Foreign matter detection sensor

A foreign matter detection sensor includes a sensor section, power supply members, a sealing member, and includes an elastic elongated hollow insulating body with separated electrode wires inside the insulating body. The sensor section includes a first end and a second end and detects foreign matter by receiving external force from the foreign matter and being elastically deformed. The power supply members are electrically connected to the electrode wires at the second end of the sensor section via electrode connecting portions. Each power supply member includes a direction changing section, extending from an associated electrode connecting portion in a direction intersecting the longitudinal direction of the sensor section and further extends in a direction toward the first end of the sensor section. The sealing member on the second end of the sensor section seals the electrode connecting portions, the direction changing sections, and one end of the hollow body.

TECHNICAL FIELD

The present invention relates to a foreign matter detection sensor.

BACKGROUND ART

An electric door opening and closing apparatus has been proposed that selectively opens and closes an opening portion (such as a door opening and a tail opening) formed in a vehicle body by moving a door panel through driving force of for example, a motor. In such an opening and closing apparatus, to prevent foreign matter from being caught between the edge of the opening portion and the door panel, a foreign matter detection sensor as disclosed in, for example, Japanese Laid-Open Patent Publication No, 2007-176322 has been proposed for detecting foreign matter located between the edge of the opening portion and the door panel.

The foreign matter detection sensor disclosed in the above-mentioned patent document includes an elongated sensor section that elastically deforms when contacting foreign matter. The sensor section, is mounted on the end portion of the door panel to extend in the vertical direction. A lead wire for supplying current to the sensor section is connected to the lower end of the sensor section. The lead wire extends from the lower end of the sensor section in the longitudinal direction of the sensor section. After being folded back upward at the lower end of the sensor section, the lead wire is drawn into the door panel. That is, after extending downward from the lower end of the sensor section in the longitudinal direction of the sensor section, the lead wire is folded back upward in a substantially U-shape and is drawn into the door panel. According to the above-mentioned foreign matter detection sensor, the foreign matter is detected by the sensor section that elastically deforms by the foreign matter that contacts the sensor section.

The above-mentioned foreign matter detection sensor is arranged such that not only the sensor section but also the lead wire folded back in a substantially U-shape at the lower end of the sensor section is arranged at the end portion of the door panel within a vertical range of the door panel. Therefore, the range in which the sensor section is arranged becomes narrow in the longitudinal direction of the sensor section by the amount corresponding to the lead wire that is folded back in a substantially U-shape at the lower end of the sensor section. As a result, the length of the sensor section is reduced. Since the foreign matter detection sensor is for detecting foreign matter that contacts the sensor section, if the length of the sensor section is reduced, the range in which the foreign matter is detected is undesirably reduced in the longitudinal direction of the sensor section.

Accordingly, it is an objective of the present invention to provide a foreign matter detection sensor that has an increased detection range in the longitudinal direction of the sensor section.

Means for Solving the Problems

To achieve the foregoing objective and in accordance with one aspect of the present invention, a foreign matter detection sensor is provided that includes an elongated sensor section, power supply members, and sealing member. The elongated sensor section includes an elongated elastic hollow insulating body and a plurality of electrode wires arranged inside the hollow insulating body to be separate from each other. The sensor section includes a first end and a second end in a longitudinal direction, and the sensor section detects foreign matter by receiving external force from the foreign matter and being elastically deformed. The power supply members are electrically connected to the electrode wires drawn out from the hollow insulating body at the second end of the sensor section via electrode connecting portions. Each power supply member includes a direction changing section, which extends from the associated electrode connecting portion in a direction intersecting the longitudinal direction of the sensor section and further extends in a direction toward the first end of the sensor section. The sealing member is provided on the second end of the sensor section, wherein the sealing member incorporates and seals the electrode connecting portions, the direction changing sections, and one longitudinal end of the hollow insulating body corresponding to the second end of the sensor section.

Effects of the Invention

The foreign matter detection sensor of the present invention increases the detection range in the longitudinal direction of the sensor section.

MODES FOR CARRYING OUT THE INVENTION

First Embodiment

A foreign matter detection sensor according to a first embodiment of the present invention will now be described.

As shown inFIG. 1, a vehicle1includes a motor-driven back door device2. At the rear part of a vehicle body3constituting the vehicle1, a tail opening4is formed. The tail opening4is selectively opened and closed by a door panel5, which has a shape corresponding to the tail opening4. The upper end of the door panel5is rotationally coupled to the upper end of the rear side surface of the vehicle body3. Thus, the door panel5is rotational in the vertical direction about the coupling portion between the door panel5and the vehicle body3, and is moved between a fully closed position and a fully opened position. The fully closed position is a position at which the door panel5fully closes the tail opening4, and the fully opened position is a position at which the door panel5fully opens the tail opening4.

A drive mechanism (not shown) is connected to the door panel5. The drive mechanism is located on the vehicle body3and includes an actuator6shown inFIG. 2. According to the motor-driven back door device2, when the actuator6is driven, the door panel5is rotated in the vertical direction to selectively open and close the tail opening4.

As shown inFIG. 2, the actuator6includes a motor7, and a speed reduction mechanism (not shown), which decelerates and outputs the rotation of the motor7. A position detection device8, which detects rotation of the motor7, is located in the actuator6. The position detection device8includes a magnet, which is provided, to rotate integrally with a rotary shaft of the motor7or a speed reducing gear of the speed reduction mechanism, and a hall IC, which is located opposite to the magnet. The hall IC outputs, as position detection signals, pulse signals corresponding to changes of the magnetic field of the magnet caused by rotation of the magnet.

The motor-driven back door device2includes a manipulation switch9for giving directions to selectively open and close the door panel5. As shown inFIGS. 1 and 2, when the manipulation switch9is manipulated by, for example, an occupant of the vehicle1to open the tail opening4, the manipulation switch9outputs an opening signal for rotating the door panel5to open the tail opening4. When the manipulation switch9is manipulated by, for example, the occupant to close the tail opening4, the manipulation switch9outputs a closing signal for rotating the door panel5to close the tail opening4. The manipulation switch9is provided on, for example, a predetermined position in the passenger compartment such as a dashboard, a door lever (not shown) of the door panel5, and a carrying item carried with an ignition key.

The motor-driven back door device2includes a foreign matter detection apparatus11for detecting foreign matter located between the edge of the door panel5and the edge of the tail opening4opposing the edge of the door panel5. The foreign matter detection apparatus11includes foreign matter detection sensors13, which are mounted on the edges of the door panel5via brackets12, and a current detector14, which is electrically connected to the foreign matter detection sensors13.

As shown inFIG. 1, the brackets12are secured to the edges of the door panel5opposing the edges of the tail opening4. More specifically, the brackets12are secured to both ends of the inner surface of the door panel5(that is, the side of the door panel5facing the vehicle compartment) in the left and right direction. The brackets12have a substantially band-like shape and extend vertically along the left and right ends of the door panel5.

The foreign matter detection sensors13are long strings. Each foreign matter detection sensor13includes a sensor section21that is a long string. As shown inFIG. 3, the sensor section21includes a long hollow insulating body22formed of elastically deformable insulating material (such as soft plastic material and elastomer). A band-like adhesion surface22a, which extends in the longitudinal direction of the hollow insulating body22, is formed on the outer circumferential surface of the hollow insulating body22. The adhesion surface22ais straight on a cross-section that is orthogonal to the longitudinal direction of the hollow insulating body22(for example, the end face22fof the hollow insulating body22in the longitudinal direction shown inFIG. 3). Part of the outer circumferential surface of the hollow insulating body22except the adhesion surface22ais substantially U-shaped and is open toward the adhesion surface22aon the cross-section that is orthogonal to the longitudinal direction of the hollow insulating body22. That is the cross-section of the hollow insulating body22that is orthogonal to the longitudinal direction is substantially D-shaped.

A hollow bore22b, which extends in the longitudinal direction of the hollow insulating body22, is formed inside the hollow insulating body22. Four separation recesses22care formed to extend toward the outer circumference on the cross-section of the hollow bore22bthat is orthogonal to the longitudinal direction of the hollow insulating body22. The separation recesses22care formed in four locations in the circumferential direction of the cross-section of the hollow insulating body22, and are connected to one another at substantially the center portion of the cross-section. That is, the cross-sectional shape in the direction orthogonal to the longitudinal direction of the hollow insulating body22is substantially X-shaped. The four separation recesses22ceach extend in a helical form in the longitudinal direction of the hollow insulating body22. Since the hollow bore22bis formed, the hollow insulating body22is hollow.

Two electrode wires23,24, which are held by the hollow insulating body22, are arranged inside the hollow insulating body22to oppose each other with a space in between. Each of the electrode wires23,24includes a flexible core electrode25, which is formed by twisting conductive thin wire, and a cylindrical conductive coating layer26, which has conductivity and elasticity and coats the outer circumference of the core electrode25. The two electrode wires23,24are arranged inside the hollow insulating body22between the four separation recesses22c, which are arranged in the circumferential direction. Two of the separation recesses22care arranged between the electrode wire23and the electrode wire24in the circumferential direction of the cross-section that is orthogonal to the longitudinal direction of the hollow insulating body22. Furthermore, the two electrode wires23,24are arranged inside the hollow insulating body22to be arranged at equal angular intervals in the circumferential direction (in this embodiment, intervals of 180°), and while keeping the intervals (intervals in the circumferential direction) to be constant, the two electrode wires23,24helically extend along the separation recesses22cin the longitudinal direction of the hollow insulating body22. Parts of the electrode wires23,24are embedded in the hollow insulating body22on the inner side of the hollow insulating body22, and held by the hollow insulating body22. The two electrode wires23,24oppose each other in the direction that is orthogonal to the longitudinal direction of the hollow insulating body22via the hollow bore22bat any position in the longitudinal direction of the hollow insulating body22.

