US 5,675,248 AGranted

Magnetic sensor with molded casing having an insert molded coil assembly, pole piece and magnet and amounting bracket assembly

AssigneeKabushi Kaisha Honda Lock

InventorsTsutomu Kurita, Kazuo Yuhi

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Abstract

Various component parts of a sensor main body are integrally insert molded, and are mounted to a mounting bracket member which is adapted to be securely attached to an external member such as a vehicle body. The sensor mount member defines a recess closely receiving an end of the molded casing, and these two parts are securely joined together by ultrasonic welding. Simultaneously, necessary electric connections are effected when the sensor main body is fitted into this recess via pin and socket connectors. Thus, both the reliability and the mechanical strength of the magnetic sensor can be ensured without involving the use potting material and the process of making electric connections which are known to complicate the fabrication process.

Claims7

Dependent claims

A magnetic sensor, comprising:

a coil assembly including electroconductive wire wound around a bobbin;
a pole piece fitted into a central bore of said coil assembly;
a permanent magnet piece attached to an inner end of said pole piece;
a molded casing;
said coil assembly, said pole piece, and said permanent magnet piece being integrally insert molded in said molded casing;
a mounting bracket assembly including a sensor mount member defining an open recess, an end of said molded casing being closely mounted in said recess, said mounting bracket assembly including a mounting bracket member integrally connected to said sensor mount member and having means for securely attaching said mounting bracket to an external member;
wherein at least one first terminal projects from said end of said molded casing mounted in said recess, and a second terminal is provided in said recess so that said first and second terminals are electrically coupled to each other when said molded casing end is mounted into said recess of said mounting bracket assembly;
and
wherein said mounting bracket member includes a reference surface and said pole piece includes an outer end surface, said molded casing being mounted in said recess to a set distance between the outer end surface and the reference surface.

6 more elements

Dependencies are inferred from the claim text.