Coil assembly and brake control device | Patent Publication Number 20200055507
US 20200055507 A1Nissin Kogyo Co. Ltd.
Takaaki KOMABA
Kyosuke ISHIAI
Takaaki Komaba
Kentaro Chiba
Kyosuke Ishiai
A coil assembly includes: a bobbin; a coil including a winding around the bobbin; a yoke attached to the bobbin; and a connection terminal electrically connected to the winding. The connection terminal is a press-fit terminal that includes a terminal portion projecting perpendicularly from the bobbin outward in an axial direction of the bobbin. The yoke is arranged on a side of the bobbin that is opposite to the terminal portion in an axial direction of the terminal portion, and supports the press-fit terminal.
1. A coil assembly comprising: a bobbin; a coil including a winding around the bobbin; a yoke attached to the bobbin; and a connection terminal electrically connected to the winding, p1 wherein the connection terminal is a press-fit terminal that includes a terminal portion projecting perpendicularly from the bobbin outward in an axial direction of the bobbin, and wherein the yoke is arranged on a side of the bobbin that is opposite to the terminal portion in an axial direction of the terminal portion, and supports the press-fit terminal.
The present invention relates to a coil assembly and a brake control device.
Conventionally, brake systems for vehicles such as two-wheel vehicles and four-wheel vehicles have been known to include a brake control device that controls the brake hydraulic pressure acting on a wheel brake. The brake control device includes a base body with brake fluid paths formed therein, solenoid valves attached to one surface of the base body, coil assemblies each surrounding the solenoid valves, a housing that covers the solenoid valves and the coil assemblies, and a control board functioning as an electrical component installed in the housing.
In such a brake control device, the control board controls the energization to the coil assemblies to open and close the solenoid valves, and thereby changes the brake hydraulic pressure in the brake fluid paths to control the braking force applied to the wheel brake.
The coil assembly includes a yoke, a bobbin disposed in the yoke, and a coil wound around the bobbin.
As for connection terminals connected to the coil, press-fit terminals have been known as described in Patent Literature 1, for example. The press-fit terminals are press-mounted into mounting holes of the control board, thereby electrically connecting the coil assembly to the control board. Further, the coil assembly is attached around the solenoid valve in such a way that the solenoid valve is inserted through a center hole of the bobbin, and the coil is energized from the control board, thereby opening and closing the solenoid valve.
Patent Literature 1: Japanese Patent Application Publication No. 2010-234826
In the above-mentioned conventional coil assembly, each press-fit terminal has a plurality of bent portions and extends toward the control board. When the press-fit terminal is press-fitted into the mounting hole formed in the control board, a tool provided at an equipment side is placed on a lower side of the bent portions and is pressed in such a way that the press-fit terminals are pressed toward the control board side. Therefore, a space for placing the tool needs to be formed on a lateral side of the coil assembly.
The present invention provides a coil assembly and a brake control device that solve the above-mentioned problem, is capable of being assembled to an electrical component without using a tool for assembly, and is capable of enhancing the downsizing and the flexibility of layout by eliminating a space for placing the tool.
To solve the above problems, the present invention provides a coil assembly including: a bobbin; a coil including a winding around the bobbin; a yoke attached to the bobbin; and a connection terminal electrically connected to the winding. The connection terminal is a press-fit terminal that includes a terminal portion projecting perpendicularly from the bobbin outward in an axial direction of the bobbin. The yoke is arranged on a side of the bobbin that is opposite to the terminal portion in an axial direction of the terminal portion, and supports the press-fit terminal.
According to the structure of the coil assembly in the present invention, the press-fit terminal is supported by the yoke located on a side of the bobbin that is opposite to the terminal portion in the axial direction of the terminal portion. Thus, the yoke can receive a load applied in the axial direction when the terminal portion is press-fitted into the mounting hole of the control board. This enables the coil assembly to be electrically connected to the control board without using a tool for assembly or the like. Therefore, it is possible to eliminate a tool space that has been necessary for the connection operation and to enhance the downsizing and the flexibility of layout accordingly.
The yoke of the above-mentioned coil assembly may be configured to support the press-fit terminal via an insulator, so that it is possible to suitably insulate the yoke from the press-fit terminal.