One of the longitudinal ends of the hollow insulating body22that is closer to the coupling portion between the door panel5and the vehicle body3(the left end inFIG. 2) is referred to as a first end22d, and the other end. (the right end inFIG. 2) is referred to as a second end22e. One of the ends of the sensor section21that corresponds to the first end22dis referred to as a first end21d, and the other end corresponding to the second end22eis referred to as a second end21e. The core electrodes25of the two electrode wires23,24are each drawn out from the first end22dof the hollow insulating body22, and a resistor28is electrically connected between the two core electrodes25. That is, the two electrode wires23,24are electrically connected via the resistor28on the first end22dof the hollow insulating body22.

Also, as shown inFIG. 1, a terminal processing section31is provided on the second end22eof each hollow insulating body22. As shown inFIGS. 5(a) and5(b), each terminal processing section31includes a support member32, which is arranged adjacent to the second end22eof the hollow insulating body22, two power supply members30, which supply electricity to the electrode wires23,24, and a sealing member34, which embeds and seals, for example, the support member32.

The support member32is formed of insulating plastic material. The support member32includes a terminal support portion41and a spacer42formed, integrally with the terminal support portion41.

The terminal support portion41supports terminals33on both end faces in the thickness direction. The terminals33are formed of conductive metal plate material. Each terminal33includes a rectangular plate-like terminal main body51, which has a transverse direction and a longitudinal direction, and a first connection piece52and a second connection piece53, which are formed integrally with the terminal main body51.

The longitudinal measurement of each terminal main body51is substantially the same as the longitudinal measurement of the terminal support portion41, and the transverse measurement of each terminal main body51is substantially the same as the transverse measurement of the terminal support portion41. The two terminal main bodies51are arranged on end faces of the terminal support portion41in the thickness direction such that the longitudinal direction, the transverse direction, and the thickness direction of the two terminal main bodies51match with the longitudinal direction, the transverse direction, and the thickness direction of the terminal support portion41. As viewed from the thickness direction of the terminal support portion41(that is, the state shown inFIG. 5(b)), the two terminal main bodies51are arranged on the end faces of the terminal support portion41to be located within the range of the outer shape of the terminal support portion41. The terminal support portion41supports the two terminals33to form a double structure in which the two terminals33overlap each other in the thickness direction while insulating the terminals33from each other.

In each terminal33, the first connection piece52extends from one longitudinal end of the terminal main body51(the upper end inFIG. 5(b)), and the second connection piece53extends from the other longitudinal end of the terminal main body51(the lower end inFIG. 5(b)). The first connection piece52and the second connection piece53are rectangular plates.

A guide portion43is integrally formed on one longitudinal end of the terminal support portion41. The guide portion43projects in one transverse direction of the terminal support portion41. As shown inFIGS. 3 and 5(b), the measurement of the guide portion43in the longitudinal direction of the terminal support portion41is substantially equal to the longitudinal measurement of the opening portion of the hollow bore22bat the end face22fon the second end22eof the hollow insulating body22(vertical measurement inFIG. 3). The measurement of the guide portion43in the thickness direction of the terminal support portion41is substantially equal to the thickness of the terminal support portion41including the terminal main body51.

The spacer42is integrally formed with the distal end of the guide portion43. The spacer42protrudes from the distal end center of the guide portion43in the transverse direction of the terminal support portion41. The spacer42is columnar. The diameter of the spacer42is substantially equal to the width of the gap between the electrode wires23,24, which oppose each other inside the hollow insulating body22, and is less than the thickness of the terminal support portion41. The support member32is mounted on the hollow insulating body22in the state in which the distal end portion of the spacer42is inserted in the hollow bore22bfrom the second end22eof the hollow insulating body22. In the first embodiment, the spacer42is inserted in the hollow bore22buntil the distal end face of the guide portion43abuts against the second end22eof the hollow insulating body22. The spacer42, which is inserted in the hollow bore22b(inside of the hollow insulating body22) from the second end22e, is arranged between the two electrode wires23,24on the second end22eand prevents contact between the electrode wires23,24.

As shown inFIGS. 5(a) and5(b), the terminal support portion41of the support member32is arranged relative to the sensor section21such that the thickness direction of the terminal support portion41is parallel to the widthwise direction of the adhesion surface22a. As shown inFIG. 4, the terminal support portion41opposes the widthwise center portion of the adhesion surface22ain the longitudinal direction of the sensor section21(the direction perpendicular to the surface of the sheet ofFIG. 4). As shown inFIG. 5(b), the longitudinal end of the terminal support portion41that is opposite to the end on which the guide portion43is provided (that is, the end on which the second connection piece53is arranged) protrudes to the outer circumference of the hollow insulating body22beyond the adhesion surface22a. The longitudinal direction of the terminal support portion41is a direction that is orthogonal to the longitudinal direction of the sensor section21(in the first embodiment, the direction perpendicular to the adhesion surface22a). Part of the terminal support portion41on the front side of the adhesion surface22a(below the adhesion surface22ainFIG. 5(b)) is longer than part of terminal support portion41on the back side of the adhesion surface22a(above the adhesion surface22ainFIG. 5(b)). Thus, the two terminals33supported by the terminal support portion41are arranged adjacent to the second end22eof the hollow insulating body22such that the transverse direction of the terminals33corresponds to the longitudinal direction of the sensor section21, and that the longitudinal direction of the terminals33is orthogonal to the longitudinal direction of the sensor section21. The longitudinal direction of the terminals33is a direction that is orthogonal to the longitudinal direction of the sensor section21(in the first embodiment, the direction orthogonal to the adhesion surface22a), Part of the terminals33on the front side of the adhesion surface22ais longer than part of the terminals33on the back side of the adhesion surface22a.

As shown inFIG. 3, the core electrodes25of the electrode wires23,24are drawn out from the second end22eof the hollow insulating body22. In the first embodiment, the end face22fat the second end22eof the hollow insulating body22is formed at a position where the helically extending two electrode wires23,24are separate in the direction parallel to the widthwise direction of the adhesion surface22a. The end face22fforms a right angle with the adhesion surface22a. Thus, on the end face22f, a straight line L1that passes through the centers of the electrode wires23,24is parallel to the widthwise direction of the adhesion surface22a.

As shown inFIG. 4, since the terminal support portion41opposes, in the longitudinal direction of the sensor section21, the center portion of the second end22eof the hollow insulating body22in the widthwise direction of the adhesion surface22a, the core electrodes25of the two electrode wires23,24that are drawn out from the second end22eof the hollow insulating body22are drawn out on both sides of the terminal support portion41in the thickness direction. That is, the terminal support portion41is arranged between the two core electrodes25. Each terminal main body51and the opposing core electrode25are electrically connected on both sides of the terminal support portion41in the thickness direction. More specifically, the two core electrodes25extend on both sides of the terminal support portion41of the guide portion43in the thickness direction and are each arranged on the associated terminal main body51. The first connection piece52of each terminal33is folded back to overlap the terminal main body51, and sandwiches the associated core electrode25arranged on the terminal main body51between the first connection piece52and the terminal main body51. The core electrode25sandwiched between the terminal main body51and the first connection piece52is electrically connected to the terminal33by soldering. InFIG. 5(b), a solder61, which electrically connects the core electrode25to the terminal33, is shown by a broken line in which a long dash alternates with a pair of short dashes. In this manner, the core electrodes25of the electrode wires23,24are each electrically connected to one longitudinal end of the associated one of the two terminal main bodies51. That is, a connection portion between each terminal33and the core electrode25of the associated one of the electrode wires23,24, which is an electrode connecting portion P1in the first embodiment, is formed on one longitudinal end of each terminal33(the direction orthogonal to the longitudinal direction of the sensor section21) adjacent to the longitudinal end (the second end22e) of the sensor section21in the longitudinal direction of the sensor section21.

As shown inFIGS. 4 and 5(b), lead wires71,72are respectively electrically connected to the terminals33. The lead wires71,72are coated wires each including a conductive metal wire73coated by an insulating coating74. The insulating coating74is removed at the distal end of each of the lead wires71,72, and the metal wire73is exposed. The two lead wires71,72are each connected to the associated terminal33at a position that is displaced from the electrode connecting portion P1in the direction orthogonal to the longitudinal direction of the sensor section21. One of the two power supply members30according to the first embodiment is configured by the terminal33corresponding to the lead wire71, and the other is configured by the terminal33corresponding to the lead wire72.

