JP7743765B2 - Electrical equipment - Google Patents

Description

The present invention relates to an electrical device.

Patent Document 1 discloses a torque detection device for detecting torque applied to a torsion bar of an electric power steering device. The torque detection device described in Patent Document 1 includes a magnetic detection element, a sensor housing that houses the magnetic detection element, a circuit board mounted in a housing recess provided in the sensor housing, terminals soldered to the circuit board, and a waterproof coating made of epoxy resin that fills the housing recess in the sensor housing and covers the circuit board and terminals.

Japanese Patent Application Laid-Open No. 2020-134440

In the torque detection device described in Patent Document 1, the soldered portions between the circuit board and the terminals are directly covered with a coating material, which can cause stress at the joints between the circuit board and the terminals, potentially reducing the electrical connectivity between the circuit board and the terminals.

The present invention was made in consideration of the above circumstances, and aims to provide an electrical device that can improve the electrical connectivity between the substrate and the terminals.

To achieve the above-mentioned objectives, the present invention provides an electrical device comprising: a substrate; terminals joined to the substrate; a housing that accommodates the substrate and the terminals and has a window that exposes the joints between the substrate and the terminals; a cover member that closes the window; and a molded resin that covers the housing and the cover member.

The present invention makes it possible to provide an electrical device that can improve the electrical connectivity between the substrate and the terminals.

FIG. 1 is a perspective view of a magnetostrictive torque sensor according to an embodiment, viewed obliquely from above. FIG. 1 is a perspective view of a magnetostrictive torque sensor according to an embodiment, viewed obliquely from below. FIG. 2 is an enlarged cross-sectional view of a portion of the magnetostrictive torque sensor on the side opposite to the cable according to the embodiment. FIG. 2 is an enlarged cross-sectional view of a cable side portion of the magnetostrictive torque sensor according to the embodiment. FIG. 1 is a perspective view of a magnetostrictive torque sensor according to an embodiment, from which a molding resin and a heat-shrinkable tube are removed, as viewed obliquely from above. FIG. 2 is a perspective view of the magnetostrictive torque sensor from which the molding resin has been removed, as viewed obliquely from below, according to the embodiment. 2 is a perspective view of a substrate, a terminal, a cable, and a first housing member in the embodiment, as viewed obliquely from above. FIG. FIG. 2 is a plan view of the substrate, terminals, cables, and first housing member in the embodiment. 10 is an enlarged bottom view of the substrate, terminals, cables, and the vicinity of the window portion of the first housing member in the embodiment. FIG. 2 is an exploded perspective view of the substrate, terminals, cables, and first housing member in the embodiment, as viewed obliquely from above. FIG. 10 is a perspective view of a second housing member and a magnetic ring according to the embodiment, as viewed obliquely from above. FIG. 10 is a perspective view of a second housing member and a magnetic ring as viewed obliquely from a lower side L in the embodiment. FIG. 10A and 10B are schematic diagrams illustrating the positional relationship between a fitting recess of a second housing member and an insertion hole of a circuit board in the embodiment. FIG. 2 is a cross-sectional view of the periphery of a cover member of a magnetostrictive torque sensor, with a mold resin removed, viewed obliquely in accordance with an embodiment. FIG. 2 is a cross-sectional view of the magnetostrictive torque sensor, with the mold resin removed, taken along a line passing through a joint between a terminal and a substrate, according to an embodiment. FIG. 2 is a perspective view of the cover member as viewed from diagonally below in the embodiment. FIG. 2 is a perspective view of the cover member as viewed from diagonally above in the embodiment. FIG. 2 is a plan view of a cover member according to the embodiment. FIG. 1 is a cross-sectional view showing a state in which a magnetostrictive torque sensor is placed in a mold for molding resin before molding resin and a heat-shrinkable tube are provided in the mold according to an embodiment. 10 is a cross-sectional view showing a state after a resin constituting a molding resin is injected into a mold for the molding resin in the embodiment. FIG.

[Embodiment]
Embodiments of the present invention will be described with reference to Figures 1 to 20. The embodiments described below are shown as preferred specific examples for carrying out the present invention, and although some of the embodiments specifically exemplify various technically preferred aspects, the technical scope of the present invention is not limited to these specific embodiments.

(Magnetostrictive torque sensor 10)
Fig. 1 is a perspective view of the magnetostrictive torque sensor 10 as seen from diagonally above U. Fig. 2 is a perspective view of the magnetostrictive torque sensor 10 as seen from diagonally below L. Fig. 3 is an enlarged cross-sectional view of a portion of the magnetostrictive torque sensor 10 on the side opposite the cable 4. Fig. 4 is an enlarged cross-sectional view of a portion of the magnetostrictive torque sensor 10 on the cable 4 side.

In this embodiment, the electrical device 1 is a magnetostrictive torque sensor 10. Note that the electrical device 1 can be a device other than the magnetostrictive torque sensor 10, as long as it has a structure in which the substrate 2 and terminals 3 are joined and covered with the housing 5, cover member 6, and molded resin 8. For example, the electrical device 1 can be a sensor device other than the magnetostrictive torque sensor 10, or a relay device that relays electrical connections between multiple cables.

The magnetostrictive torque sensor 10 of this embodiment is used to measure the rotational torque applied to a magnetostrictive material 100 (see Figure 3) that has magnetostrictive properties. Magnetostriction is a phenomenon in which distortion appears in a ferromagnetic material when a magnetic field is applied to the ferromagnetic material to magnetize it. The magnetostrictive torque sensor 10 uses this phenomenon in reverse, detecting the magnetic field generated by the distortion of the magnetostrictive material 100 with a detection coil, thereby detecting the torque acting on the magnetostrictive material 100. The magnetostrictive torque sensor 10 can be mounted on a vehicle, for example, and the magnetostrictive material 100 whose rotational torque is to be measured can be, for example, a specified rotating shaft used in a vehicle.

