WO2015029343A1 - 液面検出装置の製造方法、および液面検出装置 - Google Patents
液面検出装置の製造方法、および液面検出装置 Download PDFInfo
- Publication number
- WO2015029343A1 WO2015029343A1 PCT/JP2014/004096 JP2014004096W WO2015029343A1 WO 2015029343 A1 WO2015029343 A1 WO 2015029343A1 JP 2014004096 W JP2014004096 W JP 2014004096W WO 2015029343 A1 WO2015029343 A1 WO 2015029343A1
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- WIPO (PCT)
- Prior art keywords
- liquid level
- main body
- hole
- detection device
- terminals
- Prior art date
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F23/00—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
- G01F23/30—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by floats
- G01F23/32—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by floats using rotatable arms or other pivotable transmission elements
- G01F23/38—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by floats using rotatable arms or other pivotable transmission elements using magnetically actuated indicating means
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
- H05K3/32—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
- H05K2203/13—Moulding and encapsulation; Deposition techniques; Protective layers
- H05K2203/1305—Moulding and encapsulation
- H05K2203/1316—Moulded encapsulation of mounted components
Definitions
- the present disclosure relates to a manufacturing method of a liquid level detection device that detects the height of a liquid level of a liquid stored in a container, and a liquid level detection device manufactured by the manufacturing method.
- a method of manufacturing a liquid level detection device that detects the height of the liquid level of a liquid stored in a container is known.
- a manufacturing method of such a liquid level detection device for example, in the manufacturing method of the liquid level detection device disclosed in Patent Document 1, a longitudinal positioning groove is formed on the mounting surface, and the longitudinal direction of the positioning groove (longitudinal) The direction is a closed end where one end is closed, and the other end is an open end where the other end is open.
- the lead portion is restricted from moving in the direction intersecting the longitudinal direction of the positioning groove, that is, in the width direction of the positioning groove, by the side wall surface of the positioning groove extending along the longitudinal direction. Therefore, the electronic component in which the lead portion is inserted into the positioning groove can define the position of the positioning groove in the width direction.
- the width of the positioning groove is set so as to leave a gap with respect to the thickness of the lead portion.
- the electronic component comes off in the longitudinal direction, and in this case, it is difficult to accurately perform the next connection step.
- a jig must be prepared and a jig must be arrange
- the present disclosure has been made in view of the above-described problems, and an object of the present disclosure is to provide a method of manufacturing a liquid level detection device that can reliably perform a connection process and improve yield. There is.
- a plurality of terminals that output an electrical signal of an element detection unit that detects the height of the liquid level of the liquid stored in the container to the outside, the main body unit, and the main body unit project from the main body unit.
- a method of manufacturing a liquid level detection device including an electronic component having a lead portion connected to a terminal includes a planar reference surface, an island protruding from the reference surface to form a positioning groove, and a hole recessed from the reference surface And forming a casing that covers the terminal, and after forming, a gap is formed between the island and the positioning groove, and the lead portion along the reference surface. And arranging the main body portion so that the curved surface protruding to the mounting surface side of the main body portion is sandwiched between the edges of the holes, and connecting the lead portion to the terminal after the arrangement.
- the lead portion is disposed in the positioning groove between the islands along the reference plane so as to leave a gap with the island, and the main body portion projects toward the mounting surface side. It is arranged by sandwiching the curved surface with the edge of the hole. According to this, even if there is a gap in the positioning groove, the electronic component can be prevented from shifting. Furthermore, since the electronic components are not easily displaced by the connection after the arrangement, the lead portion and the terminal are reliably connected. As described above, it is possible to provide a method for manufacturing a liquid level detection device capable of improving the yield.
- the method for manufacturing the liquid level detection device further includes: after the connection, the casing is installed in the cavity of the mold, and the cavity is filled with the molding material. Coating. In molding, a bottomed hole is provided.
- the electronic component since the electronic component is covered by coating, the electronic component can be prevented from touching the liquid.
- the bottomed hole provided by molding can prevent the molding material from flowing into the hole from the opposite side of the mounting surface and covering the main body part to be exposed to the outside when covering.
- the lead part of the electronic component when the direction in which the arranged lead part protrudes is defined as the longitudinal direction, the lead part of the electronic component is curved so as to be curved according to the width between the terminals.
- the island In order to form and have a portion, the island is provided with a locking portion for locking the curved portion in the longitudinal direction.