The bobbin of the above-mentioned coil assembly may preferably include a resin portion formed of a resin and serving as the insulator. According to this structure, the yoke supports the press-fit terminal via the resin portion of the bobbin, so that it is possible to suitably insulate the yoke from the press-fit terminal.
The resin portion of the above-mentioned coil assembly may preferably cover a portion of the yoke that supports the press-fit terminal. With this configuration, it is possible to suitably insulate the yoke from the press-fit terminal.
Another aspect of the present invention is a brake control device that includes the above-mentioned coil assembly and further includes: a base body in which a fluid path is formed; a solenoid valve which is attached to one surface of the base body and on which the coil assembly is mounted; a housing fixed to the one surface of the base body, the housing covering the solenoid valve and the coil assembly; and a control board housed in the housing, the control board controlling an operation of the solenoid valve. The terminal portion is press-fitted into a mounting hole formed in the control board.
According to the structure of the brake control device of the present invention, when fixing the housing to the one surface of the base body, it is possible to press-fit the press-fit terminals by sandwiching the coil assembly with the base body and the control board in the axial direction of the bobbin. In other words, the press-fit terminal is supported by the yoke located on a side of the bobbin that is opposite to the terminal portion in the axial direction of the terminal portion. Moreover, the yoke is supported by the base body located spaced apart from the terminal portion in the axial direction thereof than the side of the bobbin. This enables the base body to receive the load applied when the terminal portion of the press-fit terminal is press-fitted into the mounting hole of the control board. This enables the coil assembly to be electrically connected to the control board without using a tool for assembly or the like. Therefore, the brake control device having an excellent assembling property can be obtained.
The coil assembly and the brake control device of the present invention can be assembled to an electrical component without using a tool for assembly. Further, with the structure of the coil assembly and the brake control device of the present invention, it is possible to eliminate a space for disposing a tool and enhance the downsizing and the flexibility of layout.
Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings as appropriate. In the following description, when front, rear, left, right, upper, and lower sides of a coil assembly are referred to, directions illustrated in
Firstly, the brake control device will be described.
A brake control device U includes a base body 100 to which a pressure sensor, solenoid valves
V1 and V2, a motor M, a reciprocation pump P, and the like are assembled, as illustrated in
A not-shown brake fluid path (oil path) is formed in the base body 100. The brake control device U is configured such that the control board 201 causes the solenoid valves V1 and V2 and the motor M to operate on the basis of the motion of the vehicle body, thereby causing the brake hydraulic pressure in the brake fluid path to change.
(Configuration of Base Body)
The base body 100 is a metal component formed in a substantially rectangular parallelepiped, and the brake fluid path (oil path) is formed therein.
Of the surfaces of the base body 100, a surface 101 on a front side, referred to as one surface, has a plurality of bottomed attaching holes 110 and the like formed therein in which the solenoid valves V1 and V2 and a pressure sensor (not illustrated) are mounted. Note that, the number of the solenoid valves V1 and V2 and the pressure sensors to be used differs between cases where the vehicle is a four-wheel vehicle and cases where the vehicle is a two-wheel vehicle, and the number differs depending on the difference in the function of the brake control device, for example. Coil assemblies 1 are respectively mounted on the solenoid valves V1 and V2 of the embodiment. The solenoid valve V1 is, for example, a normally open solenoid valve. The solenoid valve V2 is, for example, a normally closed solenoid valve. The coil assemblies 1 are electrically connected to the control board 201 using press-fit terminals 10, respectively, as described later.
The base body 100 has an outlet port 111 or the like formed on a side of an upper surface 103 of the base body 100, to which outlet port 111 a piping leading to a wheel brake (not illustrated) is connected.
Moreover, base body 100 has a reservoir hole or the like formed on a side of a lower surface of the base body 100, to which reservoir hole a reservoir component (not illustrated) constituting a reservoir is assembled.
Moreover, base body 100 has a pump hole 112 or the like formed on a side of a side surface 104 of the base body 100, to which pump hole 112 the reciprocation pump P is attached.
Note that, the holes formed in the base body 100 are communicated with one another directly or via a not-illustrated brake fluid path formed in the base body 100.
(Configuration of Motor)
The motor M is an electrical component serving as a driving power source of the reciprocation pump P. The motor M is integrally fixed to a surface 102 on a rear side of the base body 100, referred to as other side of the base body 100. The motor M drives the reciprocation pump P.