The magnetostrictive torque sensor 10 includes a substrate 2, terminals 3, a cable 4, a housing 5, a cover member 6, a magnetic ring 7, molded resin 8, and a heat-shrink tube 9. The substrate 2 has a detection coil (not shown) for detecting an electrical signal corresponding to the magnitude of torque applied to the magnetostrictive material 100. As shown in FIG. 4 , one end of the terminal 3 is joined to the substrate 2 and the other end is joined to the cable 4. The cable 4 transmits the output of the detection coil to an external control device (not shown). The housing 5 is formed by combining a first housing member 51 and a second housing member 52 and accommodates the substrate 2, terminals 3, and cable 4. The cover member 6 closes a window 512a formed in the first housing member 51. As shown in FIG. 3 , the magnetic ring 7 surrounds the outer periphery of the substrate 2 and serves to prevent magnetic flux generated by the detection coil in the substrate 2 from leaking to the outside, thereby reducing the torque measurement accuracy of the magnetostrictive torque sensor 10. As shown in Figures 1 to 4, the molded resin 8 is molded to cover the housing 5 and cover member 6. A heat-shrinkable tube 9 seals the gap between the cable 4 and the housing 5 and molded resin 8. Each part of the magnetostrictive torque sensor 10 will now be described in detail.

Hereinafter, the axial direction of the magnetostrictive material 100 will be referred to as the rotational axis direction Z, the longitudinal direction of the cable 4 will be referred to as the cable longitudinal direction X, and the direction perpendicular to both the rotational axis direction Z and the cable longitudinal direction X will be referred to as the width direction Y.

Figure 5 is a perspective view of the magnetostrictive torque sensor 10, excluding the molded resin 8 and heat-shrinkable tube 9, as viewed from the diagonally upper side U. Figure 6 is a perspective view of the magnetostrictive torque sensor 10, excluding the molded resin 8, as viewed from the diagonally lower side L. Figure 7 is a perspective view of the board 2, terminal 3, cable 4, and first housing member 51, as viewed from the diagonally upper side U. Figure 8 is a plan view of the board 2, terminal 3, cable 4, and first housing member 51. Figure 9 is a bottom view enlarging the board 2, terminal 3, cable 4, and the window portion 512a of the first housing member 51. Figure 10 is an exploded perspective view of the board 2, terminal 3, cable 4, and first housing member 51, as viewed from the diagonally upper side U.

The substrate 2 is made of a flexible printed circuit board (FPC: Flexible Printed Circuits). The substrate 2 can be constructed, for example, by stacking multiple wiring layers. As shown in Figure 10, the substrate 2 has a substrate cylindrical portion 21 that is curved cylindrically to surround the magnetostrictive material 100, a substrate flat portion 22 that is formed in a plane approximately perpendicular to the substrate cylindrical portion 21, and a substrate connecting portion 23 that is curved to connect the substrate cylindrical portion 21 and the substrate flat portion 22.

Detection coils are patterned on the substrate cylindrical portion 21, and output electrical signals corresponding to the magnitude of the torque applied to the magnetostrictive material 100. The shape, number, and other configuration of the detection coils can be the same as that of a typical magnetostrictive torque sensor 10.

A wiring pattern (not shown) is formed on the substrate flat portion 22 to electrically connect the detection coil to multiple terminals 3. The substrate flat portion 22 is provided with six terminal holes 221 for inserting the multiple terminals 3, and one insertion hole 222 for inserting the protrusion 614 (described below) of the cover member 6.

The six terminal holes 221 are arranged in a U-shape surrounding the insertion hole 222. That is, pairs of terminal holes 221 aligned in the width direction Y are formed at three locations in the cable longitudinal direction X on the board flat portion 22, and the pair of terminal holes 221 located farthest from the board connecting portion 23 is spaced closer to each other than the other two pairs of terminal holes 221.

The insertion hole 222 is formed in a shape that allows the projection 614 (described below) of the cover member 6 to be inserted, and in this embodiment is formed in a generally rectangular shape that is elongated in the cable longitudinal direction X. To prevent dead space from being created in the board planar portion 22, the insertion hole 222 is formed to pass between the terminal holes 221 that are aligned in the width direction Y among the multiple terminal holes 221. In this embodiment, the insertion hole 222 is formed to pass between the two terminal holes 221 that are aligned in the Y direction and closest to the board connecting portion 23 among the six terminal holes 221, and between the two terminal holes 221 adjacent to those two terminal holes 221 in the cable longitudinal direction X.

As shown in Figures 8 and 10, a pair of locking recesses 223 are provided at both ends of the board flat portion 22 in the width direction Y. The pair of locking recesses 223 are located outside, in the width direction Y, a pair of terminal holes 221 located furthest from the board connecting portion 23. The locking protrusions 512b provided on the first housing member 51 are inserted into the locking recesses 223, and the locking recesses 223 are locked to the locking protrusions 512b. Four terminals 3 are connected to the board flat portion 22.

7 and 8, the four terminals 3 are connected to different electric wires 41 of the cable 4, and the other ends are inserted into the terminal holes 221 of the board planar portion 22. The four terminals 3 are aligned in the width direction Y, with the two terminals 3 in the center in the width direction Y having substantially the same shape, and the two terminals 3 at both ends in the width direction Y having substantially symmetrical shapes in the width direction Y. The two terminals 3 in the center in the width direction Y are inserted into a pair of terminal holes 221 located farther from the board connecting portion 23. Each of the two terminals 3 at both ends in the width direction Y branches into two on the side opposite the cable 4, and are inserted into the two terminal holes 221. Of the four terminals 3, the terminals 3 arranged at one end in the width direction Y are inserted into the two terminal holes 221 located on one side of the insertion hole 222, and the terminals 3 arranged at the other end in the width direction Y are inserted into the two terminal holes 221 located on the other side of the insertion hole 222.