The electrical connection between the lead wires71,72and the terminals33will now be described. In the vicinity of the second end22eof the hollow insulating body22, the two lead wires71,72are arranged to be adjacent to the sensor section21in the direction that is orthogonal to the longitudinal direction of the sensor section21at a position facing the adhesion surface22aof the hollow insulating body22, and to be parallel to the sensor section21. That is, in the vicinity of the longitudinal end of the sensor section21close to the terminal processing section31, the lead wires71,72are arranged relative to the terminals33such that the longitudinal direction of the lead wires71,72(arrow A inFIG. 5(b)) forms an angle of 0° with the longitudinal direction of the sensor section21(arrow B inFIG. 5(b)). Thus, in the vicinity of the longitudinal end of the sensor section21close to the terminal processing section31, the longitudinal direction of the lead wires71,72is parallel to the longitudinal direction of the sensor section21. The distal ends of the two lead wires71,72(parts where the metal wires73are exposed) are arranged on both sides of the terminal support portion41in the thickness direction. Thus, the distal ends of the two lead wires71,72are adjacent to the terminals33, which are arranged on both ends of the terminal support portion41in the thickness direction, in the thickness direction of the terminal support portion41. The distal ends of the lead wires71,72extend straight on the terminal main bodies51in the longitudinal direction of the sensor section21. The distal ends of the lead wires71,72are at positions displaced from the electrode connecting portions P1in the direction that is orthogonal to the longitudinal direction of the sensor section21(arrow C inFIG. 5(b)), which is the longitudinal direction of the terminal main bodies51. Each of the lead wires71,72opposes the terminal main body51of the associated terminal33in the thickness direction of the terminal support portion41. Thus, the distal end of each of the lead wires71,72opposes the associated terminal main body51in the thickness direction of the terminal support portion41at the longitudinal end of the terminal main body51of the terminal33on which the second connection piece53is provided. The second connection piece53of each terminal33is folded back to overlap the terminal main body51and sandwiches the distal end of the associated one of the lead wires71,72arranged on the terminal main body51between the second connection piece53and the terminal main body51. The distal end of each of the lead wires71,72sandwiched between the terminal main body51and the second connection piece53is electrically connected to the terminal33by soldering. InFIG. 5(b), a solder62that electrically connects each of the lead wires71,72to the associated terminal33is shown by a broken line in which a long dash alternates with a pair of short dashes. In this manner, the two lead wires71,72are electrically connected to the longitudinal ends of the terminal main bodies51of the two terminals33where the second connection pieces53are provided, and at the positions displaced from the electrode connecting portions P1in the direction that is orthogonal to the longitudinal direction of the sensor section21, which is the longitudinal direction of the terminal main bodies51. That is, the lead wire connecting portions P2, which are the connecting portions of the terminals33and the lead wires71,72, are formed at positions of the terminals33displaced from the electrode connecting portions P1in the direction that is orthogonal to the longitudinal direction of the sensor section21toward the outer circumference of the hollow insulating body22. As shown inFIG. 4, the lead wire connecting portion P2that is located on one side of the terminal support portion41in the thickness direction and the lead wire connecting portion P2that is located on the other side of the terminal support portion41in the thickness direction are displaced from each other in the longitudinal direction of the terminal support portion41, which is the direction that is orthogonal to the longitudinal direction of the sensor section21. The thickness direction of the terminal support portion41corresponds to the widthwise direction of the adhesion surface22ain the first embodiment.

Since the lead wires71,72are connected to the terminals33as described above, the distal ends of the lead wires71,72and the end portions of the terminals33to which the lead wires71,72are connected form a bent portion301, which is bent at substantially a right angle. The bent portion301is bent such that part of the power supply member30extending in the direction opposite to the electrode connecting portion P1from the bent portion301extends toward the first end of the sensor section21. The terminal33and the bent portion301of each power supply member30configure a direction changing section310. With this configuration, the direction changing section310extends from the electrode connecting portion P1in the direction intersecting the longitudinal direction of the sensor section21, and further extends toward the first end21dof the sensor section21in the longitudinal direction.

The sealing member34is formed of insulating plastic material. As shown inFIGS. 5(a) and5(b), the sealing member34embeds and seals part of the support member32located outside of the hollow insulating body22, the terminals33, the electrode connecting portions P1, the lead wire connecting portions P2, and the second end22eof the hollow insulating body22. The sealing member34includes a terminal coating section81, which is adjacent to the second end22eof the hollow insulating body22in the longitudinal direction of the sensor section21, and a mounting leg82, which is formed integrally with the terminal coating section81.

The terminal coating section81embeds the second end22eof the hollow insulating body22, and is formed integrally with the end face22fof the hollow insulating body22on the second end22e. The terminal coating section81embeds and seals part of the terminal support portion41adjacent to the second end22eof the hollow insulating body22in the longitudinal direction of the sensor section21, part of the two terminals33adjacent to the second end22eof the hollow insulating body22in the longitudinal direction of the sensor section21(approximately half of the terminals33in the longitudinal direction where the electrode wires23,24are connected), the guide portion43, and the electrode connecting portions P1. Thus, the sealing member34seals the direction changing section310. As shown inFIG. 4, the outer shape of the terminal coating section81is a size larger than the outer shape of the hollow insulating body22, and the shape of the cross-section of the terminal coating section81orthogonal to the longitudinal direction of the sensor section21is substantially a D-shape. As shown inFIGS. 5(a) and5(b), the end of the terminal coating section81close to the second end22eof the hollow insulating body22is in close contact with the second end22eto be liquid-tight and air-tight.

The mounting leg82is formed integrally with the end of the terminal coating section81close to the lead wires71,72and the adhesion surface22aon the second end22eof the hollow insulating body22. The mounting leg82protrudes further outward than the outer circumferential surface of the hollow insulating body22, and is substantially a rectangular solid in the first embodiment. The mounting leg82has a width slightly greater than the adhesion surface22a. The measurement of the mounting leg82in the longitudinal direction of the sensor section21is substantially equal to the measurement of the terminal coating section81in the longitudinal direction of the sensor section21. The mounting leg82incorporate and seals part of the terminal support portion41that protrudes further outward than the outer circumferential surface of the hollow insulating body22, parts of the two terminals33that protrude further outward than the outer circumferential surface of the hollow insulating body22(approximately half of the terminals33in the longitudinal direction where the lead wires71,72are connected), and the lead wire connecting portions P2. The mounting leg82embeds and seals the distal ends of the lead wires71,72(parts where the metal wires73are exposed and the distal ends of the insulating coatings74). The longitudinal direction of the sealing member34is the direction that is orthogonal to the longitudinal direction of the sensor section21(the direction orthogonal to the adhesion surface22ain the first embodiment). Part of the sealing member34at the front side of the adhesion surface22ais longer than part of the sealing member34at the back side of the adhesion surface22a.

The two lead wires71,72are drawn out to the outside of the mounting leg82from one of longitudinal end faces (an end face82a) of the mounting leg82closer to the sensor section21to be parallel to the sensor section21. Thus, draw-out positions P3of the sealing member34where the lead wires71,72are drawn out from the sealing member34are located on the end face82a. Inside the sealing member34, the lead wire connecting portions P2are displaced relative to the electrode connecting portions P1on the terminals33in the direction that is orthogonal to the longitudinal direction of the sensor section21(arrow C inFIG. 5(b)) to approach the draw-out positions P3. Inside the sealing member34, the lead wires71,72extend straight from the lead wire connecting portions P2to the draw-out positions P3.

As shown inFIG. 4, a pair of mounting engagement portions83is formed in the mounting leg82. The pair of mounting engagement portions83is formed on both widthwise sides of the mounting leg82(the direction that is the same as the widthwise direction of the adhesion surface22a), that is, on both sides of the mounting leg82in the thickness direction of the terminal support portion41. The mounting engagement portions83are grooves that extend in the longitudinal direction of the sensor section21, and through the mounting leg182in the longitudinal direction of the sensor section21. The pair of mounting engagement portions93is formed between the electrode connecting portions P1and the lead wire connecting portions P2in the longitudinal direction of the terminal support portion41(the vertical direction inFIG. 4), and between the first connection pieces52and the second connection pieces53. The width of the part of the mounting leg82where the pair of mounting engagement portions83is formed (the width in the direction that is the same as the widthwise direction of the adhesion surface22a) is reduced. However, the terminal support portion41and the terminal main bodies51are embedded between bottom surfaces83aof the pair of mounting engagement portions83, that is, at the part of the mounting leg82where the width is reduced by the pair of mounting engagement portions83. That is, parts of the two terminals33are embedded inside the mounting leg82at the back side of the mounting engagement portions83.

The sealing member34as described above seals the terminal support portion41, the two terminals33, the electrode connecting portions P1, and the lead wire connecting portions P2to be liquid-tight and air-tight. The mounting leg82is engaged with the associated bracket12by inserting part of the mounting leg82between the pair of mounting engagement portions83(that is, part of the mounting leg82between the bottom surfaces83aof the pair of mounting engagement portions83) in an engaging groove12aformed at the longitudinal end of each bracket12. Both sides of the engaging groove12aof the bracket12are inserted in the pair of mounting engagement portions83. Thus, the longitudinal end of the foreign matter detection sensor13close to the sealing member34is secured to the bracket12by the mounting leg82. As shown inFIG. 5(b), the adhesion surface22aof the hollow insulating body22is adhered to the bracket12by a double-sided tape15so that the foreign matter detection sensor13is secured to the bracket12. The two lead wires71,72, which extend from the mounting leg82of the sealing member34, extend toward the first end22d(right side inFIG. 5(b)) in parallel to the sensor section21, and then drawn into the door panel5. As shown inFIG. 2, the lead wire71drawn into the door panel5is electrically connected to the current detector14inside the door panel5. The lead wire72, which is drawn into the door panel5, is connected to a ground GND (that is, grounded to the vehicle body3) inside the door panel5.

