JP6101529B2 - 流量センサ及びその製造方法 - Google Patents
流量センサ及びその製造方法 Download PDFInfo
- Publication number
- JP6101529B2 JP6101529B2 JP2013061681A JP2013061681A JP6101529B2 JP 6101529 B2 JP6101529 B2 JP 6101529B2 JP 2013061681 A JP2013061681 A JP 2013061681A JP 2013061681 A JP2013061681 A JP 2013061681A JP 6101529 B2 JP6101529 B2 JP 6101529B2
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Images
Classifications
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
- B29C66/8126—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
- B29C66/81266—Optical properties, e.g. transparency, reflectivity
- B29C66/81267—Transparent to electromagnetic radiation, e.g. to visible light
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/30—Organic material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/16—Laser beams
- B29C65/1603—Laser beams characterised by the type of electromagnetic radiation
- B29C65/1612—Infrared [IR] radiation, e.g. by infrared lasers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/16—Laser beams
- B29C65/1629—Laser beams characterised by the way of heating the interface
- B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
- B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29L2031/00—Other particular articles
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Description
被計測流体を取り込む開口部を有する副通路と、前記副通路内に配置されて被計測流体の流量を計測する流量検出部と、回路室内に前記副通路と隔離され前記流量検出部を駆動する電子部品とを収納するハウジングと、前記ハウジングに接合されて前記回路室を外気より密閉状態に封止する樹脂製カバーとを備えた流量センサを、回路パッケージの先端に備えた前記流量検出部を前記副通路内へ突出させて内部に収納し、前記カバーとの間に前記副通路を構成する前記ハウジングに形成された突起部と、前記カバーの内面に形成された接合部とがレーザ溶着によって接合され、前記カバーの接合部の両端に突起が形成されており、前記副通路側の突起の高さを前記副通路側と反対側の突起の高さよりも大きくするように構成した。
図1は、電子燃料噴射方式の内燃機関制御システムに、本発明に係る流量センサを使用した実施例を示す、システム図である。エンジンシリンダ112とエンジンピストン114を備える内燃機関110の動作に基づき、吸入空気が被計測気体30としてエアクリーナ122から吸入され、主通路124である例えば吸気ボディ、スロットルボディ126、吸気マニホールド128を介してエンジンシリンダの燃焼室112に導かれる。前記燃焼室に導かれる吸入空気である被計測気体30の流量は本発明に係る熱式流量センサ300で計測され、計測された流量に基づいて燃料噴射弁152より燃料が供給され、吸入空気である被計測気体30と共に混合気の状態で燃焼室112に導かれる。なお、本実施例では、燃料噴射弁152は内燃機関の吸気ポートに設けられ、吸気ポートに噴射された燃料が吸入空気である被計測気体30と共に混合気を形成し、吸入弁116を介して燃焼室に導かれ、燃焼して機械エネルギーを発生する。
2.1 熱式流量センサ300の外観構造
図2、図3、および図4は、熱式流量センサ300の外観を示す図であり、図2(A)は熱式流量センサ300の左側面図、図2(B)は正面図、図3(A)は右側面図、図3(B)は背面図である。熱式流量センサ300はハウジング302と表カバー303と裏カバー304とを備えている。ハウジング302は、熱式流量センサ300を主通路124である吸気ボディに固定するためのフランジ312と、外部機器との電気的な接続を行うための外部端子を有する外部接続部305と、流量等を計測するための計測部310を備えている。計測部310の内部には、副通路を作るための副通路溝が設けられており、さらに計測部310の内部には、主通路124を流れる被計測気体30の流量を計測するための流量検出部や主通路124を流れる被計測気体30の温度を計測するための温度検出部452を備える回路パッケージ400が設けられている。