The four terminals 3 are inserted into the six terminal holes 221 with their tips protruding toward the window portion 512a. The terminals 3 protruding from the six terminal holes 221 are soldered to the board flat portion 22 from the window portion 512a side. That is, the joint between the board flat portion 22 and the terminals 3 (in this embodiment, the solder 11 shown in Figures 13 and 15 described below) is provided on the window portion 512a side of the board flat portion 22. Note that Figure 9 shows the state before the solder is provided. The four terminals 3 are integrated with each other by an integrating resin 12. The integrating resin 12 is formed in a roughly rectangular column shape that is elongated in the width direction Y, and holds the four terminals 3 at a predetermined interval. The four terminals 3 on the side opposite to the side connected to the board flat portion 22 are connected to different electric wires 41 of the cable 4.

The cable 4 has four electric wires 41 and a sheath 42 that surrounds the four electric wires 41. Each electric wire 41 is a coated electric wire with a core wire and a coating. The sheath 42 is made of electrically insulating resin or the like formed into a cylindrical shape. The cable 4 has the four electric wires 41 housed within the housing 5, and the sheath 42 is positioned outside the housing 5 and molded resin 8, away from them. The board 2, four terminals 3, integrated resin 12, and cable 4 are assembled to the first housing member 51.

In this embodiment, the first housing member 51, the second housing member 52, the cover member 6, and the molded resin 8 can all be made of the same resin, such as PPS (polyphenylene sulfide). However, the first housing member 51, the second housing member 52, the cover member 6, and the molded resin 8 do not all have to be made of the same resin.

As shown in FIG. 10 , the first housing member 51 has a cylindrical portion 511 formed in a substantially cylindrical shape, and an extension portion 512 extending from the cylindrical portion 511 toward the cable 4 in the cable longitudinal direction X. In this specification, one side in the rotation axis direction Z from which the cylindrical portion 511 of the first housing member 51 protrudes (the upper side in FIGS. 1 and 5 ) is referred to as the upper side U, and the opposite side is referred to as the lower side L. Note that the expressions upper and lower do not limit the orientation of the magnetostrictive torque sensor 10 relative to the vertical direction when in use.

As shown in Figure 3, the cylindrical portion 511 is arranged to surround the magnetostrictive material 100, and the substrate cylindrical portion 21 is fixed to its outer surface using an adhesive (not shown). As shown in Figure 10, the extension portion 512 extends from the lower end of the cylindrical portion 511 toward the cable 4.

As shown in Figures 7, 8, and 10, the upper side U of the extension portion 512 is formed with a board placement recess 512c in which the board planar portion 22 is placed, and a cable placement recess 512d in which multiple electric wires 41 of the cable 4 are placed. The board placement recess 512c and the cable placement recess 512d are each recesses that are open at least to the upper side U and are connected to each other.

The board placement recess 512c is located closer to the cylindrical portion 511 than the cable placement recess 512d. As shown in Figures 8 and 9, a window 512a is formed through the bottom wall of the board placement recess 512c in the rotation axis direction Z. The window 512a is formed in a position facing the board flat portion 22. As shown in Figure 9, the window 512a exposes the tips of the terminals 3 protruding from the board flat portion 22 from the first housing member 51. Note that in Figure 9, the outline positions of the protrusion 614, clamping portion 615, and tip accommodating recess 612a (described below) of the cover member 6 projected onto the board flat portion 22 in the rotation axis direction Z are indicated by dashed-dotted lines. Figure 9 also shows the state before solder (see reference numeral 11 in Figures 13 and 15 described below) is applied to join the terminals 3 to the board 2.

The window portion 512a is provided to enable joining of the board 2 and the terminals 3 after assembling the board 2 and the multiple terminals 3 to the first housing member 51. As shown in Figure 8, the window portion 512a is formed in a rectangular shape that is slightly smaller than the board flat portion 22, and the periphery of the board flat portion 22 rests around the window portion 512a on the bottom wall of the board placement recess 512c.

As shown in Figures 6 and 9, the first housing member 51 is formed with a frame portion 512e that protrudes downward L from the periphery of the window portion 512a. As shown in Figure 9, the frame portion 512e is formed in a rectangular ring shape so as to surround the window portion 512a at a position separated from the window portion 512a. As will be described in detail later, the cover member 6 is fitted inside the frame portion 512e.

As shown in Figures 7, 8, and 10, the cable placement recess 512d is provided with three wire compartment walls 512f that are elongated in the cable longitudinal direction X and separate the four wires 41 from one another. A resin placement recess 512g in which integrated resin 12 is placed is formed between the cable placement recess 512d and the board placement recess 512c. The resin placement recess 512g is defined by one end of at least three wire compartment walls 512f. The resin placement recess 512g is also defined by an integrated resin compartment wall 512h that is arranged opposite the central wire compartment wall 512f of the three wire compartment walls 512f, with the integrated resin 12 interposed between them. The board placement recess 512c, cable placement recess 512d, and resin placement recess 512g are covered by the second housing member 52.

As shown in Figures 5 and 6, the second housing member 52 is formed along the extension portion 512 of the first housing member 51. The second housing member 52 has a pair of flexible pieces 521 extending to the lower side L, and is snap-fitted to the first housing member 51 by the pair of flexible pieces 521.