As shown inFIGS. 1 and 2, the current detector14is arranged inside the door panel5. The current detector14supplies current to the electrode wire23. In a normal state in which external force such as pressure is not applied to the sensor section21, the current supplied to the electrode wire23from the current detector14flows to the electrode wire24via the resistor28. When external force that crushes the sensor section21is applied, part of the hollow insulating body22on which the external force is applied, is elastically deformed. The elastic deformation of the hollow insulating body22flexes the electrode wires23,24so that the electrode wire23and the electrode wire24contact each other and are short-circuited. Then, the current supplied to the electrode wire23from the current detector14flows to the electrode wire24without flowing through the resistor28. Therefore, for example, since the current value changes when current is supplied to the electrode wire23at a constant voltage, the current detector14detects changes of the current value at this time, and detects foreign matter that contacts the sensor section21. Upon detection of changes of the current value, that is, upon detection of foreign matter that contacts the foreign matter detection sensor13, the current detector14outputs a foreign matter detection signal to a later-described door ECU91. When the external force applied to the sensor section21is removed, the hollow insulating body22restores, and the electrode wires23,24also restores to be in a non-conductive state.

The motor-driven back door device2includes the door ECU91, which controls opening and closing operation of the door panel5by the actuator6. The door ECU91functions as a microcomputer, includes a read only memory (ROM) and a random access memory (RAM), and receives power from a battery (not shown) of the vehicle1. The door ECU91supplies current to the current detector14, which is electrically connected to the door ECU91. The door ECU91controls the actuator6based on various types of signals input from the manipulation switch9, the position detection device8, and the current detector14.

The overall operation of the motor-driven back door device2configured as described above will now be described.

The door ECU91recognizes the rotational position of the door panel5based on position detection signals received from the position detection device8. More specifically, the door ECU91counts the number of pulse of the position detection signal, and recognizes the rotational position of the door panel5based on the count value.

Upon receipt of an open signal from the manipulation switch9, the door ECU91drives the actuator6to open the door panel5. When the door panel5reaches the fully opened position, the door ECU91stops the actuator6.

Upon receipt of a close signal from the manipulation switch9, the door ECU91drives the actuator6to close the door panel5. When the door panel5reaches the fully closed position, the door ECU91stops the actuator6. During closing operation of the door panel5, if foreign matter contacts the sensor section21of the foreign matter detection sensor13and external force is applied to the sensor section21, the hollow insulating body22of the foreign matter detection sensor13is elastically deformed so that the electrode wire23and the electrode wire24contact each other and are short-circuited. As a result, since the current value of the current supplied to the electrode wire23changes, the current detector14outputs a foreign matter detection signal to the door ECU91. Upon receipt of the foreign matter detection signal, the door ECU91reverses the actuator6to open the door panel5by a predetermined amount and subsequently stops the actuator6.

Operation of the foreign matter detection sensor13according to the first embodiment will now be described.

As shown inFIG. 5(b), in the vicinity of the second end21eof the sensor section21, the two lead wires71,72are arranged to be adjacent to the sensor section21in the direction orthogonal to the longitudinal direction of the sensor section21at a position facing the adhesion surface22aof the hollow insulating body22, and to be parallel to the sensor section21. That is, in the vicinity of the second end21eof the sensor section21, the lead wires71,72are arranged relative to the terminals33such that the longitudinal direction of the lead wires71,72forms an angle of 0° with the longitudinal direction of the sensor section21. Thus, in each of the foreign matter detection sensors13, which are secured to the door panel5via the brackets12, even if the lead wires71,72are arranged to extend toward the end of the sensor section21corresponding to the first end22d, that is, the first end21d(right side inFIG. 5(b)), the lead wires71,72do not protrude from the sealing member34in the longitudinal direction of the sensor section21at the end of the sensor section21corresponding to the second end22e, that is, in the vicinity of the second end21e.

The lead wire connecting portions P2are displaced relative to the electrode connecting portions P1on the terminals33in the direction orthogonal to the longitudinal direction of the sensor section21so as to approach the draw-out positions P3at which the lead wires71,72are drawn out from the sealing member34. Thus, the distal ends of the lead wires71,72connected to the terminals33approach the draw-out positions P3.

As described above, the first embodiment has the following advantages.

(1) The lead wires71,72are arranged relative to the two terminals33such that the longitudinal direction of the lead wires71,72forms an angle of 0° with the longitudinal direction of the sensor section21. Thus, when the lead wires71,72are arranged to extend from the second end21eof the sensor section21to which the lead wires71,72are connected (that is, the end corresponding to the second end22e) toward the first end21don the opposite side (that is, the end corresponding to the first end22d), the lead wires71,72are prevented from protruding from the sealing member34in the longitudinal direction of the sensor section21. Thus, since the lead wires71,72do not protrude from the sealing member34in the longitudinal direction of the sensor section21, the measurement of the sensor section21is increased in the longitudinal direction by the corresponding amount. As a result, in each of the foreign matter detection sensors13, the detection range of the foreign matter is increased in the longitudinal direction of the sensor section21. Also, the lead wire connecting portions P2are displaced relative to the electrode connecting portions P1on the terminals33in the direction orthogonal to the longitudinal direction of the sensor section21so as to approach the draw-out positions P3at which the lead wires71,72are drawn out from the sealing member34. Thus, the distal ends of the lead wires71,72connected to the terminals33approach the draw-out positions P3. This reduces the measurement of the lead wires71,72that are used. As a result, the manufacturing costs are reduced.

(2) The support member32supports the two terminals33so as to form the double structure while insulating the two terminals33from each other. Thus, as compared to the case in which the two terminals33are arranged without overlapping each other, the size of the sealing member34is reduced in the longitudinal direction of the sensor section21. The measurement of the sensor section21is increased in the longitudinal direction by the amount corresponding to the measurement of the sealing member34reduced in the longitudinal direction. As a result, in each foreign matter detection sensor13, the detection range of the foreign matter is increased in the longitudinal direction of the sensor section21.

(3) The lead wires71,72extend straight from the lead wire connecting portions P2to the draw-out positions P3, and are drawn out from the sealing member34to be adjacent to the sensor section21in the direction orthogonal to the longitudinal direction of the sensor section21and to be parallel to the sensor section21. Thus, the lead wires71,72drawn out from the sealing member34extend toward the first end21dof the sensor section21in the vicinity of the second end21eof the sensor section21at which the lead wires71,72are connected. Thus, the lead wires71,72are arranged to extend toward the first end21dof the sensor section21without bending the lead wires71,72. Also, a space for arranging the lead wires71,72is reduced in the direction orthogonal to the longitudinal direction of the sensor section21.

(4) Since the terminals33are arranged such that the transverse direction of the terminals33corresponds to the longitudinal direction of the sensor section21, the size of the terminals33and the sealing member34for sealing the terminals33is reduced in the longitudinal direction of the sensor section21. The measurement of the sensor section21is increased in the longitudinal direction by the amount corresponding to the size of the sealing member34reduced in the longitudinal direction. As a result, in each foreign matter detection sensor13, the detection range of the foreign matter is further increased in the longitudinal direction of the sensor section21.

(5) Since parts of the terminals33are embedded in the mounting leg82, the mounting leg82that protrudes outward from the outer circumferential surface of the hollow insulating body22is reinforced by the terminals33.

(6) The two terminals33are insulated from each other and are supported by the support member32. Thus, the support member32reinforces the terminals33. Also, since the terminals33are easily maintained in a state separated from each other by supporting the terminals33with the support member32, electric insulation between the two terminals33is easily ensured. Also, since the two terminals33are arranged relative to the sensor section21by arranging the support member32relative to the sensor section21, the position of the two terminals33relative to the sensor section21is easily determined.

(7) Parts of the terminals33are embedded in part of the mounting leg82where the width is reduced by forming the mounting engagement portions83. Thus, part of the mounting leg82where the mounting engagement portions83are formed is reinforced by the terminals33.

(8) The longitudinal direction of the sealing member34is orthogonal to the longitudinal direction of the sensor section21. Part of the sealing member34that is on the front side of the adhesion surface22aprovided on the outer circumferential surface of the hollow insulating body22is longer than part of the sealing member34that is on the back side. Thus, in the state in which the adhesion surface22ais adhered to the bracket12, the sealing member34is prevented from protruding greatly toward the back side of the adhesion surface22afrom the outer circumferential surface of the hollow insulating body22. Therefore, the appearance of the foreign matter detection sensor13mounted on the mounting position (in the first embodiment, the edge of the door panel5) is improved.

(9) The electrode wires23,24helically extend in the longitudinal direction of the hollow insulating body22. Thus, the positions on the end face22ffrom which the electrode wires23,24are drawn out are easily changed by adjusting the position of the end face22fto be provided on the second end22eof the hollow insulating body22in the longitudinal direction of the sensor section21. Also, since the electrode wires23,24helically extend in the longitudinal direction of the hollow insulating body22, the detection range in the circumferential direction of the sensor section21is increased as compared to, for example, a sensor section that includes a pair of electrodes, which linearly extend in the longitudinal direction of the hollow insulating body22inside the hollow insulating body22. Furthermore, even when the sensor section21is bent in any direction, the electrode wires23,24are unlikely to contact each other at the bent portion. Thus, the degree of freedom for arranging the foreign matter detection sensor13is increased.

