characteristics of the detection unit 20 are detected and output to the outside.
Furthermore, the control circuit 120 is formed with an input terminal insertion hole 121 and an output terminal insertion hole 122 in which a predetermined electrode pattern is formed, and the input side insertion end 412 of the input terminal 41 and the output side of the output terminal 51, respectively. An insertion end 512 is connected.

  For example, in the case of a temperature sensor, the control circuit 12 detects a change in resistance value due to a temperature change of a temperature sensing element such as a thermistor provided in the detection unit 20, and A / D converts the result to output the output line 31. Output to the outside.

In the present invention, the input line 21 does not necessarily indicate only an electric wire that transmits an input from the sensor 2 side to the sensor control device 1. For example, when a gas sensor is used as the sensor 2, When electric power is supplied from the control device 1 to the sensor 2 to the heating element built in the detection unit 20, or electrical characteristics such as resistance value, capacitance, dielectric constant, etc. of the detection element in the detection unit 20 of the sensor 2 are measured. Therefore, including the case of supplying a direct current or an alternating current, the sensor 2, that is, as a general term for an electric wire connecting the input side and the sensor control device 1, is referred to as an input line 21 for convenience. It is what.
Furthermore, in the present invention, the output line 31 does not indicate that only the transmission of the output result calculated by the control circuit 12 is shown, but the supply of the power supply voltage to the control circuit 12 and the electronic control device provided outside. For the sake of convenience, it is expressed as an output line 31 as a general term of electric wires for connecting the outside, that is, the output side and the sensor control device 1 such as a drive command signal from

The control circuit 12 is connected to the input line 21 via the input terminal 41, the input line 21 is connected to the sensor 2, and is connected to the output line 31 via the output terminal 51, and the output line 31 is connected to the other side. It is connected to the connector 3 that enables
In the present invention, the connector 3 has a connector terminal 312 that is connected to the terminal portion 311 of the output line 31 and is electrically connected to the mating side inside the connector housing 30 that fits the mating side. Is formed with connector locking means 32 for holding the connection with the other side.
In the present invention, the specific shape of the connector 3 is not particularly limited, and a known connector can be appropriately employed.

The input terminal 41 and the output terminal 51 are respectively press-fitted into a substantially L-shaped terminal fixing groove 111 formed in the terminal pedestal portion 11, and are elastically pressed and held by the terminal locking means 112 and 113. One end is exposed in the horizontal direction of the terminal pedestal 11 and constitutes an input line welded portion 411 and an output line welded portion 511, and the other end is exposed in the vertical direction of the terminal pedestal 11 and the input side An insertion end 412 and an output side insertion end 512 are configured.
The input terminal 41 and the output terminal 51 are made of, for example, a single conductive material that can be connected to an electrode pattern provided in the control circuit 12 by soldering, such as copper, aluminum, nickel, nickel alloy, and stainless steel. The metal flat plate is bent into a substantially L shape.
Furthermore, one end portion of the input terminal 41 is formed in a substantially flat plate shape as an input wire welded portion 411 to which the input wire 21 is welded, and is exposed in the horizontal direction from the terminal fixing groove 111 of the terminal base portion 11. The terminal portion 210 of the core wire of the input wire 21 is fixed to the surface by welding by a method described later.
The other end portion of the input terminal 41 is formed in a flat plate shape or a pin shape as the input side insertion end portion 412, is exposed in the vertical direction from the terminal fixing groove 111 of the terminal base portion 11, and is provided in the control circuit 12. It is inserted into an input terminal insertion hole 121 having a predetermined electrode, and is further soldered to conduct with the control circuit 12.