Figure 11 is a perspective view of the second housing member 52 and magnetic ring 7 viewed from diagonally above U. Figure 12 is a perspective view of the second housing member 52 and magnetic ring 7 viewed from diagonally below L.

As shown in FIG. 12, the second housing member 52 is formed in a concave shape that is open at least to the lower side L. The second housing member 52 has a support portion 522 that protrudes from the bottom wall of the second housing member 52 to the lower side L and supports the board flat portion 22 from the lower side L. The support portion 522 is formed in a roughly rectangular shape and is provided with a fitting recess 523 for inserting the protrusion 614 (described below) of the cover member 6, and a terminal insertion recess 524 for inserting multiple terminals 3, both of which open downward. As shown in FIG. 4, the lower surface of the support portion 522 supports the board flat portion 22.

Figure 13 is a schematic diagram illustrating the positional relationship between the mating recess 523 of the second housing member 52 and the insertion hole 222, viewed from the underside L with the cover member 6 removed from the housing 5. At least a portion of the inner surface 523a of the mating recess 523 is located more inward than the inner surface 222a of the insertion hole 222. In this embodiment, the mating recess 523 is formed shorter in the cable longitudinal direction X than the insertion hole 222, and a pair of side surfaces 523b of the inner surface 523a of the mating recess 523 that face the cable longitudinal direction X are located more inward than the inner surface 222a of the insertion hole 222. However, this is not limited to this. For example, at least a portion of one surface constituting the inner circumferential surface 523a of the fitting recess 523 may be located more inward than the inner circumferential surface 222a of the insertion hole 222, or the entire inner circumferential surface 523a of the fitting recess 523 may be located more inward than the inner circumferential surface 222a of the insertion hole 222.

11 and 12, the second housing member 52 is formed integrally with the magnetic ring 7. As shown in FIGS. 4 and 11, the end of the second housing member 52 closest to the magnetic ring 7 is provided with a retaining protrusion 525 that protrudes upward U. As shown in FIG. 4, the retaining protrusion 525 is arranged to fill the retaining recess 712 provided on the underside of the magnetic ring 7. When the second housing member 52 is molded, the resin that constitutes the second housing member 52 fills the retaining recess 712, thereby forming the retaining protrusion 525 in the same shape as the space within the retaining recess 712 and integrating the second housing member 52 with the magnetic ring 7. In this embodiment, the inner circumferential surface of the retaining recess 712 is formed in a screw groove shape, and accordingly, the outer circumferential surface of the retaining protrusion 525 is formed in a screw thread shape. Note that other uneven shapes can be used for the inner circumferential surface of the retaining recess 712 and the outer circumferential surface of the retaining protrusion 525, as long as they are mutually retaining. Details of the magnetic ring 7 will be described later.

A cover member 6 is provided to close the window portion 512a from the bottom side L. Figure 14 is an oblique cross-sectional view of the area around the cover member 6 of the magnetostrictive torque sensor 10, with the molded resin 8 removed. Figure 15 is a cross-sectional view of the magnetostrictive torque sensor 10, with the molded resin 8 removed, passing through the joint between the terminal 3 and the substrate 2. Figure 16 is a perspective view of the cover member 6, seen from the diagonally lower side L. Figure 17 is a perspective view of the cover member 6, seen from the diagonally upper side U. Figure 18 is a plan view of the cover member 6.

The cover member 6 has a substantially rectangular plate-shaped cover body 61 and three snap-fit pieces 62 extending upward from the cover body 61 toward the upper side U. As shown in Figures 17 and 18, the cover body 61 has a first step 611 protruding toward the upper side U and a second step 612 protruding further toward the upper side U from the center of the first step 611. The first step 611 is formed one turn inward from the outer edge 613 of the cover body 61. As shown in Figures 14 and 15, the outer edge 613 of the cover body 61 rests on the underside of the frame 512e of the first housing member 51. The first step 611 is fitted inside the frame 512e. The first step 611 is fitted loosely inside the frame 512e.

The upper surface of the second step portion 612 faces the board flat portion 22 with a gap therebetween. As shown in Figures 15, 17, and 18, the second step portion 612 is formed with six tip accommodating recesses 612a that respectively accommodate the six tips of the terminals 3. The six tip accommodating recesses 612a are formed at positions that overlap with the six terminal holes 221 in the rotational axis direction Z. In this embodiment, the tip accommodating recesses 612a also accommodate a portion of the solder 11. The underside of the cover main body 61 is provided with a raised portion 612b that protrudes from the lower side L. The raised portion 612b is formed at a position that overlaps with the tip accommodating recesses 612a in the thickness direction of the cover main body 61 (i.e., the rotational axis direction Z). As shown in Figure 18, the raised portion 612b is formed in a U-shape so that it overlaps with all of the U-shaped tip accommodating recesses 612a in the rotational axis direction Z.

17 and 18, the cover body 61 has a protruding portion 614 and a clamping portion 615 that protrude further upward from the second step portion 612. The protruding portion 614 is formed to protrude upward from the clamping portion 615. The protruding portion 614 is formed in a plate shape that is long in the cable longitudinal direction X and thick in the width direction Y. The longitudinal direction of the protruding portion 614 coincides with the longitudinal direction of the cover member 6. The protruding portion 614 is formed approximately in the center of the cover body 61. As shown in FIG. 14, the protruding portion 614 is inserted into the insertion hole 222 of the board flat portion 22 and the mating recess 523 of the second housing member 52. The protruding portion 614 is fitted into the mating recess 523 in a loose fit. The end face of the upper side U of the protruding portion 614 closely faces or abuts against the bottom surface of the mating recess 523.