A motor bus bar M1 for supplying electric power to a not-shown rotor is connected to the motor M. The motor bus bar M1 is inserted through a terminal hole (not shown) of the base body 100 and is electrically connected to the control board 201.
(Configuration of Electronic Control Unit)
As illustrated in
The control board 201 is a substantially rectangular substrate main body on which an electric circuit is printed and to which electronic components such as semiconductor chip are attached. The control board 201 controls, by computer programs stored in advance, energization of the coil assembly 1 (see
As illustrated in
The housing 202 is open-sided on the side opposite to the base body 100 and is open-sided on the side of the base body 100. The solenoid valves V1 and V2, the coil assembly 1, the pressure sensor, and the like are housed in an inner space of the housing 202.
The cover 203 is a lid which is made of a resin and which seals the opening of the housing 202 on the side thereof opposite to the base body 100. The cover 203 is fixed to an end face of the housing 202 by means of welding, bonding, screw-fastening, or the like.
As illustrated in
(Configuration of Bobbin)
As illustrated in the views in
As illustrated in
The hole 22a of the flange portion 22 has an inside diameter larger than the inside diameter D1 of the insertion hole 21a.
As illustrated in
The upper yoke housing portion 22c includes a predetermined clearance with respect to the housed upper portion 31 of the yoke 3 in a direction orthogonal to an axial direction of the bobbin 2 (in the horizontal direction). This allows the upper portion 31 of the yoke 3 to move in the horizontal direction by the clearance provided, in the upper yoke housing portion 22c.
Note that, the flange portion 22 covers the substantially entire upper portion 31 of the yoke 3, and thus has an excellent insulation property.
As illustrated in
The upper flange portion 22 has left and right rear portions with terminal support portions 22b, 22b formed thereon that respectively support base portions 11, 11 of the two press-fit terminals 10, 10. The press-fit terminals 10, 10 are partially embedded in the terminal support portions 22b, 22b by insert-molding, respectively (see
As illustrated in
As illustrated in
As illustrated in
The lower flange portion 23 has quadrangular column-shaped protrusions 25, 25 formed on left and right-side surfaces of the lower flange portion 23 on a rear side thereof. The protrusions 25, 25 each serve as a bonding surface for fixing to the base body 100 by an adhesive and serve as a positioning portion for assembling the coil assembly 1 to the brake control device U. Specifically, the protrusions 25, 25 can each be locked with a not-shown positioning member (rib, protrusion, or the like) provided on the front surface 101 (surface on which the solenoid valves V1 and V2 are mounted) of the base body 100, for example. By this locking, the coil assembly 1 mounted on the solenoid valve V1 or V2 is positioned so as to be unable to turn around an axis of the bobbin 2. Moreover, the protrusions 25, 25 can be locked with a not-shown wall portion provided on the inner side of the housing 202, for example. This wall portion is arranged around the coil assembly 1 and has grooves with which the protrusions 25, 25 are locked by press-insertion or the like.
The bobbin 2 described above is produced by injection-molding or the like. When the bobbin 2 is injection-molded, the press-fit terminals 10, 10 are insert-molded at the same time in such a way as to be integrally joined to the flange portion 22.
(Configuration of Yoke)
The yoke 3 is formed of a metal material having magnetic properties. As illustrated in the views in
The upper portion 31 is a part that is housed in the upper yoke housing portion 22c of the upper flange portion 22 of the bobbin 2 (see
Note that, the upper portion 31 is formed to have an outer shape that is slightly smaller than that of the lower portion 32, as illustrated in
The upper portion 31 is housed in the upper yoke housing portion 22c, and thus is arranged below the press-fit terminals 10 with the upper flange portion 22 in between. In other words, the press-fit terminals 10 (terminal portions 12 and base portions 11) are supported by the upper portion 31 located on a side of the upper flange portion 22 that is opposite to the terminal portions 12 in an axial direction thereof.
The lower portion 32 is a part that is housed in the lower yoke housing portion 23a of the lower flange portion 23 of the bobbin 2 (see
As illustrated in
The lower portion 32 is configured so as to be housed in the lower yoke housing portion 23a with a clearance therebetween, and is movable in the horizontal direction with respect to the lower yoke housing portion 23a in a state where the convex portions 23b, 23b are loosely fitted with the recessed portions 32b, 32b as described above. In other words, the convex portions 23b are fitted with the recessed portions 32b in such a way as to allow the above-described movement in the horizontal direction.