On the other hand, similarly to the input terminal 41, the output terminal 51 is also formed in a substantially flat plate shape as an output line welding portion 511 to which the output line 31 is welded, and from the terminal fixing groove 111 of the terminal base portion 11. It is exposed in the horizontal direction, and the terminal portion 310 of the core wire of the output line 31 is fixed to the surface by welding by a method described later.
The other end portion of the output terminal 51 is formed in a flat plate shape or a pin shape as the output side insertion end portion 512, and is exposed in the vertical direction from the terminal fixing groove 111 of the rotating terminal base portion 11. It is inserted into an output terminal insertion hole 122 having a predetermined electrode provided, and further soldered to ensure conduction with the control circuit 12.

The casing 10, which is a main part of the present invention, has a structure in which both ends of a substantially rectangular cylindrical casing peripheral wall portion 100 having both ends opened can be sealed by the upper surface side lid portion 105 and the lower surface side lid portion 104. Thus, it is possible to assemble the components from the vertical direction.
Here, as described above, the axial direction of the casing peripheral wall portion 100 in FIG. Since the upper surface side opening and the lower surface side opening of the housing 10 are closed by filling the sealing member 15, the upper surface side lid portion 105 or the lower surface side lid is filled when the sealing member 15 is filled. If the upper surface side opening or the lower surface side opening is closed by either one of the parts 104, the other can be omitted.

Further, in the present embodiment, an input line holding part 101 and an output line holding part 102 having a substantially U-shaped cross section opening toward the bottom surface are formed on the two opposite side surfaces of the casing peripheral wall part 100. Yes.
Sealing members 106 and 107 made of an elastic member are interposed between the input line holding unit 101 and the input line 21 and between the output line holding unit 102 and the output line 31, respectively.

  Furthermore, the sealing members 106 and 107 are made of a heat-resistant elastic member such as fluorine rubber or silicone rubber. When the lower surface side lid 104 is fixed to the housing peripheral wall 100, the sealing member 106 is compressed, The input line 21 and the output line 31 are kept airtight and watertight to prevent moisture from entering from the outside.

  here. With reference to FIG. 2, the housing 10 that is the main part of the present invention will be described in detail, and with reference to FIG. 3, a method for manufacturing the sensor control device 1 according to the present invention will be outlined.

In the housing molding step, for example, a housing 10 is formed by injecting a thermoplastic resin such as PPS, PBT, or PAI into a mold.
The housing 10 is made of a thermoplastic resin, and a terminal base portion 11 is integrally formed so as to bridge part of two side surfaces facing each other in the longitudinal direction of the housing peripheral wall portion 100.

The terminal pedestal 11 has terminal fixing grooves 111 for fixing the input terminal 41 and the output terminal 51 in the pedestal main body 110 formed in a substantially flat plate shape, depending on the number of input terminals 41 and output terminals 51 to be fixed. Is provided.
In this embodiment, since the terminal fixing groove 111 press-fits and fixes the substantially L-shaped input terminal 41 and output terminal 51 inserted from the lower surface side of the terminal pedestal 11, the fixing groove 111 is substantially L-shaped, The terminal base 11 is formed so as to extend in the vertical direction so as to penetrate from the lower surface side to the upper surface side, and the other is formed so as to extend in the horizontal direction toward the lower surface side of the terminal base 11.

In the terminal press-fitting process, the terminals 41 and 51 are press-fitted into the fixing groove 111 from either of the openings on the upper and lower surfaces.
When the input terminal 41 and the output terminal 51 are press-fitted into the fixed groove 111, the fixed groove 111 protrudes inward and extends in the vertical direction as terminal locking means 112 and 113 for preventing dropout. Protrusions are formed and elastically press both side surfaces and the back surface of the input terminal 41 and the output terminal 51.

  2A is a top view of the housing 10, a B direction arrow view of the input terminal holding unit 101, and a C direction arrow view of the output terminal holding unit 102, and FIG. Sectional drawing along A, (c) is a bottom view, (d) is a perspective view of the terminal base part 11, the input terminal 41, and the output terminal 51. FIG.