As shown in FIG. 15 , the clamping portion 615 sandwiches the board planar portion 22 between itself and the support portion 522 of the second housing member 52 and reinforces the cover member 6. As shown in FIGS. 17 and 18 , the clamping portion 615 includes a vertical portion 615a extending from the protrusion 614 toward the cable 4 in the cable longitudinal direction X, a pair of first horizontal portions 615b extending from the protrusion 614 to both sides in the width direction Y, a pair of second horizontal portions 615c extending from the end of the vertical portion 615a facing the protrusion 614 to both sides in the width direction Y, and a pair of third horizontal portions 615d extending from the end of the vertical portion 615a opposite the protrusion 614 to both sides in the width direction Y. The vertical portion 615a is formed to pass between the two of the six tip accommodating recesses 612a that are closest to the cable 4. The first horizontal portion 615b and the second horizontal portion 615c are formed to pass between adjacent tip accommodating recesses 612a in the cable longitudinal direction X. That is, the protrusion 614, vertical portion 615a, first horizontal portion 615b, and second horizontal portion 615c are formed to separate the six tip accommodating recesses 612a from one another. The third horizontal portion 615d is formed so that the edge of the second step 612 on the cable 4 side is raised upward U across the entire width direction Y.

The snap-fit piece 62 is formed to extend upward U from the second step portion 612. The snap-fit piece 62 is flexible in the cable longitudinal direction X and is fixed to the first housing member 51 by snap fitting. As shown in Figure 14, one snap-fit piece 62 is engaged with the upper surface of the integrated resin partition wall 512h.

As shown in FIG. 3 , the magnetic ring 7 is formed to face the cylindrical portion 511 of the first housing member 51 across the cylindrical substrate portion 21 of the substrate 2. The magnetic ring 7 is made of a ferromagnetic material (soft magnetic material) made of a metal (including alloys) such as iron, formed into a roughly cylindrical shape. By covering the outer periphery of the detection coil, the magnetic ring 7 serves to prevent magnetic flux generated by the detection coil from leaking to the outside, thereby reducing the accuracy of torque measurement by the magnetostrictive torque sensor 10.

As shown in Figures 3 and 11, the magnetic ring 7 has a large diameter portion 71 at its lower end, and a small diameter portion 72 with a smaller outer diameter than the large diameter portion 71, located above the large diameter portion 71 on the side U. A ring recess 711 is formed on the underside of the large diameter portion 71, recessed toward the upper side U and with the second housing member 52 disposed inside. As shown in Figure 3, the aforementioned retaining recess 712 is formed so as to open into the bottom surface of the ring recess 711. Furthermore, the portion of the underside of the large diameter portion 71 other than the portion where the ring recess 711 is formed faces the upper surface of the first housing member 51.

As shown in Figures 1 to 4, the molded resin 8 is molded to cover the housing 5, cover member 6, and part of the magnetic ring 7. The molded resin 8 is molded to cover the housing 5 and cover member 6 while leaving the small diameter portion 72 of the magnetic ring 7 exposed. As shown in Figure 3, the contact portion 13 between the outer surface of the large diameter portion 71 and the molded resin 8 has a portion whose diameter decreases toward the upper side U. This prevents the magnetic ring 7 from slipping out of the molded resin 8 to the upper side U.

2 and 4, the molded resin 8 has a first opening 81 that opens to the underside of the cover member 6. As a result, when viewed from the bottom side L, the cover member 6 can be seen inside the first opening 81. When viewed from the bottom side L, the first opening 81 is formed in a position surrounded by the U-shaped protrusion 612b. Also, as shown in FIGS. 1 and 4, the molded resin 8 has a second opening 82 that opens to the top side of the second housing member 52. The first opening 81 and the second opening 82 are portions that come into contact with the mold when molding the molded resin 8. As shown in FIG. 1, a pair of ribs 526 are provided on the second housing member 52 so as to sandwich the second opening 82. When molding the molded resin 8, the mold is aligned between the pair of ribs 526.

1, 2, and 4, a heat-shrinkable tube 9 is provided to prevent liquids and the like from penetrating into the housing 5 and molded resin 8 through gaps between the housing 5 and molded resin 8 and the cable 4. The heat-shrinkable tube 9 is formed to cover the boundary between the housing 5 and molded resin 8 and the cable 4 when viewed from the outside. The heat-shrinkable tube 9 is configured to shrink at least toward the inner periphery of the heat-shrinkable tube 9 when heated to a predetermined temperature or higher. The heat-shrinkable tube 9 covers the molded resin 8 and the end of the housing 5 facing the sheath 42, as well as the end of the sheath 42 facing the housing 5. As shown in FIG. 4, in this embodiment, the length of the portion of the heat-shrinkable tube 9 covering the sheath 42 in the cable longitudinal direction X is longer than the length of the portion covering the end of the housing 5 and the molded resin 8 in the cable longitudinal direction X. Furthermore, a portion of the heat-shrinkable tube 9 penetrates between the sheath 42 and the housing 5. The inner periphery of the heat-shrinkable tube 9 may be provided with a hot melt adhesive, which melts above a certain temperature and hardens again when the temperature drops below that temperature.

(Method for manufacturing the magnetostrictive torque sensor 10)
Next, an example of a method for manufacturing the magnetostrictive torque sensor 10 will be described.
First, the substrate 2, the four terminals 3 integrated with the integration resin 12, and the cable 4 are assembled to the first housing member 51. This results in the state shown in FIGS.

Next, the second housing member 52, which is integrated with the magnetic ring 7, is attached to the first housing member 51. As a result, one surface of the board flat portion 22 of the board 2 is supported by the support portion 522 of the first housing member 51.