- the locking portion provided on the island locks the curved portion and assists positioning in the longitudinal direction. According to this, even when the main body part is removed from the hole, the electronic parts can be prevented from being displaced by the engaging part engaging the curved part of the lead part.
- a plurality of terminals that output an electrical signal of an element detection unit that detects the height of the liquid level of the liquid stored in the container to the outside, a main body unit having a curved surface, and
- a liquid level detecting device including an electronic component having a lead portion that protrudes from the main body and is connected to the terminal includes a flat reference surface and a positioning groove that protrudes from the reference surface to one side. And a mounting surface having a hole recessed from the reference surface to the opposite side of the projecting direction of the island, and the lead portion is accommodated in the positioning groove in a casing that covers the terminal.
- the electronic component is disposed such that a part of the curved surface of the main body is accommodated in the hole, and the curved surface is supported by an edge of the reference surface and a side surface forming the hole.
- said placing After comprises a connecting said lead portions and said terminal.
- the manufacturing method according to the fourth aspect it is possible to suppress the electronic component from being displaced, and since the electronic component is difficult to be displaced in the connection, the lead portion and the terminal are reliably connected. As described above, it is possible to provide a method for manufacturing a liquid level detection device capable of improving the yield.
- the electronic parts are appropriately arranged on the mounting surface, and the lead part and the terminal part are securely connected, so the liquid level with improved connection reliability. It can be a detection device.
- FIG. 2 is a sectional view taken along line II-II in FIG. It is a front view which shows the capacitor
- FIG. 8 is a sectional view taken along line VIII-VIII in FIG. 7.
- FIG. 10 is an enlarged view of a part of a cross section taken along the line XX of FIG. It is a figure which shows the connection process of FIG. It is a figure which shows the coating
- coated process of FIG. 10 is a front view showing a caging mounting surface in an arrangement process of Modification 1.
- FIG. 10 is a front view showing a caging mounting surface in an arrangement process of Modification 2.
- FIG. 10 is a front view showing a mounting surface in an arrangement process of Modification 3.
- a liquid level detection device according to an embodiment of the present disclosure is installed in a fuel tank 90 of a vehicle, and the level of a liquid level 91 a of fuel 91 stored in the fuel tank 90 is increased.
- An example is shown in which the present invention is applied to a fuel level gauge that detects an output and outputs an output result toward a combination meter (not shown) or the like.
- the fuel level gauge 100 is fixed in a fuel tank 90 which is a container.
- the fuel level gauge 100 is attached to the wall surface of the fuel pump module 93 installed in the fuel tank 90, and is integrally fixed to the fuel tank 90 via the fuel pump module 93.
- the method of attaching the fuel level gauge 100 to the fuel tank 90 is not limited to the above-described form, and is directly fixed to the inside of the fuel tank 90 via a stage or the like (not shown). Also good.
- the fuel level gauge 100 is formed by combining a float 60, a float arm 50, a magnet holder 30, a housing 20, a circuit unit 40, a wiring 70, and the like.
- the float 60 is made of a material having a small specific gravity, such as foamed ebonite.
- the float 60 is formed from a material having a specific gravity smaller than that of the fuel 91 that is a liquid, so that the float 60 can float on the liquid surface 91 a of the fuel 91.
- the float 60 has a thin rectangular parallelepiped shape so that the height of the liquid level 91a can be detected even when the remaining amount of the fuel 91 is very small.
- a through hole 61 is formed in the float 60 so as to pass through the center of gravity of the float 60.
- the float 60 is not limited to the rectangular parallelepiped shape described above, and may be a columnar shape or the like.
- the float arm 50 is formed of a round bar-shaped core made of a metal material such as stainless steel. Of the both ends of the float arm 50, the float holding portion 53 is formed at the end on the float 60 side by bending the float arm 50 about 90 degrees in the same direction as the rotation axis of the magnet holder 30. . The float arm 50 holds the float 60 by inserting the float holding portion 53 into the through hole 61 of the float 60. A stopper 51 is formed at the end of the float arm 50 on the magnet holder 30 side by bending the float arm 50 in the same direction as the rotation axis of the magnet holder 30 and about 90 degrees toward the housing 20.
- the magnet holder 30 is formed in a cylindrical shape with, for example, polyacetal (POM) resin, which has good oil and solvent resistance and excellent mechanical properties.
- the magnet holder 30 has a flange portion 34 and a float arm fixing portion 32.