(10) The lead wires71,72are drawn out from the mounting leg82, which protrudes to the outer circumference of the hollow insulating body22. Thus, in the vicinity of the second end21eof the sensor section21, the lead wires71,72are easily arranged to be parallel to the sensor section21without bending the lead wires71,72.

(11) The lead wires71,72are not bent inside the sealing member34. This reduces the measurement of the lead wires71,72that are used. Furthermore, since the space for arranging the lead wires71,72in the sealing member34is reduced as compared to the case in which the lead wires71,72are bent inside the sealing member34, the size of the sealing member34is reduced.

(12) The two lead wire connecting portions P2embedded inside the mounting leg82are displaced in the direction orthogonal to the longitudinal direction of the sensor section21in the longitudinal direction of the terminal support portion41. That is, the two lead wire connecting portions P2are displaced in the direction orthogonal to the widthwise direction of the mounting leg82(the direction that is the same as the widthwise direction of the adhesion surface22a). Thus, for example, the width of the mounting leg82is partially reduced as compared to the case in which the two lead wire connecting portions P2are not displaced in the direction orthogonal to the longitudinal direction of the sensor section21.

Second Embodiment

A foreign matter detection sensor according to a second embodiment of the present invention will now be described. The second embodiment mainly differs from the first embodiment in the structure of the terminal processing section31. The differences in this respect will mainly be discussed below. Like or the same reference numerals are given to those components that are like or the same as the corresponding components of the first embodiment, and detailed explanations are omitted.

The terminal support portion41according to the second embodiment is a rectangular plate. The thickness of the terminal support portion41is thinner than the thickness of the hollow insulating body22, and is substantially equal to the distance D1between the core electrodes25of the two electrode wires23,24. The spacer42is integrally formed at the end of the terminal support portion41adjacent to the second end22e. The spacer42protrudes from the center of the end of the terminal support portion41opposing the second end22eof the hollow insulating body22. The spacer42is columnar. The diameter of the spacer42is less than the thickness of the terminal support portion41, and is substantially equal to the width of the gap between the electrode wires23,24, which oppose each other inside the hollow insulating body22. The support member32is mounted on the hollow insulating body22in a state in which the distal end of the spacer42is inserted in the hollow bore22bfrom the second end22eof the hollow insulating body22. In the second embodiment, the spacer42is inserted in the hollow bore22buntil the end surface of the terminal support portion41opposing the second end22eof the hollow insulating body22abuts against the second end22e. The spacer42that is inserted in the hollow bore22b(inside of the hollow insulating body22) from the second end22eis arranged between the two electrode wires23,24at the second end22e, and prevents contact between the electrode wires23,24.

As shown inFIGS. 6,7(a), and7(b), in the support member32mounted on the hollow insulating body22, the terminal support portion41is arranged relative to the sensor section21such that the thickness direction of the terminal support portion41is parallel to the widthwise direction of the adhesion surface22a. The support member32is arranged within the range of the outer shape of the hollow insulating body22as viewed from the longitudinal direction of the sensor section21(left and right direction inFIG. 7(b)).

Two power supply members130are configured by a pair of terminals51, and a pair of lead wires171,172. That is, one of the power supply members130includes one of the terminals51and the lead wire171, and is electrically connected to the electrode wire23to supply power to the electrode wire23. Similarly, the other one of the power supply members130includes the other one of the terminals51and the lead wire172, and is electrically connected to the electrode wire24to supply power to the electrode wire24.

One of the terminals51is secured to one end face of the terminal support portion41in the thickness direction, and the other one of the terminals51is secured to the other end face of the terminal support portion41in the thickness direction. That is, the terminal support portion41supports the terminals51on both end faces in the thickness direction. Each terminal51is formed of conductive metal plate, and is a rectangular plate that is a size larger than the terminal support portion41. The two terminals51are arranged on the end faces of the terminal support portion41in the thickness direction such that the thickness direction of the two terminals51match with the thickness direction of the terminal, support portion41. The terminal support portion41supports the two terminals51so as to form a double structure in which the two terminals51are overlapped with each other in the thickness direction while insulating the two terminals51from each other.

As shown inFIG. 3, the core electrodes25of the electrode wires23,24are drawn out from the second end22eof the hollow insulating body22. In the second embodiment, the end face22fat the second end22eof the hollow insulating body22is formed at a position where the helically extending two electrode wires23,24are separate in the direction parallel to the widthwise direction of the adhesion surface22a. The end face22fforms a right angle with the adhesion surface22a. Thus, on the end face22f, the straight line L1that passes through the center of the electrode wires23,24is parallel to the widthwise direction of the adhesion surface22a.

As shown inFIG. 6, the core electrodes25of the two electrode wires23,24, which are drawn out from the second end22eof the hollow insulating body22, are drawn out to both sides of the terminal support portion41in the thickness direction. That is, the terminal support portion41is arranged between the two core electrodes25. Each of the terminals51and the opposing core electrode25are electrically connected on both sides of the terminal support portion41in the thickness direction. More specifically, weld beads are formed in advance by arc welding (for example, TIG welding) on the distal ends of the core electrodes25of the electrode wires23,24, and the distal ends of the core electrodes25are respectively connected to the terminals51by resistance welding. Accordingly, the electrode wires23,24are electrically connected to the corresponding terminals51.

As shown inFIGS. 6 and 7(b), the lead wires171,172are electrically connected to the terminals51. The lead wires171,172are coated wires each including a conductive metal wire173coated by an insulating coating174. The insulating coating174is removed at the distal end of each of the lead wires171,172, and the associated metal wire173is exposed. Weld beads are formed in advance by arc welding (for example, TIG welding) on the distal ends of the metal wires173of the lead wires171,172, and the distal ends of the metal wires173at which the weld beads are formed are connected to the terminals51by resistance welding. Accordingly, the lead wires171,172are electrically connected to the corresponding terminals51. The lead wire171is welded to a position on one of the terminals51that is the same as the position where the core electrode25of the electrode wire23is connected, and is electrically connected to the electrode wire23. Similarly, the lead wire172is welded to a position on the other one of the terminals51that is the same as the position where the core electrode25of the electrode wire24is connected, and is electrically connected to the electrode wire24. The connecting portion between the electrode wire23and the lead wire171, and the connecting portion between the electrode wire24and the lead wire172are referred to as electrode connecting portions P1.

The lead wires171,172extend from the electrode connecting portions P1in a direction that is orthogonal to the sensor section21(in the second embodiment, in a direction that is orthogonal to the adhesion surface22aand towards the front side of the adhesion surface22a), and are then bent to extend toward the first end21dof the sensor section21. Thereafter, the lead wires171,172extend toward the first end21dof the sensor section21to be parallel to the sensor section21. That is, the lead wires171,172have direction changing sections175at the distal ends, and the direction changing sections175extend from the electrode connecting portions P1in a direction intersecting the sensor section21(in the second embodiment, in the direction orthogonal to the adhesion surface22a), and further extend in the direction toward the first end21dof the sensor section21(the end corresponding to the first end22d). The direction changing sections175include bent portions176, which are bent such that the direction in which the lead wires171,172extend is changed from the direction that separates from the electrode connecting portions P1to the direction toward the first end21dof the sensor section21.

The sealing member34is formed of insulating plastic material. As shown inFIGS. 7(a) and7(b), the sealing member34embeds and seals part of the support member32arranged outside of the hollow insulating body22, the terminals51, the electrode connecting portions P1, the distal ends of the lead wires171,172, and the second end22eof the hollow insulating body22. The sealing member34includes a terminal coating section181, which is adjacent to the second end22eof the hollow insulating body22in the longitudinal direction of the sensor section21, and a mounting leg182, which is formed integrally with the terminal coating section181.

The terminal coating section181embeds the second end22eof the hollow insulating body22, and is formed integrally with the end face22fon the second end22eof the hollow insulating body22. The terminal coating section181embeds and seals the terminal support portion41, the two terminals51, the electrode connecting portions P1, and parts of the direction changing sections175in the vicinity of the electrode connecting portions P1. Also, as shown inFIG. 6, the outer shape of the terminal coating section181is a size larger than the outer shape of the hollow insulating body22, and the cross-section of the terminal coating section181that is orthogonal to the longitudinal direction of the sensor section21is substantially D-shaped. As shown inFIGS. 7(a) and7(b), the end of the terminal coating section181close to the second end22eof the hollow insulating body22is in close contact with the second end22eto be liquid-tight and air-tight.

The mounting leg182is formed integrally with the end of the terminal coating section181close to the lead wires171,172and the adhesion surface22aat the second end22eof the hollow insulating body22. The mounting leg182protrudes toward the front side of the adhesion surface22a(below the adhesion surface22ainFIG. 7(b)) to the outer side than the outer circumferential surface of the hollow insulating body22, and has a substantially rectangular solid shape. The mounting leg182is slightly wider than the adhesion surface22a, and the measurement of the mounting leg182in the longitudinal direction of the sensor section21is substantially equal to the measurement of the terminal coating section181in the longitudinal direction of the sensor section21. The mounting leg182embeds and seals part of the lead wires171,172in the vicinity of the distal ends, that is, part of the direction changing sections175in the vicinity of the bent portions176. The two lead wires171,172are drawn out to the outside of the mounting leg182from one of longitudinal end faces (an end face182a) of the mounting leg182closer to the sensor section21to be parallel to the sensor section21. Parts of the lead wires171,172that extend from the bent portions176toward the end face182ainside the sealing member34extend linearly to the end face182ato be substantially parallel to the longitudinal direction of the sensor section21. The direction changing sections175of the power supply members130correspond to the section embedded in the sealing member34.

