Electronic device having molded resin case, and molding tool and method of manufacturing the same

• US 20080287008A1
• Filed: 05/13/2008
• Published: 11/20/2008
• Est. Priority Date: 05/18/2007
• Status: Abandoned Application

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Watanabe, Tatsuya, Imoto, Masahiko, Goshima, Yoshinari
• Application Number:
  US12/152,206
• Publication Number:
  US 20080287008A1
• Time in Patent Office: Days
• US Class Current: 439/620.25
• CPC Class Codes: B29C 33/123 for centering the inserts
• CPC Class Codes: G01P 1/023 for acceleration measuring devices
• CPC Class Codes: G01P 15/125 by capacitive pick-up
• CPC Class Codes: H01L 21/565 Moulds
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H01R 43/24 Assembling by moulding on contact members
• CPC Class Codes: H05K 5/0034 having an overmolded housing covering the PCB
• CPC Class Codes: H05K 5/0078 specially adapted for acceleration sensors, e.g. crash sensors, airbag sensors
• CPC Class Codes: H05K 5/065 sealed by encapsulation, e.g. waterproof resin forming an integral casing, injection moulding

Abstract

An electronic device includes an electronic circuit section, a case, and a connector housing. The electronic circuit section includes a connector terminal. The case seals the electronic circuit section in such a manner that the connector terminal protrudes to an outside of the case. The connector housing is integrated with the case and has an approximately cylindrical shape to surround an outer circumference of the connector terminal. The case and the connector housing are made of resin with a molding tool by filling resin into a case cavity and a connector-housing cavity of the molding tool in a state where the electronic circuit section is held by a holding portion of the molding tool.

Claims

1. An electronic device comprising:

an electronic circuit section that includes a connector terminal;

a case that seals the electronic circuit section in such a manner that the connector terminal protrudes to an outside of the case; and

a connector housing that is integrated with the case and that has an approximately cylindrical shape to surround an outer circumference of the connector terminal, wherein;

the case and the connector housing are made of resin with a molding tool that includes a case cavity, a connector-housing cavity, and a holding portion, by filling resin into the case cavity and the connector-housing cavity in a state where the electronic circuit section is held by the holding portion;

the connector-housing cavity has the approximately cylindrical shape and one end portion of the connector-housing cavity is communicated with the case cavity; and

the holding portion protrudes to the case cavity from a portion of an inner surface that defines the case cavity and that is partitioned by the connector-housing cavity.

2. The electronic device according to claim 1, wherein:

the electronic circuit section further includes an electronic element and a wiring member that is configured to wire the electronic element; and

the connector terminal is electrically coupled with the wiring member.

3. The electronic device according to claim 2, wherein

the wiring member is made of a metal plate and is integrated with the connector terminal.

4. The electronic device according to claim 2, wherein:

the electronic circuit section further includes a sealing member that seals the electronic element;

the sealing member is made of resin and is independent from the case and the connector housing; and

the sealing member is configured to be held by the holding portion when the case and the connector housing are made.

5. A molding tool of manufacturing an electronic device including an electronic circuit section that includes a connector terminal, a case that seals the electronic circuit section in such a manner that the connector terminal protrudes to an outside of the case, and a connector housing that is integrated with the case and that has an approximately cylindrical shape to surround an outer circumference of the connector terminal, the molding tool comprising:

a case cavity that is configured to house the electronic circuit section and to provide the case;

a connector-housing cavity that has the approximately cylindrical shape to provide the connector housing, wherein one end portion of the connector-housing cavity is communicated with the case cavity;

a holding portion that protrudes to the case cavity from a portion of an inner surface, wherein the portion of the inner surface defines the case cavity and is partitioned by the connector-housing cavity; and

a supplying passage configured to introduce resin to the case cavity and the connector-housing cavity.

6. The molding tool according to claim 5, wherein

the holding portion includes a plurality of holding elements.

7. A method of manufacturing an electronic device, comprising:

preparing a molding tool that includes a case cavity, a connector-housing cavity, and a holding portion, wherein the connector-housing cavity has an approximately cylindrical shape and one end portion of the connector-housing cavity is communicated with the case cavity, and the holding portion protrudes to the case cavity from a portion of an inner surface that defines the case cavity and that is partitioned by the connector-housing cavity;

disposing an electronic circuit section having a connector terminal in the case cavity in such a manner that the electronic circuit section is held by the holding portion; and

filling melting resin into the case cavity and the connector-housing cavity and solidifying the melting resin so as to form a case that seals the electronic circuit section in such a manner that the connector terminal protrudes to an outside of the case and the connector housing that surrounds an outer circumference of the connector terminal.

8. The method according to claim 7, wherein:

the electronic circuit section further includes an electronic element and a wiring member configured to wire the electronic element; and

the connector terminal is electrically coupled with the wiring member.

9. The method according to claim 8, wherein

the wiring member is made of a metal plate and is integrated with the connector terminal.

10. The method according to claim 8, wherein:

the electronic circuit section further includes a sealing member that seals the electronic element;

the sealing member is made of resin and is independent from the case and the connector housing; and

the sealing member is held by the holding portion when the electronic circuit section is disposed in the case cavity.

11. The method according to claim 10, wherein:

the sealing member has a plurality of inserting holes; and

the holding portion includes a plurality of holding elements respectively inserted into the plurality of inserting holes when the sealing member is held by the holding portion.

12. The method according to claim 10, wherein:

the sealing member has a plurality of grooves; and

the holding portion includes a plurality of holding elements respectively engaged with the plurality of grooves when the sealing member is held by the holding portion.