- the flange portion 34 has a bearing portion 33, a magnet 31, and a stopper hole 35.
- the magnet holder 30 is rotatably supported by the housing 20 by a bearing portion 33 formed on the inner peripheral surface thereof.
- the magnet 31 is a cylindrical member exhibiting ferromagnetism, and is fixed in the magnet holder 30 by insert molding or the like.
- the magnet 31 is fixed so that its central axis coincides with the central axis of the magnet holder 30, and rotates integrally with the magnet holder 30.
- a permanent magnet such as a ferrite magnet, a rare earth magnet, an alnico magnet, or a bonded magnet is used.
- the flange portion 34 is provided on the outer peripheral surface of the magnet holder 30 and includes a stopper hole 35.
- the float arm 50 is fixed to the float arm fixing portion 32 in a state where the stopper portion 51 is inserted through the stopper hole 35.
- the reciprocating motion of the float 60 that moves up and down following the liquid level 91a of the fuel 91 by the float arm 50 supported at one end by the magnet holder 30 is converted into a rotational motion, and the float arm 50 and the magnet holder 30 are transmitted to an integral element. Therefore, the magnet holder 30 follows the liquid level of the fuel 91 stored in the fuel tank 90 and rotates relative to the housing 20.
- the housing 20 is formed in a rectangular plate shape by polyphenylene sulfide (PPS) resin or the like that is not affected by an organic solvent such as the fuel 91 and does not decrease in strength even at high temperatures.
- PPS polyphenylene sulfide
- the housing 20 is attached to the wall surface of the fuel pump module 93 with its longitudinal direction oriented in the vertical direction, and fixes the fuel level gauge 100 to the fuel tank 90.
- the housing 20 includes a shaft portion 21 and stopper walls 24a and 24b.
- the shaft portion 21 is a cylindrical convex portion that is formed near the center portion of the housing 20 and protrudes in the plate thickness direction of the housing 20.
- the shaft portion 21 is fitted with a bearing portion 33 of the magnet holder 30 so that the magnet holder 30 is rotatably supported by the housing 20.
- the magnet holder 30 can be smoothly rotated with respect to the housing 20.
- the stopper walls 24a and 24b are provided on two wall portions facing each other in the horizontal direction in a state where the housing 20 is attached to the wall surface of the fuel pump module 93. These stopper walls 24 a and 24 b are arranged at positions on the rotation path of the stopper portion 51 so as to come into contact with the stopper portion 51 of the float arm 50.
- One stopper wall 24a is for preventing the float 60 from contacting the bottom surface 90b of the fuel tank 90, and the fuel 91 in the fuel tank 90 is in a very small amount (solid line in FIG. 1). In FIG. 4, the stopper portion 51 is provided so as to abut.
- the other stopper wall 24b is for preventing the float 60 from contacting the ceiling surface 90a of the fuel tank 90, and the fuel tank 90 is filled with the maximum amount of fuel 91 (see FIG. 1). In the two-dot chain line), it is provided so as to come into contact with the stopper portion 51.
- the rotating unit 40 includes a magnetoelectric conversion element 42, terminals 41a, 41b, and 41c, and a capacitor 44, and detects the rotation angle of the magnet holder 30.
- the magnetoelectric conversion element 42 is embedded in the shaft portion 21 of the housing 20 so as to be positioned on the inner peripheral side of the magnet 31 disposed in the magnet holder 30.
- the magnetoelectric conversion element 42 includes three input / output units 42a serving as an input terminal, a ground terminal, and an output terminal.
- the three input / output units 42a are connected to terminals 41a, 41b, and 41c, respectively (see FIG. 9).
- the magnetoelectric conversion element 42 is a Hall element and receives a magnetic field action from the outside in a state where a voltage is applied, thereby detecting a voltage proportional to the density of magnetic flux passing through the magnetoelectric conversion element 42 as a detection result. Output from the output terminal.
- the terminals 41a, 41b, and 41c are made of a highly conductive phosphor bronze plate or brass plate, and three of them are embedded in the housing 20 in parallel in the horizontal direction of the housing 20.
- Each terminal 41a, 41b, 41c has a plate shape extending along the vertical direction of the housing 20.
- the terminal 41a is the closest to the stopper wall 24a
- the terminal 41c is the closest to the stopper wall 24b.
- a central one sandwiched between the terminal 41a and the terminal 41c is referred to as a terminal 41b.