As shown inFIG. 6, a pair of mounting engagement portions183is formed in the mounting leg182. The pair of mounting engagement portions183are formed on both sides of the mounting leg182in the widthwise direction (the direction that is the same as the widthwise direction of the adhesion surface22a), that is, on both sides of the mounting leg182in the thickness direction of the terminal support portion41. The pair of mounting engagement portions183are recesses formed to reduce the width of the mounting leg182. The mounting engagement portions183are grooves that extend in the longitudinal direction of the sensor section21through the mounting leg182in the longitudinal direction of the sensor section21. The pair of mounting engagement portions183is formed at a position between the electrode connecting portions P1and the bent portions176in a direction that is orthogonal to the longitudinal direction of the sensor section21(in the second embodiment, a direction orthogonal to the adhesion surface22a). The width of part of the mounting leg182where the pair of mounting engagement portions183is formed (the width in the same direction as the widthwise direction of the adhesion surface22a) is reduced. However, the direction changing sections175of the lead wires171,172are embedded between bottom surfaces183aof the pair of mounting engagement portions183, that is, at part of the mounting leg182where the width is reduced by the pair of mounting engagement portions183. That is, parts of the two lead wires171,172are located on the back side of the mounting engagement portions183inside the mounting leg182.

The sealing member34as described above seals the terminal support portion41, the two terminals51, the electrode connecting portions P1, and parts of the lead wires171,172close to the distal ends to be liquid-tight and air-tight. The mounting leg182is engaged with the bracket12by inserting part of the mounting leg182between the pair of mounting engagement portions183(that is, part of the mounting leg182between the bottom surfaces183a) in the engaging groove12aformed in the longitudinal end of the bracket12. Then, parts of the bracket12on both sides of the engaging groove12aare inserted in the pair of mounting engagement portions183. Thus, the longitudinal end of the foreign matter detection sensor13close to the sealing member34is secured to the bracket12by the mounting leg182. As shown inFIG. 7(b), the adhesion surface22aof the hollow insulating body22is adhered to the bracket12by the double-sided tape15so that the foreign matter detection sensor13is secured to the bracket12. The two lead wires171,172, which extend from the mounting leg182of the sealing member34, extend toward the first end22d(right side inFIG. 7(b)) in parallel to the sensor section21, and are then drawn into the door panel5. As shown inFIG. 2, the lead wire171drawn in to the door panel5is electrically connected to the current detector14inside the door panel5. The lead wire172, which is drawn into the door panel5is connected to the ground GND (that is, grounded to the vehicle body3) inside the door panel5.

As shown inFIGS. 1 and 2, the current detector14is arranged inside the door panel5. The current detector14supplies current to the electrode wire23. In the normal state, in which external force such as pressure is not applied to the sensor section21, the current supplied to the electrode wire23from the current detector14flows to the electrode wire24via the resistor28. When external force that crushes the sensor section21is applied, part of the hollow insulating body22on which the external force is applied is elastically deformed. The elastic deformation of the hollow insulating body22flexes the electrode wires23,24so that the electrode wire23and the electrode wire24contact each other and are short-circuited. Then, the current supplied to the electrode wire23from the current detector14flows to the electrode wire24without flowing through the resistor28. Therefore, for example, since the current value changes when current is supplied to the electrode wire23at a constant voltage, the current detector14detects changes of the current value at this time, and detects foreign matter that contacts the sensor section21. Upon detection of changes of the current value, that is, upon detection of foreign matter that contacts the foreign matter detection sensor13, the current detector14outputs a foreign matter detection signal to the door ECU91. When the external force applied to the sensor section21is removed, the hollow insulating body22restores, and the electrode wires23,24also restores to be in a non-conductive state.

The motor-driven back door device2includes the door ECU91, which controls opening and closing operation of the door panel5by the actuator6. The door ECU91functions as a microcomputer, includes a read only memory (ROM) and a random access memory (RAM), and receives power from a battery (not shown) of the vehicle1. The door ECU91supplies current to the current detector14, which is electrically connected to the door ECU91. The door ECU91controls the actuator6based on various types of signals input from the manipulation switch9, the position detection device8, and the current detector14.

The operation of the motor-driven back door device2configured as described above will now be described.

The door ECU91recognizes the rotational position of the door panel5based on position detection signals received from the position detection device8. More specifically, the door ECU91counts the number of pulse of the position detection signal, and recognizes the rotational position of the door panel5based on the count value.

Upon receipt of an open signal from the manipulation switch9, the door ECU91drives the actuator6to open the door panel5. When the door panel5reaches the fully opened position, the door ECU91stops the actuator6.

Upon receipt of a close signal from the manipulation switch9, the door ECU91drives the actuator6to close the door panel5. When the door panel5reaches the fully closed position, the door ECU91stops the actuator6. During closing operation of the door panel5, if foreign matter contacts the sensor section21of the foreign matter detection sensor13and external force is applied to the sensor section21, the hollow insulating body22of the foreign matter detection sensor13is elastically deformed so that the electrode wire23and the electrode wire24contact each other and are short-circuited. As a result, since the current value of the current supplied to the electrode wire23changes, the current detector14outputs a foreign matter detection signal to the door ECU91. Upon receipt of the foreign matter detection signal, the door ECU91reverses the actuator6to open the door panel5by a predetermined amount and subsequently stops the actuator6.

Operation of the foreign matter detection sensor13according to the second embodiment will now be described.

As shown inFIG. 7(b), the lead wire171, which configures one of the power supply members130, has the direction changing section175, which includes the bent portion176. Thus, the lead wire171extends from the electrode connecting portion P1in a direction orthogonal to the sensor section21(in the second embodiment, a direction orthogonal to the adhesion surface22aand toward the front side of the adhesion surface22a), and then extends toward the first end21dof the sensor section21to be parallel to the sensor section21. Similarly, the lead wire172, which configures the other one of the power supply members130, has the direction changing section175, which includes the bent portion176. Thus, the lead wire172extends from the electrode connecting portion P1in a direction orthogonal to the sensor section21(in the second embodiment, a direction orthogonal to the adhesion surface22aand toward the front side of the adhesion surface22a), and then extends toward the first end21dof the sensor section21to be parallel to the sensor section21. Thus, even when the lead wires171,172that are drawn out from the sealing member34are arranged to extend toward the first end21dof the sensor section21(rightward inFIG. 7(b)), the lead wires171,172do not protrude from the sealing member34in the longitudinal direction of the sensor section21in the vicinity of the second end21eof the sensor section21.

As described above, the second embodiment has the following advantages.

(1) The power supply member130that is connected to the electrode wire23has the direction changing section175. The direction changing section175extends from the electrode connecting portion P1, which is the connecting portion between the power supply member130and the electrode wire23, in the direction orthogonal to the longitudinal direction of the sensor section21, and further extends in the direction toward the first end21dof the sensor section21. Similarly, the power supply member130that is connected to the electrode wire24has the direction changing section175. The direction changing section175extends from the electrode connecting portion P1, which is the connecting portion between the power supply member130and the electrode wire24, in the direction orthogonal to the longitudinal direction of the sensor section21, and further extends in the direction toward the first end21dof the sensor section21. That is, immediately after being connected to the electrode wires23,24, the power supply members130extend in the direction orthogonal to the longitudinal direction of the sensor section21, and further extend toward the first end21dof the sensor section21. Thus, when the power supply members130are arranged to extend toward the first end21dof the sensor section21on one longitudinal end of the foreign matter detection, sensor13(the end corresponding to the second end22e), the power supply members130are prevented from protruding from the sealing member34in the longitudinal direction of the sensor section21. Furthermore, the measurement of the part of the power supply members130that protrude from one longitudinal end (the end closer to the second end22e) of the hollow insulating body22in the longitudinal direction of the sensor section21is reduced in the longitudinal direction of the sensor section21. As a result, the measurement of the sensor section21is increased in the longitudinal direction by the amount corresponding to the reduced measurement of the part of the power supply members130that protrude from one longitudinal end of the hollow insulating body22in the longitudinal direction of the sensor section21. Also, since the direction changing sections175are sealed inside the sealing member34, the power supply members130are prevented from protruding from the sealing member34in the longitudinal direction of the sensor section21. Thus, the longitudinal measurement of the sensor section21is prevented from being reduced due to the power supply members130. Therefore, in each foreign matter detection sensor13, the detection range of the foreign matter is increased in the longitudinal direction of the sensor section21.

(2) One of the power supply members130is arranged adjacent to the second end21eof the sensor section21, and includes one of the terminals51, to which the electrode wire23is electrically connected, and the lead wire171, which is electrically connected to the terminal51. The other one of the power supply members130is arranged adjacent to the second end21eof the sensor section21, and includes the other one of the terminals51to which the electrode wire24is electrically connected, and the lead wire172, which is electrically connected to the terminal51. Thus, since the electrode wires23,24are electrically connected to the terminals51, the electrode wires23,24and the power supply members130are easily connected to each other.

(3) The bent portions176are formed by bending the lead wires171,172. In this manner, the bent portions176are easily formed by bending the lead wires171,172.

(4) The mounting leg182is reinforced by the power supply members130embedded inside the mounting leg182.