  The casing 10 which is a main part of the present invention can be formed by injection molding using, for example, a thermoplastic resin such as PPS, PBT, PAI, etc. FIGS. 2 (a), 2 (b), 2 (c). As shown in FIG. 4, the opening direction of the upper and lower surfaces of the housing 10, the opening portion of the input line holding portion 101, the opening portion of the output line holding portion 102, and the terminal fixing groove 111 of the terminal base portion 11 are either in the vertical direction. Since there is no need to provide a horizontally movable core including a conventional connector or to hold the inserted part, it is simply divided into two parts. It can be easily formed by using a metal mold and is excellent in mass productivity.

In the present embodiment, as shown in FIG. 2 (d), the input terminal 41 and the output terminal 51 are viewed from the bottom surface direction of the terminal pedestal portion 11 formed integrally with the casing 10 formed by injection molding. Press fit.
Since the housing 10 is greatly opened in the vertical direction, there are few obstacles when the input terminal 41 and the output terminal 51 are press-fitted, and automation is easy.

As shown in FIG. 3A, sealing members 106 and 107 are attached to the input line 21 and the output line 31, respectively.
The sealing members 106 and 105 are made of an elastic member such as fluorine rubber or silicone rubber, and are in close contact with the input line 21 and the output line 31, respectively.
An input line terminal is connected to each of the input line welded portion 411 and the output line welded portion 511 that extend in the horizontal direction of the input terminal 41 and output terminal 51 fixed to the terminal pedestal portion 11 and are exposed to the outside of the terminal pedestal portion 111. The unit 210 and the output line terminal unit 310 are provided.

In the terminal welding process, as shown in FIG. 3B, the input line welded portion 411 exposed in the horizontal direction of the terminal pedestal portion 11 and the output line welded portion using the openings on the upper and lower surfaces of the housing 10. The input line terminal unit 210 and the output line terminal unit 310 are welded to 511, respectively.
In this embodiment, a laser welder LW is used as a welding means.
Since the upper and lower surfaces of the casing 10 which is the main part of the present invention are greatly opened, the welding operation is easy.

In addition, when welding an electric wire to a wiring pattern on a conventional circuit board, there is a limit to the wire and laser output that can be connected by laser welding due to the need to prevent damage to the board, including dissimilar metal materials It was difficult to directly weld the heat-resistant conductor, for example, the input wire 21 having the heat resistance of about 250 ° C. and the output wire 31 to the electrode pattern on the circuit board.
However, in the present embodiment, the input line terminal portion 210 and the input line welded portion 411, and the output line terminal portion 310 and the output line welded portion 511 are welded at positions exposed from the terminal pedestal portion 11, so that the input line 21, and, as the core of the output line 31, even if the wire was twisted heat conductor subjected to high heat resistant nickel-plated high conductivity copper wire is used, the portion to be a weld _PWLD Since there is no substrate that is damaged in the surroundings, welding can be performed using a relatively high output laser beam that can weld the input wire 21 and the output wire 31 using a heat-resistant conductor having a high melting temperature as a core wire. it can.

Furthermore, since the welded portion P _WLD is provided outside the terminal pedestal portion 11 and the upper and lower surfaces of the housing 10 are open, it is easy to support with a jig or the like.
In the present invention, the welding means is not limited, and in this embodiment, an ultrasonic welding machine USW and a resistance welding machine RW described later can also be used as the welding means.

As shown in FIG. 3B, the sealing members 106 and 107 are moved to the input line holding unit 101 and the output line holding unit 102, respectively. Further, as shown in FIG. The lower surface side lid portion 104 closes the opening portion 101, the opening portion of the output line holding portion 102, and the lower surface side opening portion of the casing peripheral wall air portion 100.
At this time, the sealing members 106 and 107 are compressed and elastically deformed to increase the adhesion strength between the input line 21 and the input line holding portion 101 and the adhesion strength between the output line 31 and the output line holding portion 102. , Can prevent the intrusion of moisture from the outside.
Further, in order to maintain confidentiality between the casing peripheral wall portion 100 and the lower surface side lid portion 104, the respective interfaces are bonded or welded over the entire circumference.