- These three terminals 41a to 41c are electrically connected to the respective input / output portions 42a of the magnetoelectric transducer 42 at the lower ends in the vertical direction among both ends in the extending direction.
- the upper end in the vertical direction protrudes outside the housing 20.
- the capacitor 44 is a passive element that can store and discharge an amount of electric charge according to a predetermined capacitance, and removes noise generated or input to the circuit unit 40.
- the capacitor 44 has a main body 44a and two lead portions 44b.
- the main body 44a forms a curved surface 45 projecting outside by sandwiching a dielectric (not shown) between electrodes electrically connected to the lead 44b and covering them with an exterior material such as a resin.
- the lead part 44b is a wire made of metal, and two lead parts 44b protrude from the side face 46 of the main body part 44a substantially in parallel.
- the direction in which the lead portion 44 b protrudes is defined as the longitudinal direction of the capacitor 44.
- the capacitor 44 is connected to the terminals 41a to 41c by welding the longitudinal ends of the lead portions 44b to any of the terminals 41a to 41c.
- the circuit unit 40 is provided with two capacitors 44.
- One capacitor 44 has one lead portion 44b connected to the terminal 41a and the other lead portion 44b connected to the terminal 41b.
- one lead portion 44b is connected to the terminal 41b, and the other lead portion 44b is connected to the terminal 41c.
- the two lead parts 44b form the curved part 47 curved according to the width
- a portion to which the input / output unit 42a of the magnetoelectric conversion element 42 is connected is referred to as a detection element connection unit 40a.
- a portion to which the lead portion 44b of the capacitor 44 is connected is referred to as a capacitor connecting portion 40b.
- Three wirings 70 are provided and connected to terminals 41a to 41c, respectively.
- the detection result of the rotation angle of the magnet holder 30 by the magnetoelectric conversion element 42 is transmitted to a measuring device such as a combination meter outside the fuel tank 90 via these wires 70.
- These wirings 70 each have a terminal portion 72 and a conductive wire 73.
- the terminal portion 72 is formed of a highly conductive phosphor bronze plate or brass plate or the like, and is securely electrically connected to the terminals 41a to 41c by caulking or fusing (heat caulking) or the like.
- the conducting wire 73 is formed by coating the outer surface of a highly conductive metallic wire with an insulator such as rubber.
- one terminal 41a is electrically connected to a battery (not shown) via the connected wiring 70, and transforms and applies the battery voltage to the input / output unit 42a as the input terminal of the magnetoelectric transducer 42. It is possible.
- Another terminal 41b is installed via a connected wiring 70 or the like, and can provide a ground voltage to the input / output unit 42a serving as a ground terminal of the magnetoelectric transducer 42.
- another terminal 41c is connected to an external measuring device such as a combination meter via the connected wiring 70 and the like, and is detected as an electric signal from the input / output unit 42a serving as the output terminal of the magnetoelectric transducer 42. The result can be output.
- the fuel level gauge 100 outputs a voltage corresponding to the level of the liquid level 91a of the fuel 91 by the configuration described so far. Specifically, the voltage as the output result output by the magnetoelectric conversion element 42 varies depending on the angle between the magnetic lines of force of the magnet 31 that rotates integrally with the magnet holder 30 and the magnetoelectric conversion element 42.
- the manufacturing method of the fuel level gauge 100 includes a molding step S10, an arrangement step S30, a connection step S40, and a covering step S50.
- the terminals 41a to 41c are installed in the cavity 82 in the first mold 81 (see FIG. 6). Then, the casing 26 covering the terminals 41a to 41c is molded by melting and filling the molding material (for example, PPS resin) of the housing 20 into the cavity 82 in the first mold 81. Note that the gate for filling the cavity 82 with the molten molding material is omitted in FIG.
- the mounting surface 36 as shown in FIGS. 7 and 8 is provided in the casing 26 molded in the molding step S10.
- the mounting surface 36 has a reference surface 37, an island 38, and a hole 39.
- the reference surface 37 is formed in a planar shape substantially parallel to the extending direction of the terminals 41a to 41c.
- the island 38 protrudes from the reference surface 37 in the thickness direction of the terminals 41a to 41c to the opposite side of the terminals 41a to 41c, and forms a plurality of positioning grooves 25 to be described later together with the peripheral wall portion 27 surrounding the reference surface 37.