(5) The rear portion of the mounting engagement portions183in the mounting leg182is a part where load is likely to be applied in the state in which the mounting leg182is mounted on the bracket12. Since the power supply members130are embedded in the rear portion of the mounting engagement portions183on which load is likely to be applied, the mounting leg182is more effectively reinforced.

(6) Parts of the power supply members130are embedded in the part of the mounting leg182where the recess-like mounting engagement portions183are formed and the width of the mounting leg182is reduced. Thus, part of the mounting leg182where the recess-like mounting engagement portions183are formed is further effectively reinforced by the power supply members130.

The embodiments of the present invention may be modified as follows.

In the first embodiment, the foreign matter detection sensors13are adhered to the edges of the door panel5(mounting positions) via the brackets12. However, the foreign matter detection sensors13may be adhered directly to the edges of the door panel5without using the brackets12. Also, the foreign matter detection sensors13may be mounted on the brackets12or the edges of the door panel5by method other than adhesion by the double-sided tape15, such as sticking with an adhesive.

In the first embodiment, the longitudinal direction of the sealing member34is a direction orthogonal to the longitudinal direction of the sensor section21. Part of the sealing member34at the front side of the adhesion surface22ais longer than part of the sealing member34at the back side of the adhesion surface22a. However, the longitudinal direction of the sealing member34does not necessarily have to be the direction orthogonal to the longitudinal direction of the sensor section21. Also, the part of the sealing member34at the front side of the adhesion surface22adoes not necessarily have to be longer than the part of the sealing member34at the back side of the adhesion surface22a.

In the first embodiment, parts of the two terminals33are embedded in the mounting leg82at the back side of the two mounting engagement portions83. However, the two terminals33do not need to be embedded in the mounting leg82at the back side of the two mounting engagement portions83.

In the first embodiment, the mounting leg82includes the pair of mounting engagement portions83. However, the mounting leg82may include only one mounting engagement portion83. Also, the mounting leg82does not necessarily have to include the mounting engagement portion83.

In the first embodiment, parts of the two terminals33are embedded inside the mounting leg82. However, the two terminals33do not necessarily have to be embedded in the mounting leg82.

The sealing member34does not necessarily have to include the mounting leg82for engaging the sealing member34to the bracket12.

In the first embodiment, the two terminals33are arranged adjacent to the second end22eof the hollow insulating body22such that the transverse direction of the terminals33corresponds to the longitudinal direction of the sensor section21, and the longitudinal direction of the terminals33is orthogonal to the longitudinal direction of the sensor section21. However, the two terminals33may be arranged adjacent to the second end22eof the hollow insulating body22such that the transverse direction of the terminals33is orthogonal to the longitudinal direction of the sensor section21, and the longitudinal direction of the terminals33corresponds to the longitudinal direction of the sensor section21.

In the first embodiment, the terminals33each include the terminal main body51, which is a rectangular plate having the transverse direction and the longitudinal direction. The terminals33are also plates having the transverse direction and the longitudinal direction. However, the shape of the terminals33is not limited to this. For example, the electrode wires23,24and the lead wires71,72may be electrically connected to one another by substantially shaped terminals102as a foreign matter detection sensor101shown inFIGS. 8(a) and8(b). InFIGS. 8 and 9, like or the same reference numerals are given to those components that are like or the same as the corresponding components of the first embodiment.

A support member103, which supports the terminals102, includes a terminal support portion104, the guide portion43, and the spacer42. The terminal support portion104has an L-shape like the terminals102. The two terminals102are arranged on the end faces of the terminal support portion104in the thickness direction. The terminal support portion104supports the two terminals102so as to form the double structure in which the two terminals102are overlapped with each other in the thickness direction while insulating the two terminals102from each other. In a state in which the support member103is mounted on the second end22eof the hollow insulating body22, the terminals102extend in the direction to separate from the second end22ein the longitudinal direction of the sensor section21, are bent at right angle toward the adhesion surface22a, and protrude further outward than the outer circumferential surface of the hollow insulating body22.

As shown inFIG. 9, on both sides of the terminal support portion104in the thickness direction, the terminals102and the opposing core electrodes25of the electrode wires23,24are electrically connected by welding. On both sides of the terminal support portion104in the thickness direction, the terminals102and the opposing lead wires71,72are electrically connected by welding. The connecting portions between the terminals102and the lead wires71,72are lead wire connecting portions P5. The connecting portions between the terminals102and the electrode wires23,24are electrode connecting portions P4. As shown inFIGS. 8(b) and9, the lead wire connecting portions P5are displaced relative to the electrode connecting portions P4on the terminals102in the direction orthogonal to the longitudinal direction of the sensor section21(arrow C inFIG. 8(b)) so as to approach the draw-out positions P3at which the lead wires71,72are drawn out from the sealing member34. Furthermore, the lead wire connecting portions P5are displaced relative to the electrode connecting portions P4to a position further from the sensor section21than the electrode connecting portions P4in the longitudinal direction of the sensor section21. The lead wires71,72extend straight from the lead wire connecting portions P5to the draw-out positions P3, and are drawn out from the sealing member34to be adjacent to the sensor section21in the direction orthogonal to the longitudinal direction of the sensor section21and to be parallel to the sensor section21. The case in which the above-described configuration is employed also has advantages that are the same as the advantages (1) to (3), (5) to (7), and (9) to (12) of the first embodiment.

Also, in a case in which the terminals are substantially L-shaped, the configuration as shown inFIG. 11may be employed. According to the example shown inFIG. 11, terminals131each include a substantially L-shaped terminal main body132and the first connection piece52and the second connection piece53, which extend from the terminal main body132. The terminals131are supported by a support member141. The support member141includes a terminal support portion142, which is an L-shaped plate that is similar to the terminal main body132, the guide portion43, and the spacer42. The two terminals131are arranged on both end faces of the terminal support portion142in the thickness direction. The terminal support portion142supports the two terminals131so as to form the double structure in which the two terminals131are overlapped with each other in the thickness direction while insulating the two terminals131from each other. In the state in which the support member141is mounted on the second end22eof the hollow insulating body22, the terminals131extend forward of the adhesion surface22ain the direction orthogonal to the longitudinal direction of the sensor section21, and are then bent at right angle to be parallel to the adhesion surface22a. The first connection piece52of each terminal131is provided on one end of the terminal main body132in the direction orthogonal to the adhesion surface22a. Furthermore, the second connection piece53of each terminal131is provided on the other end of the terminal main body132in the direction orthogonal to the adhesion surface22a, that is, on the end opposite to the first connection piece52. The second connection piece53of each terminal131is located relative to the first connection piece52closer to the first end21dof the sensor section21than the first connection piece52in the longitudinal direction of the sensor section21. After the core electrodes25of the electrode wires23,24are each sandwiched between the associated first connection piece52and the terminal main body132on both sides of the terminal support portion142in the thickness direction, the electrode wires23,24are electrically connected to the terminals131by soldering.FIG. 11shows the solder61, which electrically connects each core electrode25to the corresponding terminal131, by a broken line in which a long dash alternates with a pair of short dashes. After the metal wires73of the lead wires71,72are each sandwiched between the associated second connection piece53and the terminal main body132on both sides of the terminal support portion142in the thickness direction, the metal wires73are electrically connected to the terminals131by soldering.FIG. 11shows the solder62, which electrically connects each metal wire73to the corresponding terminal131by a broken line in which a long dash alternates with a pair of short dashes. The connecting portions between the terminals131and the lead wires71,72are lead wire connecting portions P12. The connecting portions between the terminals131and the electrode wires23,24are electrode connecting portions P13. The lead wire connecting portions P12are displaced relative to the electrode connecting portions P13on the terminals131in the direction orthogonal to the longitudinal direction of the sensor section21(vertical direction inFIG. 11) so as to approach the draw-out positions P3at which the lead wires71,72are drawn out from the sealing member34. The lead wire connecting portions P12are located relative to the electrode connecting portions P13to be closer to the first end21dof the sensor section21than the electrode connecting portions P13in the longitudinal direction of the sensor section21. The lead wires71,72are drawn out from the sealing member34so as to be adjacent to the sensor section21in the direction orthogonal to the longitudinal direction of the sensor section21and to be parallel to the sensor section21. In the case in which the above-mentioned configuration is employed, advantages that are the same as the advantages (1) to (3), (5) to (7), and (9) to (12) of the first embodiment are obtained. Furthermore, in this case, the protruding amount of the sealing member34from the longitudinal end of the sensor section21in the longitudinal direction of the sensor section21is reduced as compared to the example shown inFIGS. 8(a) and8(b). The measurement of the sensor section21is increased in the longitudinal direction by the amount corresponding to the reduced protruding amount of the sealing member34from the longitudinal end of the sensor section21in the longitudinal direction of the sensor section21. As a result, in the foreign matter detection sensor, the detection range of the foreign matter is further increased in the longitudinal direction of the sensor section21.

In the first embodiment, the lead wires71,72are drawn out from the sealing member34in the vicinity of the longitudinal end of the sensor section21close to the terminal processing section31so as to be adjacent to the sensor section21in the direction orthogonal to the longitudinal direction of the sensor section21and to be parallel to the sensor section21. However, the lead wires71,72may be arranged relative to the terminals33in the vicinity of the longitudinal end of the sensor section21close to the terminal processing section31such that the longitudinal direction of the lead wires71,72and the longitudinal direction of the sensor section21form an angle less than or equal to the right angle (that is, 0° to 90°).

