TOUCH SENSOR UNIT AND MANUFACTURING METHOD THEREOF
20180274269 ยท 2018-09-27
Assignee
Inventors
- Yasuhiro Orihara (Gunma, JP)
- Naruhito Ogino (Gunma, JP)
- Hideki Kubota (Gunma, JP)
- Mitsuhiro Okada (Gunma, JP)
Cpc classification
E05B81/77
FIXED CONSTRUCTIONS
H03K2217/96078
ELECTRICITY
H03K17/965
ELECTRICITY
E05F15/44
FIXED CONSTRUCTIONS
E05B81/78
FIXED CONSTRUCTIONS
International classification
Abstract
The disclosure makes an insulating component and a sensor bracket to be an integrally molded article, simplifies the manufacturing process and cuts down the cost. A sensor holder and a sensor bracket made of a resin are made to be an integrally molded article, wherein the sensor holder inside which a pair of electrodes are arranged, and the sensor bracket made of a resin which holds the sensor holder and is attached to a tailgate. During an operation of filling a molten resin to a cavity, a part of the sensor holder is melted by the molten resin, and thus integrating the sensor holder and the molten resin, therefore, the two components can be structurally and firmly integrated. Accordingly, a touch sensor unit which endures long-term use can be obtained.
Claims
1. A touch sensor unit used to detect contact of a blocking, comprising: a hollow insulating component, which deforms elastically due to a stress of an external force; a plurality of electrodes, which are arranged inside the insulating component and contact with each other due to an elastic deformation of the insulating component; and a sensor bracket made of a resin, which holds the insulating component and is attached to an attachment object, wherein the insulating component and the sensor bracket is an integrally molded article.
2. The touch sensor unit according to claim 1, wherein the insulating component comprises: an electrode holder, which holds the plurality of electrodes; and a bracket fixture, which is fixed to the sensor bracket.
3. The touch sensor unit according to claim 2, wherein a width of the electrode holder along a direction across an extending direction of the insulating component is the same as a width of the bracket fixture.
4. The touch sensor unit according to claim 2, wherein a groove into which the bracket fixture enters is arranged on the sensor bracket.
5. The touch sensor unit according to claim 3, wherein a groove into which the bracket fixture enters is arranged on the sensor bracket.
6. A manufacturing method of a touch sensor unit used to detect contact of a blocking, wherein the touch sensor unit comprises: a hollow insulating component, which deforms elastically due to a stress of an external force; a plurality of electrodes, which are arranged inside the insulating component and contact with each other due to an elastic deformation of the insulating component; and a sensor bracket made of a resin, which holds the insulating component and is attached to an attachment object; wherein the manufacturing method comprises: a first process, which sets the insulating component to an insulating component accommodating section of a first mold; a second process, which makes a second mold butt with the first mold, and forms a cavity which shapes the sensor bracket inside the first mold and the second mold; a third process, which fills the cavity with a molten resin, melts a part of the insulating component by the molten resin, and integrates the insulating component with the molten resin; and a fourth process, which releases the sensor bracket integrally molded with the insulating component from the first mold and the second mold.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0016]
[0017]
[0018]
[0019]
[0020]
[0021]
[0022]
[0023]
[0024]
[0025]
DESCRIPTION OF THE EMBODIMENTS
[0026] One embodiment of the disclosure is described in detail below with reference to the drawings.
[0027]
[0028] A vehicle 10 shown in
[0029] Besides, a power tailgate device 13 is mounted on the vehicle 10 according to this embodiment. The power tailgate device 13 includes: an actuator 13a, which opens and closes the tailgate 12 and is equipped with a speed reducer; a controller 13b, which controls the actuator 13a based on operation signals of an operation switch (not shown);
[0030] and a pair of touch sensor units 20, which detect contact of a blocking BL.