- the hole 39 has a cylindrical hole shape that is recessed from the reference surface 37 toward the terminals 41a to 41c, and has a bottom by forming a cylindrical side surface 39a and a planar bottom surface 39b.
- the hole 39 is formed with a substantially right-angled edge 39 c in a circumferential shape between the hole 39 and the reference surface 37.
- an electrode hole 29a is provided in the reference surface 37 of the casing 26 that covers the terminals 41a to 41c, so that the capacitor connecting portions 40b of the terminals 41a to 41c are exposed.
- the reference surface 37 is provided with an element accommodating portion 28 b that accommodates the magnetoelectric conversion element 42.
- the reference surface 37 is provided with the electrode holes 29b, so that the detection element connection portions 40a of the terminals 41a to 41c are exposed.
- the positioning groove 25 has a longitudinal shape extending from the inner peripheral side of the peripheral wall portion 27 toward the outer peripheral side. In other words, the positioning groove 25 has a longitudinal shape extending from the inside to the outside of the mounting surface 36.
- the positioning groove 25 has an open end 25a, a closed end 25b, and a side wall surface 25c. Further, the number of the positioning grooves 25 formed coincides with the total number of lead portions 44b of the capacitor 44 connected to the terminals 41a to 41c.
- the adjacent positioning grooves 25 are formed substantially parallel to each other in accordance with the width between the terminals (41a and 41b or 41b and 41c).
- the open end 25 a is one end in the longitudinal direction of the positioning groove 25 and is open to the inner peripheral side of the peripheral wall portion 27.
- the closed end 25 b is the other end in the longitudinal direction of the positioning groove 25 and is closed by the peripheral wall portion 27.
- the side wall surface 25c is a wall surface of the positioning groove 25 extending from the open end 25a to the closed end 25b, and is opposed to each other in the width direction of the positioning groove 25. Since the width of the positioning groove 25, which is the width between the side wall surfaces 25c, is set in consideration of the angular error of the lead portion 44b protruding from the main body portion 44a, the width of the positioning groove 25 is set to the thickness of the lead portion 44b. Is set so as to leave a gap.
- the width of the positioning groove 25 is set so as to form a gap between the lead portion 44b and the side wall portion 25c.
- the upper side of the closed end 25 b and the upper side of the side wall surface 25 c are inclined so as to descend toward the positioning groove 25.
- the upper side of the closed end 25 b is an inclined surface 38 c that decreases toward the open end 25 a
- the upper side of the side wall surface 25 c is an inclined surface 38 c that decreases in the width direction toward the positioning groove 25.
- the island 38 is provided with a protrusion 38a protruding between the open ends 25a of the adjacent positioning grooves 25 in the longitudinal direction to the opposite side of the closed end 25b.
- the island 38 is provided with a locking portion 38 b protruding from the peripheral wall portion 27 in the width direction of the positioning groove 25.
- the locking portion 38b closes a part of the open end 25a on the opposite side of the open end 25a from the closed end 25b.
- the upper side of the locking portion 38b is also a slope 38c that goes down toward the positioning groove 25.
- the hole 39 is formed on the reference surface 37 away from the protrusion 38a to the opposite side of the closed end 25b in consideration of the longitudinal dimension L1 of the capacitor main body 44a. That is, the hole 39 is formed so as to be aligned with the curved surface 45 of the main body 44a.
- the magnetoelectric conversion element 42 is inserted into the element housing portion 28b (see FIG. 9). Then, by accommodating the magnetoelectric conversion element 42 in the element accommodating portion 28b, the input / output portion 42a and the detection element connecting portion 40a are brought into contact with each other.
- a pair of columnar electrodes is prepared, and the detection element connection part 40a and the input / output part 42a are sandwiched between the pair of electrodes.
- the detection element connection portion 40a and the input / output portion 42a are brought into contact with each other. Resistive heat is generated.
- the magnetoelectric transducer 42 is connected to the terminals 41a to 41c by welding by melting the contact portion of the detection element connecting portion 40a and the input / output portion 42a with this resistance heat.
- the capacitors 44 are arranged on the mounting surface 36 as shown in FIG. Specifically, the lead portion 44 b is disposed in the positioning groove 25 along the reference surface 37, and the main body portion 44 a is disposed by sandwiching the curved surface 45 by the edge 39 c of the hole 39.
- the terminals 41a to 41c and the casing 26 are set in a posture in which the exposed side of the reference surface 37 is directed upward.