The yoke 3 has a circular insertion hole 31a formed in the upper portion 31 as a yoke-side mounting hole and has a circular mounting hole 32a formed in the lower portion 32. These insertion holes 31a, 32a have substantially the same inside diameter D2 as illustrated in
(Configuration of Press-Fit Terminal)
As illustrated in
As illustrated in the views in
As illustrated in
As illustrated in
The connection portion 13 is connected to the winding 51 of the coil 50. The connection portion 13 has a contact portion 14 with which the winding 51 comes into contact and which has a smaller plate thickness than other portion of the connection portion 13. In other words, the press-fit terminal 10, the plate thickness of which is likely to be limited due to the requirement for being press-fitted, is configured such that the connection portion 13 to which the winding 51 is connected is thin-walled to scrape off the coating of the winding 51 by the contact.
As illustrated in
As illustrated in
The press-fit terminal 10 can be obtained by pressworking (press punching), for example. In the press punching, a flat, belt-like metal plate or the like having conductivity and a predetermined thickness is used to obtain a press punched material including the press-fit terminals 10, as illustrated in
The thin-walled contact portion 14 is formed to have a thin thickness by performing an additional pressworking after the press punching has been performed. Thereafter, the groove 15 is formed by punching.
Note that, the contact portion 14 may be formed by pressworking at the same time as when the press punching is performed, or the contact portion 14 may be formed in advance by pressworking and then the punching-out may be performed.
(Configuration of Coil)
The coil 50 is obtained by winding the wire of the winding 51 around the cylindrical portion 21 of the bobbin 2, as illustrated in
Firstly, as illustrated in
Thereafter, the end portions of the winding 51 of the coil 50 are wound around the connection portions 13, 13 of the press-fit terminals 10, 10 to connect the winding 51 to the connection portions 13, 13, respectively. In this operation, as illustrated in
At this time, when the wire of the winding 51 comes into contact with the step portion 16 of the groove 15, the scraping-off of the coating of the winding 51 is facilitated, and the electrical connection of the winding 51 is reliably established. Moreover, as the width L1 (width in the left-and-right direction) of the groove 15b defined by the step portions 16, 16 of the groove 15 is smaller than the wire diameter D3 (wire diameter of the wire with coating) of the winding 51, the coating of the wire of the winding 51 is scrapped off more suitably by inserting the wire of the winding 51 into the deepest part 15c in the winding operation.
Thereafter, as illustrated in
Note that, when the yoke 3 is inserted in the mounting direction more than necessary, the side portion 33 of the yoke 3 abuts on the protrusions 22e, 22e provided on the upper flange portion 22 of the bobbin 2. This prevents the yoke 3 from coming into contact with the coil 50.
In this way, the assembling of the coil assembly 1 is completed.
According to the embodiment of the brake control device U, as illustrated in
When attaching the coil assembly 1 to the brake control device U, firstly, the coil assemblies 1 are mounted on the solenoid valves V1 and V2 having been attached to the base body 100. In this operation, if not-shown positioning members such as ribs are provided on the surface 101 on the front side of the base body 100, the protrusions 25, 25 of the bobbin 2 of the coil assembly 1 are locked with the positioning members. This positions the coil assembly 1 so as to be unable to turn around the axis of the bobbin 2. Accordingly, the press-fit terminals 10 are disposed at predetermined positions of the base body 100.
Thereafter, the housing 202 is attached to the base body 100. Subsequently, the control board 201 is brought closer to the housing 202, the press-fit terminals 10 are placed into mounting holes 205 of the control board 201, and the control board 201 is pressed toward the base body 100.
In this situation, as illustrated in
The lower portion 32 of the yoke 3 is abutted on the surface 101 of the front side of the base body 100. This enables the base body 100 (product) to receive the load that is applied in the axial direction when the terminal portion 12 is press-fitted into the mounting hole 205 of the control board 201.
The inside diameter D1 of the insertion hole 21a of the bobbin 2 is larger than the inside diameter D2 of the insertion holes 31a, 32a of the yoke 3. This allows, when placing the press-fit terminals 10 into mounting holes 205 of the control board 201, sliding of the bobbin 2 in a direction orthogonal to the axial direction of the solenoid valves V1 and V2 relative to the yoke 3 attached to the solenoid valves V1 and V2. Accordingly, the positioning of the press-fit terminals 10 with respect to the mounting holes 205 of the control board 201 is easy.