[0031] As shown in
[0032] Each touch sensor unit 20 is electrically connected to the controller 13b, and detection signals generated during an elastic deformation of each touch sensor units 20 are input to the controller 13b. Based on the input of the detection signals from each touch sensor unit 20, the controller 13b drives the tailgate 12 which is driven to be closed to be opened without depending on the operation of the operation switch, or stops the tailgate 12 which is driven to be closed immediately. In this way, the inserting of the blocking BL is prevented in advance.
[0033] Here, as shown in
[0034] On the contrary, when the blocking BL contacts with the touch sensor units 20 and the touch sensor units 20 deform elastically, the pair of electrodes 31b and 31c contact with each other and are short circuited. Then, a resistance value not via the resistor R is input to the controller 13b. In this way, the controller 13b detects the change of the resistance value and, triggered by the change of the resistance value, implements the control which drives the tailgate 12 to be opened or stops the tailgate 12 immediately.
[0035] As shown in
[0036] As shown in
[0037] In addition, the boundary of the sensor body 31 and the sensor holder 32 is protected by a molding resin MR.
[0038] As shown in
[0039] By spirally fixing each electrode 31b and 31c to the inner side in the diameter direction of the insulating tube 31a, even if the blocking BL (see
[0040] As shown in
[0041] Here, in order to show that the insulating tube 31a and the sensor holder 32 are melted and combined with each other to be structurally integrated, in
[0042] The sensor holder 32 includes a hollow sensor section (electrode holder) 32a which accommodates the sensor body 31 inside. That is, the sensor section 32a holds the pair of electrodes 31b and 31c. And the cross section of the sensor section 32a along a direction across the extending direction of the sensor holder 32 is approximately circle-shaped. Besides, the sensor holder 32 includes a bracket fixture 32b which is fixed to a groove 41a of the sensor bracket 40. And the cross section of the bracket fixture 32b along the direction across the extending direction of the sensor holder 32 is approximately quadrangular. In addition, the two-dot chain line in
[0043] A width W1 (diameter size) of the sensor section 32a along a direction across the longitudinal direction of the sensor holder 32 is set to the same width as a width W2 of the bracket fixture 32b along the direction across the longitudinal direction of the sensor holder 32 (W1=W2). In this way, the shape of the sensor holder 32 can be simplified, and the shape of the mold which is used in the extrusion formation of the sensor holder 32 can also be simplified. Accordingly, the cost can be cut down.
[0044] Besides, as shown in
[0045] Here, a part of the sensor holder 32 on the boundary section with the sensor bracket 40 is melted by a molten resin MP (see
[0046] The wall thickness of the sensor section 32a is approximately the same as the wall thickness of the insulating tube 31a. Accordingly, the sensor section 32a is easy to deform elastically due to the stress of the external force. Therefore, the electrodes 31b and 31c held on the sensor section 32a via the insulating tube 31a easily contact with each other due to the elastic deformation of the sensor section 32a, and sufficient detection performance of the sensor body 31 is ensured.
[0047] Here, the bracket fixture 32b situated near the bracket body 41 in relation to the sensor section 32a can also easily deform elastically as the sensor section 32a does.
[0048] In this way, under any of a load F1 applied directly from the upper side in
[0049] As shown in
[0050] On two ends of the resistor R, a longer connecting part P I and a shorter connecting part P2 are arranged. And by folding the longer connecting part P1 back for 180 in relation to the shorter connecting part P2, the longer connecting part P1 and the shorter connecting part P2 face the conductive wire 31e of the electrodes 31b and 31c respectively. The longer connecting part P I and the shorter connecting part P2 are electrically connected with the conductive wire 31e of the electrodes 31b and 31c respectively via each swaged component SW. In this way, the ends of the electrodes 31b and 31c are electrically connected with each other via the resistor R.
[0051] In addition, each swaged component SW is swaged by swaging jigs (not shown) such as a lineman's plier, and the resistor R is electrically connected with the respective conductive wire 31e of the electrodes 31b and 31c firmly. Besides, each swaged component SW are disposed on two sides of the separator SP to be centrally symmetric in relation to the separator SP, and the parts of the separator SP are prevented from being short circuited with each other.