- the longitudinal direction of the lead portion 44 b and the reference surface 37 are substantially parallel (in other words, the curved surface 45 protrudes toward the mounting surface 36), and the longitudinal direction of the lead portion 44 b and the positioning groove 25.
- the posture is kept in agreement with the stretching direction.
- the capacitor 44 is placed on the mounting surface 36 from above. More specifically, the capacitor 44 is dropped toward the mounting surface 36 from the upper drop start position at a short distance.
- the lead portion 44 b is accommodated in the positioning groove 25, and the curved surface 45 of the main body portion 44 a is sandwiched between the edges 39 c of the holes 39. That is, a part of the curved surface 45 of the main body 44a is accommodated in the hole 39, and the curved surface 45 is supported by being in contact with and supported by the edge 39c between the reference surface 37 and the side surface 39a forming the hole 39, The main body 44 a is disposed on the mounting surface 36.
- the position of the capacitor 44 arranged in this way is defined, for example, by a portion of the side surface 46 of the main body portion 44a sandwiched between the two lead portions 44b abutting against the protruding portion 38a of the mounting surface 36.
- the position of the capacitor 44 may be defined by the leading end of the lead portion 44b hitting the closed end 25b.
- the capacitor 44 is restricted from moving in the direction intersecting the longitudinal direction, that is, in the width direction of the positioning groove 25 by contact between the side wall 25c and the lead portion 44b.
- the curved surface 45 of the main body 44a is sandwiched between the edges 39c of the holes 39, so that the displacement of the capacitor 44 is restricted.
- the diameter Rh of the hole 39 is equal to or smaller than the dimension L1 in the longitudinal direction of the main body portion 44a, and the depth Dh of the hole 39 is curved.
- the relationship of the protrusion dimension L2 or more of the surface 45 is satisfied.
- the protrusion dimension L2 is the distance from the edge of the hole 39 to the vertex 45a of the curved surface 45 in the height direction on the cross section along the longitudinal direction when the curved surface 45 is sandwiched between the edges 39c of the hole 39. It is height.
- the capacitor 44 is disposed at a desired position even when an error occurs in the drop start position due to the slope 38c provided on the island 38. That is, when the drop start position has an error in the width direction of the positioning groove 25, the lead portion 44b falls on the slope 38c provided on the upper side of the side wall surface 25c and slides down in the width direction. Is placed at a desired position. When the drop start position has an error in the longitudinal direction, the lead portion 44b falls on the slope 38c provided on the upper side of the closed end 25b or on the upper side of the locking portion 38b and slides in the longitudinal direction. 44 is arranged at a desired position.
- the lead portion 44b is connected to the terminals 41a to 41c.
- the electrode 89 is inserted into each of the electrode holes 29a. Accordingly, the pair of electrodes 89 sandwich the lead portion 44b and the capacitor connection portion 40b. In the state sandwiched between the electrodes 89, the lead portion 44b is pressed toward the capacitor connecting portion 40b. In this way, when the lead portion 44b is pressed toward the capacitor connecting portion 40b, a current is applied to the lead portion 44b and the capacitor connecting portion 40b via the electrode 89, whereby resistance heat is generated between the contact portions. Give rise to By melting the contact portion between the lead portion 44b and the capacitor connecting portion 40b by this resistance heat, the lead portion 44b of the capacitor 44 is connected to the terminals 41a to 41c by welding.
- the casing 26 is placed in the cavity 85 in the second mold 84, and the cavity 85 is filled with a molding material to cover the capacitor 44.
- the casing 26 is first installed in the cavity 85 in the second mold 84.
- the molding material for example, PPS resin
- the molding material of the housing 20 is melted and filled in the cavity 85 in the second mold 84 through the gate 86 provided in the second mold 84, thereby the capacitor 44 and the magnetoelectric conversion.
- the element 42 and the like are covered, and the appearance of the housing 20 is molded.
- the peripheral wall 27 is located between the capacitor 44 and the gate 86 in the casing 26 installed in the cavity 85 in the second mold 84.
- the magnet holder 30 is fitted to the shaft portion 21 of the housing 20 formed by the covering step S50 described above. Further, the float arm 50 is attached to the magnet holder 30, and the wiring 70 is connected to the terminals 41a to 41c, thereby completing the fuel level gauge 100 (see FIGS. 1 and 2).