As shown in FIG. 3 (c), the insertion end 412 of the input terminal 41 in which the control circuit 12 in which the predetermined active element 13 and the passive element 14 are arranged is fixed to the terminal base 11, and the output terminal The insertion end portions 51 of 51 are respectively inserted into insertion holes provided with predetermined electrode patterns provided in the control circuit 12 and fixed by soldering (SOL).
The circuit board 12 is fixed to the board holding portions 103 provided at the four corners inside the housing 10.
At this time, since the upper surface of the housing 10 is greatly opened, the control circuit 12 can be easily accommodated in the housing 10 and the soldering work of the input terminal 41 and the output terminal 51 is also easy. It can be carried out.

  Further, a filling material 15 made of a heat-effective resin such as an epoxy resin, a fluororesin, or a silicone resin is injected into the space inside the housing peripheral wall portion 100, and the control circuit 12, the terminal base portion 11, the input terminal, for example. 41, the output terminal 51, and the control circuit 12 are integrally covered. After the filling material 15 is injected, the opening of the housing 10 is closed by the upper surface side cover portion 105, and an adhesive is applied or welded over the entire circumference, so that the sensor control device 1 of the present invention can be used. Complete.

  In the present embodiment, since the input terminal 21 and the output terminal 41 are inserted and fixed from the lower surface side of the terminal pedestal 11, when the input line 21 and the output line 41 are welded, As shown in FIGS. 2B and 2C, an example is shown in which the welding operation is performed by turning the top and bottom of the housing 10 so that the terminals 41 and 51 are not dropped from the terminal base 11 during welding. However, the input terminal 41 and the output terminal 51 may be welded without turning over the top and bottom of the housing 10 in a state where the input terminal 41 and the output terminal 51 are fixed by some jig so that the terminal base 11 does not fall off.

With reference to FIG. 4, the housing | casing 10a in the 2nd Embodiment of this invention is demonstrated, and the principal part of the manufacturing method of the sensor control apparatus 1a in this embodiment is demonstrated with reference to FIG.
In addition, about the structure similar to the said embodiment, since the same code | symbol was attached | subjected, description is abbreviate | omitted and it demonstrates centering on difference with the said embodiment.
In the above-described embodiment, the example in which the terminal fixing groove 111 is drilled so as to insert the input terminal 41 and the output terminal 51 from the lower surface side of the terminal pedestal portion 11 has been shown, but in this embodiment, The difference is that the terminal fixing groove 111a is formed so as to insert the input terminal 41 and the output terminal 51 from the upper surface side of the terminal base portion 11a.

  The terminal fixing groove 111a is formed in a substantially L-shape and protrudes inward to form terminal locking means 112a and 113a for elastically pressing and fixing the input terminal 41 and the output terminal 51. .

As shown to Fig.5 (a), after fixing the input terminal 41 and the output terminal 51 to the terminal base 11a, the input line 21 and the output line 31 are inserted, the input line terminal part 210, and the output line terminal The parts 310 are arranged in the input line welding part 411 and the output line welding part 511, respectively.
As shown in this figure (b), in this embodiment, the ultrasonic welding machine USW is used as a welding means.
The ultrasonic welder USW converts the electrical signal into ultrasonic vibration by the transducer TRS, transmits the ultrasonic signal to the welding tip CHP via the ultrasonic horn HRN, and pressurizes the welding tip CHP by the pressurizing unit LRD. Atomic diffusion is induced between the input line welded portion 411 and the input line end portion 210 by causing the input line welded portion 411 and the input line end portion 210 supported by the anvil ANV to vibrate in parallel while applying moderate pressure. In other words, bonding at a metal atom level is caused, and dissimilar metals can be joined.