[0052] As shown in
[0053] On the sensor bracket 40, the bracket body 41 on which the sensor 30 is fixed is arranged. Besides, on the front surface section 40b side of the bracket body 41, the groove 41a into which the bracket fixture 32b enters is arranged. And the groove 41a of the bracket body 41 extends along the bending shape of the door frame of the tailgate 12 in the state that the sensor bracket 40 is fixed to the tailgate 12 (see
[0054] A protruding section 42 is integrally arranged on the side (the left side in
[0055] Besides, a gap portion 43 is arranged between the protruding section 42 and the bracket fixture 32b. When the sensor holder 32 deforms elastically due to the contact of the blocking BL, the elastically deformed part of the sensor holder 32 (the sensor section 32a and the bracket fixture 32b) enters into the gap portion 43. That is, the gap portion 43 functions as a clearance when the sensor holder 32 deforms elastically. In this way, the sensor holder 32 is protected from breaking and so on.
[0056] Next, the manufacturing method of the touch sensor unit 20 formed in the above way is described in detail with reference to the drawings.
[0057]
[0058] As mentioned above, the touch sensor units 20 includes the sensor 30 and the sensor bracket 40, and the sensor 30 is integrated with the sensor bracket 40 by insert molding during the formation of the sensor bracket 40. First, structures of the upper and lower molds used during the insert molding of the touch sensor units 20 are described.
[0059] As shown in
[0060] On the other hand, the upper mold (second mold) 52 becomes a movable mold which is moved up and down by a hydraulically-driven mechanism (not shown), for example. On the upper mold 52, a front surface section formation convex 52a which forms the front surface section 40b (see
[0061] On the entrance side (the upper side in the drawing) of the gate path 52c of the upper mold 52, a dispenser DP supplying the molten resin MP is disposed, and the heated and melted molten resin MP is supplied from the dispenser DP to the gate path 52c under a predetermined pressure. In this way, the molten resin MP is evenly supplied to every corner inside the cavity CA which is formed by butting the upper mold 52 and the lower mold 51.
[0062] [Sensor Setting Process (First Process)]
[0063] First, as shown in
[0064] Here, in the state where the sensor 30 is set to the sensor accommodating section 51c (the state shown in
[0065] In this way, the sensor setting process is completed.
[0066] [Butting Process (Second Process)]
[0067] Next, drive the hydraulically-driven mechanism to descend the upper mold 52 as shown by an arrow M2 in
[0068] In this way, the butting process is completed.
[0069] [Molten Resin Filling Process (Third Process)]
[0070] Next, the dispenser DP is driven. In this way, the heated and melted molten resin MP is supplied from the dispenser DP to the interior of the gate path 52c under a predetermined pressure. After that, by driving the dispenser DP continuously, the molten resin MP is filled inside the cavity CA as shown by the arrow in
[0071] In addition, among the components constituting the sensor 30, the sensor body 31 which has the most important function is disposed on the bottom side of the sensor accommodating section 51c. Therefore, the heat of the molten resin MP is hard to be transferred to the sensor body 31. Accordingly, the insulating tube 31a of the sensor body 31 and the like are prevented from melting or deforming under heat.
[0072] In this way, the molten resin filling process is completed.
[0073] [Releasing Process (Fourth Process)]
[0074] Next, by forcibly cooling the upper mold 52 and the lower mold 51 with cooling water and so on (not shown), the molten resin MP is hardened. In this way, the touch sensor units 20 can be quickly and efficiently released from the upper mold 52 and the lower mold 51. Here, the method for forcibly cooling is not illustrated in detail, and a method which feeds the cooling water and so on to the cooling water path (not shown) arranged on the upper mold 52 and the lower mold 51 is adopted.