Next, the terminals 3 and the board flat portion 22 are joined through the window 512a of the first housing member 51. To join the terminals 3 and the board flat portion 22, a tool (not shown) for forming solder 11 is inserted into the housing 5 through the window 512a, and the terminals 3 and the board flat portion 22 are joined using the solder 11. At this time, because the board flat portion 22 is supported by the support portion 522, deformation of the board flat portion 22 due to being pressed by the tool, etc., is prevented. After the terminals 3 and the board flat portion 22 are joined, the window 512a is closed with the cover member 6.

Next, the molded resin 8 is formed. Figure 19 is a cross-sectional view showing the magnetostrictive torque sensor 10 placed in the mold for the molded resin 8 before the molded resin 8 and heat-shrinkable tube 9 are provided. Figure 20 is a cross-sectional view showing the state after the resin that makes up the molded resin 8 has been injected into the mold for the molded resin 8.

To form the molded resin 8, as shown in FIG. 19 , the magnetostrictive torque sensor 10 is placed in a mold without the molded resin 8 and heat-shrink tubing 9. The mold has at least an upper mold 141 and a lower mold 142 that overlap in the rotation axis direction Z. The lower mold 142 has a lower mold abutment portion 142a that abuts against a portion of the underside of the cover member 6, and the upper mold 141 has an upper mold abutment portion 141a that abuts against a portion of the upper surface of the second housing member 52. This presses the cover member 6 toward the second housing member 52, preventing the molded resin 8 from penetrating the interface between the cover member 6 and the window portion 512a. The molded resin 8 is formed by injecting molten resin that will become the molded resin 8 into the cavity surrounded by the upper mold 141 and lower mold 142 and then hardening the resin. When molding the mold resin 8, the area where the lower die contact portion 142a was located becomes the first opening 81, and the area where the upper die contact portion 141a was located becomes the second opening 82.

Next, the heat-shrinkable tube 9 is provided. To provide the heat-shrinkable tube 9, first, the heat-shrinkable tube 9 before heat shrinking, which has an outer diameter larger than the portions of the housing 5, molded resin 8, and cable 4 to be covered by the heat-shrinkable tube 9, is arranged so as to surround the portions of the housing 5, molded resin 8, and cable 4 to be covered by the heat-shrinkable tube 9. Next, the heat-shrinkable tube 9 is heated and shrunk, so that the heat-shrinkable tube 9 is adhered to the surfaces of the housing 5, molded resin 8, and cable 4 directly or via hot melt, if present. At this time, the diameter of a portion of the heat-shrinkable tube 9 is reduced so as to enter the space between the sheath 42 and the housing 5.
As described above, the magnetostrictive torque sensor 10 of this embodiment can be manufactured.

(Functions and Effects of the Embodiments)
In the magnetostrictive torque sensor 10 of this embodiment, the housing 5 is provided with a window 512a that exposes the joints (solder 11) between the substrate 2 and the terminals 3, and the cover member 6 closes the window 512a. The housing 5 and the cover member 6 are covered with a molded resin 8. This prevents the molded resin 8 from entering the space where the joints between the substrate 2 and the terminals 3 are located. This prevents the molded resin 8 from entering around the joints between the substrate 2 and the terminals 3, which would cause stress between the substrate 2 and the terminals 3 and inhibit the electrical connectivity between the substrate 2 and the terminals 3 from being impaired.

In addition, in this embodiment, the housing 5 is provided with a window 512a that exposes the joint between the substrate 2 and the terminal 3. Therefore, after the substrate 2 and terminal 3 are assembled to the housing 5, the substrate 2 and terminal 3 can be joined through the window 512a. This improves the flexibility of the manufacturing method for the magnetostrictive torque sensor 10.

The housing 5 also has a first housing member 51 with a window portion 512a formed therein, and a second housing member 52 that covers the board 2 and terminals 3 from the side opposite the first housing member 51. This makes it easy to attach the board 2 and terminals 3 to the housing 5.

The cover member 6 also has a protrusion 614 that protrudes toward the second housing member 52, and the substrate 2 has an insertion hole 222 into which the protrusion 614 is inserted. Therefore, the protrusion 614 ensures the strength of the cover member 6 and the second housing member 52. In this embodiment, when the molded resin 8 is being formed, the injection pressure of the molded resin 8 acts on the housing 5 and the cover member 6, but the second housing member 52 and the cover member 6 abut against each other via the protrusion 614, thereby preventing deformation of the cover member 6 and the second housing member 52. Before the molded resin 8 is formed, the cover member 6 and the second housing member 52 do not have to abut via the protrusion 614. However, when the injection pressure of the molded resin 8 acts on the cover member 6 and the second housing member 52, this injection pressure presses the cover member 6 and the second housing member 52, causing the protrusion 614 to abut against the second housing member 52, thereby suppressing deformation of the second housing member 52 and the cover member 6.

Although it is possible to provide the protrusion on the second housing member 52 so that the protrusion on the second housing member 52 abuts against the cover member 6, in this embodiment, the protrusion 614 is provided on the cover member 6. This facilitates assembly of the magnetostrictive torque sensor 10. Unlike this embodiment, if the protrusion 614 were formed on the second housing member 52, the protrusion 614 would protrude from the insertion hole 222 of the board 2 toward the window 512a when the first housing member 51, the second housing member 52, the board 2, and the terminals 3 are assembled together. This raises the concern that the joining tool may interfere with the protrusion 614 when joining the board 2 and the terminals 3 from the window 512a side. However, in this embodiment, the protrusion 614 is provided on the cover member 6, eliminating this concern.