In order to directly connect the heat-resistant conductors to the wiring pattern formed on the circuit board, heat-resistant conductors are placed on the electrode patterns on the board, and the heat-resistant conductor and the electrode patterns are pressed using an ultrasonic welding machine. However, even if ultrasonic vibration is applied, vibration energy is absorbed by the substrate, so it was difficult to directly connect the circuit board, the input line, and the output line by ultrasonic welding. According to the present invention, the input wires 21 and the output wires 31 have core wires made of a heat-resistant conductor made of a stranded wire made of a copper wire having a high electrical conductivity and a stainless steel wire having a high heat resistance. The wire welding portion 411 and the output wire welding portion 511 are exposed from the terminal pedestal portion 11a, and vibration energy is not absorbed by the substrate, and the input wire 21 and the input terminal are used by the vibration ultrasonic welding machine USW. 41 and Welding of the force line 31 and the output terminal 51 becomes possible.
When the welding of the input line 21 and the input terminal 41 and the output line 31 and the output terminal 51 is completed, the lower surface side cover 104 is bonded or joined as in the above embodiment, and the control circuit 12 and the input terminal 41 are joined. And after connecting the output terminal 51 and filling the sealing member 15, the upper surface side cover part 105 is adhere | attached or joined, and the sensor control apparatus 1a in this embodiment is completed.

With reference to FIG. 6, the outline | summary of the sensor control apparatus 1c in the 3rd Embodiment of this invention is demonstrated.
In the above embodiment, an example in which the input line holding unit 101 and the output line holding unit 102 are formed so as to open in the lower surface direction has been described. However, in this embodiment, when the housing 10c is formed, the input line holding unit 101 and the output line holding unit 102 are input. The line holding portion 101c and the output line holding portion 102c are formed so as to open in the upper surface direction, and the casing peripheral wall portion 100c, the input line holding portion 101c, and the output line holding portion 102c are integrated by the upper surface side lid portion 105c. However, in other respects, configurations similar to those of the first embodiment and the second embodiment can be applied.

  Also in this embodiment, as in the above embodiment, the connection between the input line 21 and the input terminal 41 and the connection between the output line 31 and the connection terminal 51 can be performed by laser welding or ultrasonic welding. It is possible to easily automate, and the interface between the housing outer wall 100c and the lower surface side lid portion 104c and the interface between the housing outer peripheral wall 100c and the upper surface side lid portion 105c are hermetically and watertightly sealed. Further, the sealing members 106 and 107 ensure airtightness and watertightness between the input line 21 and the housing 10c and between the output line 31 and the housing 10c, and prevent moisture from entering from the outside. It is sure to stop.

With reference to FIG. 7, the sensor control apparatus 1d in the 4th Embodiment of this invention is demonstrated.
In the above-described embodiment, the configuration in which the sensor control devices 1, 1a, 1b, and 1c each control only one sensor 2 has been described. However, in the present embodiment, a plurality of sensors 2 are controlled, or two or more. This is different from the sensor control device 1d to which the input line 21 is connected.

In the present invention, as shown in the present embodiment, when a plurality of sensors 2 are controlled, a pair of signal lines connected to the detection unit as the input line 21 such as a gas sensor, and a heater for heating the detection unit are used. Even in the case where two or more input lines 21 such that four wires of a pair of power lines for supplying the power are used are connected, the same effect as in the above embodiment can be exhibited.
In the above-described embodiment, the input line holding units 101 and 101c and the output line holding unit 102 are used in order to make the molds forming the casings 10, 10a to 10d into a very simple two-divided type. , 102c is formed in a substantially U-shape that opens in either one of the upper and lower surfaces. However, it may be formed in a cylindrical shape like the input line holding portion 101d shown in FIG. .
However, in this case, the mold forming the housing 10d is not a simple mold divided only in the upper and lower surfaces of the housing 10, but uses a core that moves in the horizontal direction. There is no need to insert an input terminal coupled to the input line or an output connector, and the housing 10d can be manufactured alone, and the terminal base portions of the input terminal 41 and the output terminal 51 thereafter. 11 and the connection of the input line 21 and the output line 31 are easy to automate as in the above embodiment.