[0075] Next, the hydraulically-driven mechanism not shown is driven to ascend the upper mold 52 in relation to the lower mold 51. In this way, the upper mold 52 is released from the touch sensor units 20 which is completed by integrally molding the sensor 30 and the sensor bracket 40. After that, by driving a releasing pin (not shown) arranged on the lower mold 51, the completed touch sensor units 20 is also released from the lower mold 51 as shown by an arrow M3 in
[0076] In this way, the releasing process is completed and the manufacture of the touch sensor units 20 is ended.
[0077] As elaborated above, according to this embodiment, because the sensor holder 32 and the sensor bracket 40 made of a resin are made to be an integrally molded article, the operation to adhere by a double-faced tape as in a conventional way is not needed, wherein the sensor holder 32 inside which the pair of electrodes 31b and 31c are arranged, and the sensor bracket 40 made of a resin which holds the sensor holder 32 and is attached to the tailgate 12. Besides, because the adhesion of the double-faced tape is not needed, the surfaces of the sensor holder 32 and the sensor bracket 40 do not need to be degreased. Therefore, the manufacturing process can be simplified and the manufacturing cost can be cut down.
[0078] In addition, according to this embodiment, during an operation of filling the molten resin MP to the cavity CA, a part of the sensor holder 32 is melted by the molten resin MP, and thus integrating the sensor holder 32 and the molten resin MP, therefore, the two components can be structurally and firmly integrated. Accordingly, the touch sensor unit 20 which endures long-term use can be obtained.
[0079] Furthermore, according to this embodiment, the sensor holder 32 includes the sensor section 32a which holds the pair of electrodes 31b and 31c, and the bracket fixture 32b which is fixed to the sensor bracket 40, therefore, the sensor section 32a can be disposed away from the sensor bracket 40 by the bracket fixture 32b. In this way, the sensitivity of the sensor 30 can be maintained good. Besides, when the blocking BL makes contact and the sensor 30 is subject to the stress, the load is distributed to the thick bracket fixture 32b and the thin sensor section 32a respectively, thus, stress can be prevented from concentrating on the thin sensor section 32a and the thin sensor section 32a can be protected.
[0080] Besides, according to this embodiment, because the width W1 of the sensor section 32a along the direction across the longitudinal direction of the sensor holder 32 is the same width as the width W2 of the bracket fixture 32b (W1=W2), the shape of the mold used for the extrusion formation of the sensor holder 32 can be simplified. Besides, during the formation of the sensor bracket 40, the sensor holder 32 can be easily set to the sensor accommodating section 51c of the lower mold 51.
[0081] Furthermore, according to this embodiment, because the groove 41a into which the bracket fixture 32b enters is arranged on the sensor bracket 40, the sensor holder 32 and the sensor bracket 40 can be integrated more firmly. Accordingly, the touch sensor units 20 can endure long-term use.
[0082] The disclosure is not limited to the above embodiment, and can be modified in various ways without departing from the spirit of the disclosure. For example, in the above embodiment, a pair of electrodes 31b and 31c are spirally fixed inside the insulating tube 31a, but the disclosure is not limited to this situation, and four, six or other number of electrodes may be arranged spirally or in parallel in accordance with the thickness of the electrodes or the necessary detection performance and the like.
[0083] Besides, in the above embodiment, the case in which the touch sensor units 20 are fixed to the tailgate 12 of the vehicle 10 is shown, but the disclosure is not limited to this case, and can also be applied to a sunroof device, a slide door device, or a power window device and so on which is mounted on a vehicle. To sum it up, the disclosure can be applied to an opening/closing device which opens and closes automatically. For example, the disclosure is not limited to the application in the vehicle 10 and can also be applied to an automatic door device which is used to open and close the entrance of a building.
[0084] Besides, as long as the disclosure can be achieved, the material, shape, size, number, position and so on of the structural elements of the above embodiment can be arbitrarily set, without being limited to the above embodiment.