熱式流量センサ300の入口350が、フランジ312から主通路124の中心方向に向かって延びる計測部310の先端側に設けられているので、主通路124の内壁面近傍ではなく、内壁面から離れた中央部に近い部分を流れる気体を副通路に取り込むことができる。このため熱式流量センサ300は主通路124の内壁面から離れた部分の気体の流量や温度を測定することができ、熱などの影響による計測精度の低下を抑制できる。主通路124の内壁面近傍では、主通路124の温度の影響を受け易く、気体の本来の温度に対して被計測気体30の温度が異なる状態となり、主通路124内の主気体の平均的な状態と異なることになる。特に主通路124がエンジンの吸気ボディである場合は、エンジンからの熱の影響を受け、高温に維持されていることが多い。このため主通路124の内壁面近傍の気体は、主通路124内を流れる気体の本来の気温に対して高いことが多く、計測精度を低下させる要因となる。
熱式流量センサ300を構成する計測部310の上流側側面と下流側側面にそれぞれ上流側突起317と下流側突起318とが設けられている。上流側突起317と下流側突起318は根元に対して先端に行くに従い細くなる形状を成しており、主通路124内を流れる吸入空気である被計測気体30の流体抵抗を低減できる。熱絶縁部315と入口343との間に上流側突起317が設けられている。上流側突起317は断面積が大きく、フランジ312あるいは熱絶縁部315からの熱伝導が大きいが、入口343(図2(B))の手前で上流側突起317が途切れており、さらに上流側突起317の温度検出部452側から温度検出部452への距離が、後述するようにハウジング302の上流側外壁の窪みにより、長くなる形状を成している。このため温度検出部452の支え部分への熱絶縁部315からの熱伝導が抑制される。
3.1 副通路と流量検出部の構造と効果
熱式流量センサ300から表カバー303および裏カバー304を取り外したハウジング302の状態を図4および図5に示す。図4(A)はハウジング302の左側面図であり、図4(B)はハウジング302の正面図であり、図5(A)はハウジング302の右側面図であり、図5(B)はハウジング302の背面図である。ハウジング302はフランジ312から計測部310が主通路124の中心方向に延びる構造を成しており、その先端側に副通路を形成するための副通路溝306が設けられている。副通路の入口350を形成するための入口溝351と出口352を形成するための出口溝353が、ハウジング302の先端部に設けられているので、主通路124の内壁面から離れた部分の気体を、言い換えると主通路124の中央部分に近い部分を流れている気体を被計測気体30として入口350から取り込むことができる。主通路124の内壁面近傍を流れる気体は、主通路124の壁面温度の影響を受け、吸入空気などの主通路124を流れる気体の平均温度と異なる温度を有することが多い。また主通路124の内壁面近傍を流れる気体は、主通路124を流れる気体の平均流速より遅い流速を示すことが多い。実施例の熱式流量センサ300ではこのような影響を受け難いので、計測精度の低下を抑制できる。
図6は、回路パッケージ400の計測用流路面430が副通路溝306の内部に配置されている状態を示す部分拡大図であり、図4(B)のA−B断面図である。なお、この図は概念図であり、図4や図5に示す詳細形状に対して、図6では細部の省略および単純化を行っており、細部に関して少し変形している。図6の左部分が裏側の副通路溝306の終端部であり、右側部分が表側の副通路溝306の始端部分である。図6では明確に記載していないが、計測用流路面430を有する回路パッケージ400の左右両側には、貫通部が設けられていて、計測用流路面430を有する回路パッケージ400の左右両側で裏側の副通路溝306と表側の副通路溝306とが繋がっている。
図7は表カバー303の外観を示す図であり、図7(A)は左側面図、図7(B)は正面図、図7(C)は平面図である。図8は裏カバー304の外観を示す図であり、図8(A)は左側面図、図8(B)は正面図、図8(C)は平面図である。図2および図3において、表カバー303や裏カバー304はハウジング302の副通路溝306を塞ぐことにより、副通路を作るのに使用される。また突起部356を備え、流路に絞りを設けるために使用される。表カバー303や裏カバー304は金型に熱可塑性樹脂を注入する樹脂モールド工程により作られるので、高い成形精度で作ることができる。また、表カバー303と裏カバー304には、突起部380と突起部381が形成されており、ハウジング302との溶着の際に、図4(B)及び図5(B)に表記した回路パッケージ400の先端側の空洞部382の隙間を埋めると同時に回路パッケージ400の先端部を覆う構成となる。
本発明の熱式流量センサ300の主な特徴は、前記ハウジング302と表カバー303、裏カバー304とをレーザ溶着する方法及びその構造に関わる。以下、ハウジング302や表カバー303、裏カバー304には、耐熱性が高い結晶性樹脂であるポリブチレンテレフタレート(PBT)、ポリフェニレンサルファイド(PPS)、ナイロン6(PA6)、ナイロン66(PA66)、ナイロン6T(PA6T)が使われることが多い。
30…被計測気体
110…内燃機関
112…エンジンシリンダ
114…エンジンピストン
116…吸入弁
118…排気弁
122…エアクリーナ
124…主通路
126…スロットルボディ
128…吸気マニホールド
132…スロットルバルブ
144…角度センサ
146…回転角度センサ
148…酸素センサ
152…燃料噴射弁
154…点火プラグ
156…アイドルエアコントロールバルブ
200…制御装置
300…熱式流量センサ
302…ハウジング
303…表カバー
304…裏カバー
305…外部接続部
306…副通路溝
307…レーザ溶着用のハウジング突起部
308…カバーの副通路側の突起部
