Transmission sensor with overmolding and method of manufacturing the same

Abstract

A sensor including a sensor core is disclosed. The sensor core includes a magnet, a pole piece, a bobbin, at least two terminals coupled to the bobbin, and a conductor wound about the bobbin and coupled to the terminals. At least a portion of the windings are disposed about at least a portion of the pole piece. The magnet is disposed substantially adjacent the pole piece. A support contacts at least a portion of the conductor. A supported portion of the conductor is located between the windings and the terminals. A sensor housing surrounds at least a portion of the sensor core. A method of manufacturing a sensor including providing a sensor core including a magnet, a pole piece, a bobbin, at least two terminals, and a conductor which is wound about the bobbin and coupled to the terminals is further disclosed. At least a portion of the windings surround at least a portion of the pole piece. The magnet is disposed substantially adjacent the pole piece. The method further includes adding support for a portion of conductor located in a region between windings, introducing the sensor core into a housing, and forming a seal between the sensor core and the housing. A manufacturing method including providing a magnetic circuit including a wire, the wire having a wound portion, a first portion conductively coupled to a first terminal, and second portion conductively coupled to a second terminal, the first terminal and the second terminal conductively coupled to a third terminal and a fourth terminal is also disclosed. The method further includes reinforcing a section of the wire located in a position between the wound portion and at least one of the first terminal and the second terminal, surrounding the magnetic circuit with a protective shell, and providing a seal effective to substantially seal the magnetic circuit within the shell.

Dependencies are inferred from the claim text.