The second housing member 52 is also provided with a mating recess 523 that fits into the protrusion 614. Therefore, when the cover member 6 is used to cover the window 512a, the protrusion 614 of the cover member 6 is guided straight into the mating recess 523, preventing the protrusion 614 from interfering with the insertion hole 222 of the board 2 and causing deformation, displacement, etc. of the board 2.

Furthermore, at least a portion of the inner peripheral surface 523a of the fitting recess 523 is located more inward than the inner peripheral surface 222a of the insertion hole 222. Therefore, when the protrusion 614 of the cover member 6 is inserted into the insertion hole 222 of the board 2 and the fitting recess 523 of the second housing member 52, the protrusion 614 interferes with the inner peripheral surface 523a of the fitting recess 523, which is located more inward than the insertion hole 222, thereby preventing the protrusion 614 from interfering with the inner peripheral surface 222a of the insertion hole 222 of the board 2.

The protrusion 614 is shaped like a long plate extending in the longitudinal direction of the cover member 6. This increases the rigidity of the cover member 6. Furthermore, in this embodiment, even if the injection pressure of the molded resin 8 acts on the second housing member 52 and the cover member 6 during molding of the molded resin 8, the protrusion 614 of the cover member 6 abuts against the second housing member 52 over a long range in the cable longitudinal direction X, thereby further suppressing deformation of the second housing member 52 and the cover member 6.

The substrate 2 is also formed with a plurality of terminal holes 221 into which the terminals 3 are inserted, and the insertion hole 222 is located between at least one pair of the plurality of terminal holes 221. While the space between the terminal holes 221 on the substrate 2 tends to become dead space, this embodiment makes effective use of this dead space, preventing the substrate 2 from becoming larger.

The second housing member 52 also has a support portion 522 that supports one surface of the board 2. Therefore, when the board 2 and terminals 3 are assembled inside the housing 5, the board 2 is supported by the support portion 522, preventing deformation and displacement of the board 2. In addition, in this embodiment, when joining the board 2 and terminals 3 from the window portion 512a side, the board 2 is prevented from being pressed by the joining tool, causing deformation and displacement.

The cover member 6 also has a clamping portion 615 that clamps the substrate 2 between itself and the support portion 522. This prevents deformation and displacement of the substrate 2.

The housing 5 also has a ring-shaped frame 512e that protrudes toward the side where the window 512a opens (i.e., downward) and surrounds the window 512a at a distance from the window 512a, and the cover member 6 fits inside the frame 512e. This allows the shape of the interface between the cover member 6 and the second housing member 52 to be complex, preventing the molded resin 8 from penetrating into the housing 5 from the interface between the cover member 6 and the second housing member 52 during molding of the molded resin 8.

Furthermore, a tip accommodating recess 612a in which the tip of the terminal 3 is disposed is formed on the inner surface (top surface) of the cover member 6. This prevents the tip of the terminal 3 from interfering with the cover member 6. Furthermore, a protruding portion 612b is provided on the outer surface (bottom surface) of the cover member 6, protruding from the lower side L, at a position overlapping the tip accommodating recess 612a in the thickness direction of the cover member 6 (i.e., the rotational axis direction Z). Without special ingenuity, the cover member 6 is prone to becoming thin at the location where the tip accommodating recess 612a is formed, which could reduce the strength of the cover member 6 or lead to molding defects. However, in this embodiment, by forming the protruding portion 612b at the location where the tip accommodating recess 612a is formed, it is possible to prevent a reduction in the strength of the cover member 6 and molding defects.

The molded resin 8 also has a first opening 81 that opens into the cover member 6. The first opening 81 is an opening created when the mold abuts against the cover member 6 during molding of the molded resin 8. Therefore, during molding of the molded resin 8, the clamping force of the mold presses the cover member 6 toward the second housing member 52, preventing a gap from forming between the cover member 6 and the second housing member 52. This prevents the molded resin 8 from seeping into the housing 5 and the cover member 6.

As described above, this embodiment provides an electrical device that can improve the electrical connectivity between the substrate and the terminals.

(Summary of the embodiment)
Next, the technical ideas grasped from the above-described embodiments will be described by using the reference numerals and the like in the embodiments. However, the reference numerals and the like in the following description do not limit the components in the claims to the members and the like specifically shown in the embodiments.

[1] An electrical device (1) comprising: a substrate (2); terminals (3) joined to the substrate (2); a housing (5) that accommodates the substrate (2) and the terminals (3) and has a window (512a) that exposes the joint (11) between the substrate (2) and the terminals (3); a cover member (6) that closes the window (512a); and a molded resin (8) that covers the housing (5) and the cover member (6).

[2] The housing (5) is an electrical device (1) described in [1], which has a first housing member (51) in which the window portion (512a) is formed, and a second housing member (52) that covers the board (2) and the terminals (3) from the side opposite the first housing member (51).

[3] An electrical device (1) according to [2], wherein one of the cover member (6) and the second housing member (52) has a protrusion (614) that protrudes toward the other side, and the substrate (2) has an insertion hole (222) into which the protrusion (614) is inserted.

[4] The electrical device (1) described in [3], wherein the protrusion (614) is provided on the cover member (6).

[5] The electrical device (1) described in [4], wherein the second housing member (52) is provided with a mating recess (523) that fits into the protrusion (614).

[6] An electrical device (1) described in [5], wherein at least a portion of the inner peripheral surface (523a) of the fitting recess (523) is located more inward than the inner peripheral surface (222a) of the insertion hole (222).

[7] An electrical device (1) described in any one of [3] to [6], wherein the protrusion (614) is a plate-like member extending in the longitudinal direction of the cover member (6).