- the lead portion 44b is arranged in the positioning groove 25 between the islands 38 along the reference plane 37 so as to leave a gap with the island 38, and the main body portion. 44 a is disposed by sandwiching the curved surface 45 protruding toward the mounting surface 36 between the edges 39 c of the holes 39. According to this, even if there is a gap in the positioning groove 25, the capacitor 44 can be prevented from shifting. Further, in the connection step S40 after the arrangement step S30, the capacitor 44 is not easily displaced, so that the lead portion 44b and the terminals 41a to 41c are securely connected. From the above, it is possible to provide a method for manufacturing the fuel level gauge 100 which is a liquid level detection device that improves the yield.
- the main body 44a when a longitudinal load is applied to the main body 44a by the main body 44a in which the curved surface 45 is sandwiched between the edges 39c of the holes 39 on the cross section along the longitudinal direction, the main body 44a Stops by receiving a repulsive force from the edge 39c of the hole 39. Therefore, the capacitor 44 can be prevented from shifting in the longitudinal direction.
- the body portion 44a is sandwiched between the edges 39c of the holes 39 formed so as to be aligned with the curved surface 45 of the body portion 44a, whereby a desired arrangement is achieved. Can be realized. Therefore, it is possible to suppress the displacement of the capacitor 44 by a simple arrangement step S30.
- the capacitor 44 can be prevented from touching the fuel 91 by the covering of the capacitor 44 in the covering step S50 after the connecting step S40. Further, the bottomed hole 93 provided in the covering step S50 allows the molding material to flow into the hole 39 from the opposite side of the mounting surface 36 during the covering step S50, and the main body 44a is lifted and exposed to the outside. Can be suppressed.
- the locking portion 38b provided on the island 38 locks the curved portion 47. Assists in longitudinal positioning. According to this, even when the main body portion 44a is removed from the hole 39, the locking portion 38b can lock the curved portion 47 of the lead portion 44b, thereby preventing the capacitor 44 from shifting.
- the fuel 91 is “liquid”
- the fuel tank 90 is “container”
- the magnetoelectric conversion element 42 is “detection element”
- the capacitor 44 is “electronic component”
- the fuel level gauge 100 is Each corresponds to a “liquid level detection device”.
- the hole 39 may have a shape other than the cylindrical hole shape as long as the curved surface 45 is sandwiched between the edges 39c of the hole 39 in the placement step S30.
- the hole 39 has a rectangular shape that is recessed from the reference plane 37 toward the terminals 41a to 41c. Then, in the arranging step S30, the four edges 39c of the rectangle have the curved surface 45 between the two points of the edge 39c of the hole 39 on the cross section along the longitudinal direction, and also on the cross section along the width direction. The two points of the edge 39 c of the hole 39 sandwich the curved surface 45.
- a locking portion 38 b that protrudes in the plate thickness direction may be provided on the inner peripheral side of the casing 26, that is, at the center of the mounting surface 36.
- the number of the three terminals 41a to 41c and the two capacitors 44 corresponding to the terminals 41a to 41c can be freely set.
- the present disclosure can be applied to a liquid level detection device including two terminals 41 and one capacitor 44 corresponding to the terminals as shown in FIG.
- the electronic component is not limited to the capacitor 44, and may be a resistor or the like for adjusting the output level of the magnetoelectric conversion element 42, for example.
- the curved surface 45 is formed in the hole 39 on the cross section other than the longitudinal direction. It may be sandwiched between the edges 39c.
- the hole 39 may be formed in the molding step S10 so that the curved surface 45 and the center of the main body 44a are eccentric.
- the covering step S50 may be replaced with another method.
- a hole 39 penetrating on the opposite side of the mounting surface 36 may be provided in the molding step S10.
- the island 38 may not be provided with the locking portion 38b for locking the curved portion 47 in the longitudinal direction.
- the application target of the present disclosure need not be limited to the fuel level gauge 100 for a vehicle, but may be in a container of other liquids mounted on the vehicle, such as brake fluid, engine cooling water, and engine oil.
- the present disclosure may be applied to a liquid level detection device.