After the positioning has been completed, the control board 201 is pressed toward the base body 100, so that the terminal portions 12 are press-fitted into the mounting holes 205 of the control board 201. This electrically connects the coil assembly 1 to the control board 201 via the press-fit terminals 10.
According to the above-described structure of the coil assembly 1 of the embodiment, the yoke 3 supports the press-fit terminals 10, at a location spaced apart from the terminal portions 12 in the axial direction of the terminal portions 12. Thus, the yoke 3 can receive the load that is applied in the axial direction when the terminal portions 12 are press-fitted into the mounting holes 205 of the control board 201. This enables the coil assembly 1 to be electrically connected to the control board 201 without using a tool for assembly or the like. Therefore, it is possible to eliminate a space for placing a tool that was necessary for connection and to enhance the downsizing and the flexibility of layout accordingly.
The yoke 3 supports the press-fit terminals 10 via the bobbin 2 (upper flange portion 22) serving as an insulator. Therefore, it is possible to suitably insulate the yoke 3 from the press-fit terminals 10. Note that, the bobbin 2 is entirely made of resin, and thus insulation is easily achieved.
As the terminal support portions 22b, 22b (resin portions) of the bobbin 2 cover portions of the yoke 3 that support the press-fit terminals 10 (portions of the upper portion 31 that support the press-fit terminals 10), it is possible to suitably insulate the yoke 3 from the press-fit terminals 10.
According to the structure of the brake control device U of the embodiment, when fixing the housing 202 to the one surface of the base body 100, it is possible to press-fit the press-fit terminals 10 by sandwiching the coil assembly 1 with the base body 100 and the control board 201 in the axial direction of the bobbin 2. In other words, the press-fit terminals 10 are supported by the yoke 3 located on a side of the bobbin 2 that is opposite to the terminal portions 12 in the axial direction of the terminal portions 12. Moreover, the yoke 3 is supported by the base body 100 located spaced apart from the terminal portions 12 in the axial direction of the terminal portions 12 than the side of the bobbin 2. This enables the base body 100 to receive the load applied when the terminal portions 12 of the press-fit terminals 10 are press-fitted into the mounting holes 205 of the control board 201. This enables the coil assembly 1 to be electrically connected to the control board 201 without using a tool for assembly or the like. Therefore, the brake control device U having an excellent assembling property can be obtained.
The present invention has been described in the foregoing on the basis of the embodiment. However, the present invention is not limited to the configuration of the embodiment described. The configuration can be changed as appropriate in a range without departing the scope of the present invention. Moreover, a part of the configuration of the embodiment can be added, removed, and replaced.
For example, although the bobbin 2 is described as being entirely formed of a resin, the embodiment is not limited thereto. At least portions that support the press-fit terminals 10 maybe formed of a resin to cause this resin portion to function as an insulator.
Moreover, the terminal portion 12 of each press-fit terminal 10 only needs to protrude upward from the bobbin 2, and the connection portion 13 and the like of the press-fit terminal 10 may be disposed on a lateral side and the like of the bobbin 2.
Moreover, although the press-fit terminals 10 have been described as being insert-molded in the bobbin 2, the press-fit terminals 10 are not limited thereto and may be adapted to be attached to the bobbin 2 later.
Moreover, the press-fit terminals 10 may be configured to be attached to the bobbin 2 via insulators separated from the bobbin 2. In this case, the separate insulators may be configured to cover portions of the yoke 3 that support the press-fit terminals 10.
1 coil assembly
2 bobbin
3 yoke
10 press-fit terminal (connection terminal)
12 terminal portion
13 connection portion
14 contact portion
15 groove
16 step portion
21a insertion hole
31a, 32a insertion hole
22 upper flange portion (insulator, resin portion)
23 lower flange portion
31 upper portion (end portion)
32 lower portion (end portion)
33 side portion
50 coil
51 winding
100 base body
201 control board
205 mounting hole
202 housing
L1 width of groove (deepest portion)
D1 inside diameter of insertion hole on bobbin side
D2 inside diameter of insertion hole on yoke side
D3 wire diameter of winding
V1, V2 solenoid valve (mounted body)
U brake control device