With reference to FIG. 8, another welding method that can be employed in any of the above-described embodiments will be described.
In the said embodiment, although the example which performs the connection of the input line 21 and the output line 31, and the input terminal 41 and the output terminal 51 by laser welding or ultrasonic welding was demonstrated, well-known resistance welding Can also be done.
In resistance welding, for example, when the input line 21 and the input terminal 41 are connected, the electrode EL ₁ , EL ₂ is pressed against the input terminal 31 and pressed while the input line terminal portion 210 is in close contact with the input terminal 31. The input line terminal unit 210 and the input terminal are caused by flowing a large current of tens to tens of thousands of amperes for a very short time of about several milliseconds to several hundred milliseconds, generating Joule heat due to metal resistance and melting. A weld portion P _WLD made of an alloy with 41 is formed.
The same applies to the welding of the output line 31 and the output terminal 51.
Also in this case, since the upper and lower surfaces of the housing 10 are greatly opened, the input terminal 41, the output terminal 51, the input line 21, and the output that are exposed from the terminal pedestal 11 as in the above embodiment. Automation is easy when the connection of the wire 31 is performed using the resistance welding machine RW.

DESCRIPTION OF SYMBOLS 1 Sensor control apparatus 10 Case 100 Case surrounding wall part 104 Lower surface side cover part 105 Upper surface side cover part 11 Terminal base part 12 Control circuit 2 Sensor 20 Detection part 21 Input line 210 Input line terminal part 41 Input terminal 411 Input line welding part 412 Input side insertion end P _WLD weld

JP 2002-71640 A US2008 / 0026610A1 Publication

Claims (6)

The sensor is connected to a sensor having a detector whose electrical characteristics change according to the physical quantity of the detection target in a high-temperature environment via an input line having a heat-resistant conductor containing a different metal as a core, and controls the sensor. A sensor control device in which a control circuit for outputting the detection result to the outside is enclosed in a housing,
The housing is at least
A substantially cylindrical casing peripheral wall opening at both ends ;
A lid portion that seals both of the both ends of the peripheral wall portion of the housing, or only one of them;
It consists of a flat terminal pedestal that bridges part of the opposing side surfaces of the casing peripheral wall,
It is press-fitted and fixed to the terminal pedestal,
One end is exposed in a direction parallel to the plate surface of the terminal pedestal, and the input line is welded to the input line welded portion;
A sensor control device comprising: an input terminal having an input side insertion end connected to the control circuit, the other end exposed in a direction perpendicular to the plate surface of the terminal pedestal.   The sensor control device according to claim 1, wherein the terminal pedestal portion includes a terminal fixing groove that opens toward one of opening directions of the housing. It is press-fitted and fixed to the terminal pedestal,
One end is exposed in a direction parallel to the plate surface of the terminal pedestal, and an output line welded portion in which an output line for connection to the outside is fixed by welding,
3. The sensor control device according to claim 1, further comprising an output terminal having an output side insertion end connected to the control circuit, the other end being exposed in a direction perpendicular to the plate surface of the terminal base. . at least,
The housing includes an input line holding unit for holding the input line;
4. The sensor control device according to claim 1, wherein a sealing member made of an elastic member is interposed between the input line holding portion and the input line. A method of manufacturing a sensor control device according to any one of claims 1 to 4,
at least,
A housing molding step for integrally forming the housing peripheral wall portion and the terminal pedestal portion using a thermoplastic resin;
A terminal press-fitting step of press-fitting the input terminal into a terminal fixing groove formed in the terminal base portion;
A terminal welding step of welding the input terminal exposed from the terminal pedestal portion and the terminal portion of the input line using the openings on the upper and lower surfaces of the housing;
A method for manufacturing a sensor control device.   6. The sensor control device according to claim 5, wherein the welding means used in the terminal welding process for welding the input terminal and the terminal portion of the input line is any one of laser welding, ultrasonic welding, and resistance welding. Method.

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