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Abstract
Description
まず、燃料レベルゲージ100の基本構成について図1及び図2に基づいて説明する。燃料レベルゲージ100は、フロート60、フロートアーム50、マグネットホルダ30、ハウジング20、回路部40、及び配線70等を組み合わせてなる。
リード部44bは、金属からなる線材であり、当該本体部44aの側面46から2本のリード部44bが実質平行に突出している。ここで、リード部44bが突出する方向をコンデンサ44の長手方向と定義する。コンデンサ44は、リード部44bの長手方向の先端がターミナル41a~41cのいずれかに溶接されることにより、当該ターミナル41a~41cに接続されている。
次に、本実施形態による燃料レベルゲージ100の製造方法について、図5~12を用いて詳細に説明する。図5のフローチャートに示すように、この燃料レベルゲージ100の製造方法には、成形工程S10、配置工程S30、接続工程S40、及び被覆工程S50が含まれている。
以上説明した本実施形態の作用効果を以下に説明する。
以上、本開示の一実施形態について説明したが、本開示は、当該実施形態に限定して解釈されるものではなく、本開示の要旨を逸脱しない範囲内において種々の実施形態に適用することができる。
Claims (7)
- 容器(90)に貯留されている液体(91)の液面の高さを検出する素子検出部(42)の電気信号を外部に出力する複数のターミナル(41,41a,41b,41c)と、
本体部(44a)及び前記本体部から突出し前記ターミナルに接続されるリード部(44b)を有する電子部品(44)と、を備える液面検出装置の製造方法であって、
平面状の基準面(37)と、前記基準面から突出し、位置決め溝(25)を形成する島(38)と、前記基準面から凹となる穴(39)と、を有する実装面(36)を有し、前記ターミナルを被覆するケーシング(26)を成形すること(S10)と、
前記成形することの後、前記島との間に隙間を空けるようにして前記位置決め溝(25)に、前記リード部を前記基準面に沿って配置し、前記本体部を、前記本体部において前記実装面側に突出する湾曲面(45)を前記穴のエッジ(39c)で挟むようにして配置すること(S30)と、
前記配置することの後、前記リード部を前記ターミナルと接続すること(S40)と、を含む液面検出装置の製造方法。 - 前記配置することにおいて、配置された前記リード部が突出する方向を長手方向と定義したとき、
前記本体部は、前記長手方向に沿った断面上において、前記湾曲面が前記穴の前記エッジで挟まれるように配置される請求項1に記載の液面検出装置の製造方法。 - 前記成形することにおいて、前記穴を、前記本体部の前記湾曲面と中心が合う配置となるように形成する請求項1又は2に記載の液面検出装置の製造方法。
- さらに、前記接続することの後、前記ケーシングを金型(84)のキャビティ(85)に設置し、前記キャビティに成形材料を充填することにより、前記電子部品を被覆すること(S50)と、を含み、
前記成形することにおいて、有底の前記穴を設ける請求項1から3のいずれか1項に記載の液面検出装置の製造方法。 - 前記配置することにおいて、配置された前記リード部が突出する方向を長手方向と定義したとき、
前記電子部品の前記リード部は、前記ターミナル間の幅に合わせて湾曲する湾曲部(47)を有し、
前記成形することにおいて、前記島には、前記湾曲部を長手方向に係止する係止部(38b)を設ける請求項1から4のいずれか1項に記載の液面検出装置の製造方法。 - 容器(90)に貯留されている液体(91)の液面の高さを検出する素子検出部(42)の電気信号を外部に出力する複数のターミナル(41,41a,41b,41c)と、
湾曲面(45)を有する本体部(44a)及び前記本体部から突出し前記ターミナルに接続されるリード部(44b)を有する電子部品(44)と、を備える液面検出装置の製造方法であって、
平面状の基準面(37)と、前記基準面から一方側へ突出し、位置決め溝(25)を形成する島(38)と、前記基準面から前記島(38)の突出方向とは反対側へ凹となる穴(39)と、を有する実装面(36)を有し、前記ターミナルを被覆するケーシング(26)に、前記リード部が前記位置決め溝(25)に収容され、前記本体部の前記湾曲面の一部が前記穴に収容され、かつ、前記湾曲面が前記基準面と前記穴を形成する側面(39a)とのエッジ(39c)で支持されるように前記電子部品を配置すること(S30)と、
前記配置することの後、前記リード部を前記ターミナルと接続すること(S40)と、を含む液面検出装置の製造方法。 - 請求項1から6のいずれか1項に記載の製造方法により形成された液面検出装置。
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BR112016004138-0A BR112016004138B1 (pt) | 2013-08-27 | 2014-08-06 | Método para fabricar um dispositivo de detecção de superfície de líquido, e, dispositivo de detecção de superfície de líquido |
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