309…カバーの副通路と反対側の突起部
310…計測部
312…フランジ
315…熱絶縁部
317…上流側突起
318…下流側突起
320…端子接続部
322…保護部
324…突き出しピン
326…挿入孔
328…位置合わせ部
331…カバーの接合
341…下流部
342…上流部
343…入口
347…急傾斜部
350…入口
351…入口溝
352…出口
353…出口溝
356…突起部
361…外部端子内端
380…突起部
381…突起部
382…空洞部
386…表側流路
387…裏側流路
390…回路室部の溶着部
391…副通路部の溶着部
392…ハウジングの凹凸形成部
400…回路パッケージ
412…接続端子
430…計測用流路面
431…計測用流路面裏面
436…熱伝達面露出部
438…開口
452…温度検出部
500…レーザ光
602…流量検出部
Claims (13)
- 被計測流体を取り込む開口部を有する副通路と、前記副通路内に配置されて被計測流体の流量を計測する流量検出部と、前記副通路と隔離され前記流量検出部を駆動する電子部品を収納する回路室と、を有するハウジングと、前記ハウジングに接合されて前記回路室を外気より密閉状態に封止する樹脂製カバーとを備えた流量センサにおいて、
回路パッケージの先端に備えた前記流量検出部を前記副通路内へ突出させて前記副通路内に収納し、前記ハウジングに形成された突起部と前記樹脂製カバーに形成された接合部とがレーザ溶着によって接合されて前記副通路が構成され、
前記樹脂製カバーは、前記接合部の前記開口部を有する副通路側と該副通路と反対側の両端に突起が形成されており、前記開口部を有する副通路側の突起の高さが前記副通路と反対側の突起の高さよりも大きいことを特徴とする流量センサ。 - 請求項1に記載の流量センサにおいて、前記樹脂製カバーに形成された前記接合部の幅は、前記ハウジングに形成された突起の上面の幅よりも、溶融した樹脂のバリを形成する幅だけ大きく形成されていることを特徴とする流量センサ。
- 請求項1に記載の流量センサにおいて、前記ハウジングに形成した突起部の上面の幅よりも入射するレーザ光のスポット径が大きいことを特徴とする流量センサ。
- 請求項1及至3のいずれかの請求項に記載の流量センサにおいて、前記ハウジングに形成した突起部の少なくとも一部には、側面に傾斜が設けられていることを特徴とする流量センサ。
- 請求項4に記載の流量センサにおいて、前記ハウジングに形成した突起部の傾斜角度を、前記副通路側において、前記樹脂製カバーに形成した突起部の傾斜角度より大きくしたことを特徴とする流量センサ。
- 請求項4に記載の流量センサにおいて、前記ハウジングに形成した突起部の傾斜角度を、前記副通路と反対側において、前記樹脂製カバーに形成した突起部の傾斜角度より小さくしたことを特徴とする流量センサ。
- 請求項1及至6のいずれかの請求項に記載の流量センサにおいて、前記樹脂製カバーの前記接合部の端部に設けられた突起部の側面に微小な凹凸が形成されていることを特徴とする流量センサ。
- 請求項1及至7のいずれかの請求項に記載の流量センサにおいて、前記副通路と前記回路室とを隔てる位置に在る前記ハウジングに形成された突起部と接合される、前記樹脂製カバーの前記接合部の両端に形成された突起部が、前記副通路側の突起の高さが前記回路室の内側の突起の高さよりも大きいことを特徴とする流量センサ。
- 請求項1及至7のいずれかの請求項に記載の流量センサにおいて、前記回路室の周囲に在る前記ハウジングに形成された突起部と接合される、前記樹脂製カバーの前記接合部の両端に形成された突起部が、前記回路室の内側の突起の高さが前記回路室の外側の突起高さよりも大きいことを特徴とする流量センサ。
- 請求項1及至9のいずれかの請求項に記載の流量センサにおいて、前記樹脂製カバー材の熱可塑性樹脂中に添加するガラスファイバー割合が、前記ハウジング材の熱可塑性樹脂中に添加するガラスファイバーの割合よりも小さいことを特徴とする流量センサ。
- 請求項1及至10のいずれかの請求項に記載の流量センサにおいて、前記樹脂製カバー材の結晶化度に比べ、前記ハウジング材の結晶化度が大きいことを特徴とする流量センサ。
- 被計測流体を取り込む開口部を有する副通路が形成され、前記副通路内に配置されて被計測流体の流量を計測する流量検出部と、前記副通路と隔離され前記流量検出部を駆動する電子部品を収納する回路室と、を有するハウジングに、樹脂製カバーにより前記回路室を封止するための第1の突起部、および前記樹脂製カバーとの間で前記副通路を構成するための第2の突起部を形成し、
前記樹脂製カバーに、前記ハウジングに形成した第1、第2の突起部と接合される接合部を形成すると共に、前記第2の突起部と接合される接合部の前記開口部を有する副通路側と該副通路と反対側の両端に第3の突起部を形成し、
前記第3の突起部は、前記開口部を有する副通路側に形成した突起の高さを前記副通路と反対側に形成した突起の高さより大きくして形成され、
各部品を収納した前記ハウジングと前記樹脂製カバーとを位置合わせして重ね、加圧して、前記樹脂製カバー上よりレーザ照射して、前記第1の突起部と対応する接合部間を溶着した後、前記第2の突起部と対応する接合部間を溶着して前記樹脂製カバーを接合することを特徴とする流量センサの製造方法。 - 前記樹脂製カバーを接合する工程に替えて、各部品を収納した前記ハウジングと前記樹脂製カバーとを位置合わせして重ね、加圧して、前記樹脂製カバー上よりレーザ照射して、前記第2の突起部と対応する接合部間を溶着した後、前記第1の突起部と対応する接合部間を溶着して前記樹脂製カバーを接合することを特徴とする請求項12に記載の流量センサの製造方法。
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