[8] An electrical device (1) described in any one of [3] to [7], wherein the substrate (2) is formed with a plurality of terminal holes (221) into which the terminals (3) are inserted, and the insertion hole (222) is located at a position sandwiched between at least one pair of the terminal holes (221) among the plurality of terminal holes (221).

[9] An electrical device (1) described in any one of [2] to [8], wherein the second housing member (52) has a support portion (522) that supports one side of the substrate (2).

[10] The electric device (1) described in [9], wherein the cover member (6) has a clamping portion (615) that clamps the substrate (2) between itself and the support portion (522).

[11] An electrical device (1) described in any one of [1] to [10], wherein the housing (5) has a frame portion (512e) formed in an annular shape that protrudes toward the side where the window portion (512a) opens and surrounds the window portion (512a) at a position away from the window portion (512a), and the cover member (6) is fitted inside the frame portion (512e).

[12] An electrical device (1) described in any one of [1] to [11], wherein a tip accommodating recess (612a) in which the tip of the terminal (3) is disposed is formed on the inner surface of the cover member (6), and an outwardly protruding protrusion (612b) is provided on the outer surface of the cover member (6) at a position overlapping the tip accommodating recess (612a) in the thickness direction of the cover member (6).

[13] An electrical device (1) described in any one of [1] to [12], wherein the molded resin (8) has an opening (81) that opens into the cover member (6).

[14] An electrical device (1) according to any one of [1] to [13], used as a magnetostrictive torque sensor (10).

(Additional Note)
Although the embodiments of the present invention have been described above, the invention according to the claims is not limited to the above-described embodiments. It should be noted that not all of the combinations of features described in the embodiments are necessarily essential to the means for solving the problems of the invention. Furthermore, the present invention can be appropriately modified and implemented within the scope of its spirit.

1... Electrical device 10... Magnetostrictive torque sensor 11... Solder (joint)
2...substrate 221...terminal hole 222...insertion hole 222a...inner peripheral surface 3...terminal 5...housing 51...first housing member 512a...window portion 512e...frame portion 52...second housing member 522...support portion 523...fitting recess 523a...inner peripheral surface 6...cover member 612a...tip accommodating recess 612b...raised portion 614...protruding portion 615...clamping portion 8...molded resin 81...first opening

Claims (15)

A substrate;
a terminal joined to the substrate;
a housing that accommodates the substrate and the terminals and has a window that exposes a joint between the substrate and the terminals;
a cover member that closes the window portion;
a molding resin that covers the housing and the cover member ,
the housing includes a first housing member in which the window portion is formed, and a second housing member that covers the board and the terminals from the side opposite to the first housing member,
one of the cover member and the second housing member has a protruding portion that protrudes toward the other side,
The substrate has an insertion hole formed therein into which the protrusion is inserted.
Electrical equipment. The protrusion is provided on the cover member.
10. The electrical device of claim 1 . The second housing member is provided with a fitting recess that fits into the protrusion.
3. The electrical device of claim 2 . At least a part of an inner peripheral surface of the fitting recess is located more inward than an inner peripheral surface of the insertion hole.
4. The electrical device of claim 3 . The protrusion has a plate shape that is elongated in the longitudinal direction of the cover member.
5. An electrical device according to any one of claims 1 to 4 . The substrate is formed with a plurality of terminal holes into which the terminals are inserted,
The insertion hole is provided at a position sandwiched between at least a pair of terminal holes among the plurality of terminal holes.
6. An electrical device according to any one of claims 1 to 5 . the second housing member has a support portion that supports one surface of the substrate;
7. An electrical device according to any one of claims 1 to 6 . A substrate;
a terminal joined to the substrate;
a housing that accommodates the substrate and the terminals and has a window that exposes a joint between the substrate and the terminals;
a cover member that closes the window portion;
a molding resin that covers the housing and the cover member ,
the housing includes a first housing member in which the window portion is formed, and a second housing member that covers the board and the terminals from the side opposite to the first housing member,
the second housing member has a support portion that supports one surface of the substrate;
Electrical equipment. the cover member has a clamping portion that clamps the substrate between itself and the support portion,
9. An electrical device according to claim 7 or 8 . the housing has a frame portion that protrudes toward the opening of the window portion and is formed in an annular shape so as to surround the window portion at a position spaced from the window portion,
The cover member is fitted inside the frame portion.
10. An electrical device according to any one of claims 1 to 9 . A substrate;
a terminal joined to the substrate;
a housing that accommodates the substrate and the terminals and has a window that exposes a joint between the substrate and the terminals;
a cover member that closes the window portion;
a molding resin that covers the housing and the cover member ,
the housing has a frame portion that protrudes toward the opening of the window portion and is formed in an annular shape so as to surround the window portion at a position spaced from the window portion,
The cover member is fitted inside the frame portion.
Electrical equipment. a tip receiving recess in which the tip of the terminal is disposed is formed on the inner surface of the cover member;
An outer surface of the cover member is provided with a protruding portion that protrudes outward at a position that overlaps the tip end accommodating recess in the thickness direction of the cover member.
12. An electrical device according to any one of the preceding claims. A substrate;
a terminal joined to the substrate;
a housing that accommodates the substrate and the terminals and has a window that exposes a joint between the substrate and the terminals;
a cover member that closes the window portion;
a molding resin that covers the housing and the cover member ,
a tip receiving recess in which the tip of the terminal is disposed is formed on the inner surface of the cover member;
An outer surface of the cover member is provided with a protruding portion that protrudes outward at a position that overlaps the tip end accommodating recess in the thickness direction of the cover member.
Electrical equipment. The molding resin has an opening formed therein that opens to the cover member.
14. An electrical device according to any one of the preceding claims. Used as a magnetostrictive torque sensor,
15. An electrical device according to any one of the preceding claims.