In the first embodiment, the two terminals33are supported by the support member32to form the double structure while being insulated from each other. However, the two terminals33do not necessarily have to be overlapped, but may be arranged in a row in the direction orthogonal to the longitudinal direction of the sensor section21, or in the longitudinal direction of the sensor section21. For example, a first terminal111and a second terminal112shown in FIG.10are arranged in a row in the longitudinal direction of the sensor section21(left and right direction inFIG. 10). The first terminal111and the second terminal112are supported by a support member113formed of insulating plastic material. The support member113is a rectangular plate. The support member113is arranged adjacent to the other end of the sensor section21in the longitudinal direction (the second end22eof the hollow insulating body22). The longitudinal direction of the support member113is a direction orthogonal to the longitudinal direction of the sensor section21(longitudinal direction of the hollow insulating body22). Part of the support member113at the front side of the adhesion surface22a(below the adhesion surface22ainFIG. 10) is longer than part of the support member113at the back side of the adhesion surface22a(above the adhesion surface22ainFIG. 10). In the example shown inFIG. 10, the longitudinal direction of the support member113is parallel to the direction orthogonal to the adhesion surface22a. The first terminal111and the second terminal112are arranged and secured to the end surface of the support member113in the thickness direction. The first terminal111and the second terminal112are formed of conductive metal plates. The first terminal111is a rectangular plate that is smaller than the support member113, and is arranged at substantially the center portion of the end surface of the support member113in the thickness direction. The second terminal112is configured by a pair of connecting portions112a, which is arranged on both sides of the first terminal111in the longitudinal direction, and a coupling portion112b, which connects the connecting portions112a. The second terminal112as viewed from the thickness direction of the support member113(in a direction perpendicular to the sheet ofFIG. 10) is substantially U-shaped. The connecting portions112aare rectangular plates, and the coupling portion112hhas an elongated band shape. One of the connecting portions112ais located on the back side of the adhesion surface22a, and the other one of the connecting portions112ais located on the front side of the adhesion surface22a. The coupling portion112bis arranged at a position further than the first terminal111from the sensor section21in the longitudinal direction of the sensor section21(the same as the transverse direction of the support member113). The first terminal111and the second terminals112as described above are supported by the support member113in a state separate from each other.

The core electrode25of the electrode wire24that is drawn out from the second end22eof the hollow insulating body22and the metal wire73that is exposed at the distal end of the lead wire72are connected to the first terminal111. Weld beads114are formed on the distal end of the core electrode25of the electrode wire24drawn out from the second end22eand the distal end of the metal wire73exposed at the distal end of the lead wire72by arc welding for example, TIG welding). The core electrode25of the electrode wire24drawn out from the second end22eand the metal wire73exposed at the distal end of the lead wire72are electrically and mechanically connected to the first terminal111by connecting the weld beads114to the first terminal111by resistance welding. A lead wire connecting portion PG of the first terminal111to which the lead wire72is connected is located at the position displaced from an electrode connecting portion P7of the first terminal111to which the electrode wire24is connected in the direction orthogonal to the longitudinal direction of the sensor section21, and at the position on the front side of the adhesion surface22a.

The core electrode25of the electrode wire23drawn out from the second end22eof the hollow insulating body22, and the metal wire73exposed at the distal end of the lead wire71are connected to the second terminal112. Weld beads114are formed on the distal end of the core electrode25of the electrode wire23drawn out from the second end22eand on the distal end of the metal wire73exposed at the distal end of the lead wire71by arc welding (for example, TIG welding). The core electrode25of the electrode wire23drawn out from the second end22eis electrically and mechanically connected to the second terminal112by connecting the weld bead114of the core electrode25to one of the connecting portions112alocated on the back side of the adhesion surface22aby resistance welding. The metal wire73exposed at the distal end of the lead wire71is electrically and mechanically secured to the second terminal112by connecting the weld bead114of the metal wire73to the other one of the connecting portions112aarranged on the front side of the adhesion surface22aby resistance welding. A lead wire connecting portion P8of the second terminal112to which the lead wire71is connected is provided at a position displaced from an electrode connecting portion P9of the second terminal112to which the electrode wire23is connected in a direction orthogonal to the longitudinal direction of the sensor section21, and at a position on the front side of the adhesion surface22a.

In the example shown inFIG. 10, the lead wires71,72are arranged relative to the first terminal111and the second terminal112such that the longitudinal direction of the lead wires71,72forms an angle of 0° with the longitudinal direction of the sensor section21. That is, the lead wires71,72are arranged to be parallel to the sensor section21. Also, inFIG. 10, illustration of the sealing member34, which embeds the first terminal111, the second terminal112, and the support member113, is omitted. In the case in which the above configuration is employed, the same advantages as the advantages (1) and (3) to (12) of the first embodiment are obtained.

In the case in which the terminals33can be supported by the sealing member34, the foreign matter detection sensor13does not necessarily have to include the support member32.

The number of the terminals33provided, in the foreign matter detection sensor13may be changed in accordance with the number of the electrode wires23,24. For example, in a case in which three or more terminals33are provided in the foreign matter detection sensor13, the support member may support the terminals33to form a multilayer structure or the terminals33may be arranged in a row while the support member insulates the terminals33from one another. As long as the terminals33are insulated from one another, the foreign matter detection sensor13does not necessarily have to include the support member for supporting the terminals33.

In the first embodiment, after being sandwiched between the first connection piece52and the terminal main body51, each of the electrode wires23,24is electrically connected to the associated terminal33by soldering. After being sandwiched between the second connection piece53and the terminal main body51, each of the lead wires71,72is electrically connected to the associated terminal33by soldering. However, each of the electrode wires23,24does not need to be soldered, but may be electrically connected to the corresponding terminal33by only being sandwiched and crimped, between the associated first connection piece52and the terminal main body51. Similarly, each of the lead wires71,72does not need to be soldered, but may be electrically connected to the corresponding terminal33by only being sandwiched and crimped between the associated second connection piece53and the terminal main body51. Also, the electrode wires23,24and the lead wires71,72may be electrically connected to the terminals33by welding. For example, in the example shown inFIGS. 12(a) and12(b), terminals121do not include the first connection pieces52and the second connection pieces53, and have a rectangular plate-like shape. That is, the terminals121are plates having the transverse direction and the longitudinal direction. The terminals121are secured to both sides of the terminal support portion41in the thickness direction, and the two terminals121, which are insulated from each other and supported by the terminal support portion41, are arranged adjacent to the longitudinal end of the sensor section21(the end close to the second end22e) such that the transverse direction of the terminals121corresponds to the longitudinal direction of the sensor section21. The weld beads114are formed on the distal ends of the core electrodes25of the electrode wires23,24drawn out from the second end22eand the distal ends of the metal wires73exposed at the distal ends of the lead wires71,72by arc welding (for example, TIG welding). The core electrodes25of the electrode wires23,24drawn out from the second end22eand the metal wires73exposed at the distal ends of the lead wires71,72are electrically and mechanically secured to the terminals121by connecting the weld beads114to the terminals121by resistance welding. Lead wire connecting portions P10of the terminals121to which the lead wires71,72are connected are located at positions displaced from electrode connecting portions P11of the terminals121to which the electrode wires23,24are connected in a direction orthogonal to the longitudinal direction (left and right direction inFIG. 12(b)) of the sensor section21, and are located at positions on the front side of the adhesion surface22a. In a case in which the above configuration is employed, advantages that are the same as the advantages (1) to (12) of the first embodiment are obtained.

In the first embodiment, the spacer42is cylindrical. However, as long as the spacer42is columnar, the spacer42does not necessarily have to be cylindrical. For example, the spacer42may be a polygonal column.

The shape of the sealing member34is not limited to the one illustrated in the first embodiment. The sealing member34may have any shape as long as the sealing member34seals the terminals33, the lead wire connecting portions P2, and the electrode connecting portions P1. For example, the sealing member34may be a cover attached to the outer circumference of the support member32so as to accommodate the terminals33, the lead wire connecting portions P2, and the electrode connecting portions P1.

According to the foreign matter detection sensor13of the first embodiment, the longitudinal end of the sensor section21close to the first end22dmay be configured as shown inFIGS. 13(a) and13(h). InFIGS. 13(a) and13(b), like or the same reference numerals are given to those components that are like or the same as the corresponding components of the first embodiment. An element-side terminal151is provided on the first end22dof the hollow insulating body22. The element-side terminal151includes the support member32, which is arranged to be adjacent to the first end22dof the hollow insulating body22, and two element connecting terminals152, which are supported by the support member32, a resistive element153, and an element-side sealing member154, which embeds and seals the support member32and the resistive element153.

The element connecting terminals152have the same shape as the terminals33of the first embodiment, and are each configured by the terminal main body51, the first connection piece52, and the second connection piece53. Thus, the element connecting terminals152are plates having the transverse direction and the longitudinal direction. The two element connecting terminals152are arranged on both end faces of the terminal support portion41. The terminal support portion41supports the two element connecting terminals152so as to form the double structure in which the element connecting terminals152overlap each other while insulating the two element connecting terminals152. The support member32is mounted on the hollow insulating body22by inserting the spacer42in the hollow bore22bfrom the first end22d. The terminal support portion41of the support member32is arranged relative to the sensor section21such that the thickness direction of the terminal support portion41is parallel to the widthwise direction of the adhesion surface22a. The terminal support portion41is adjacent to the widthwise center portion of the adhesion surface22ain the longitudinal direction of the sensor section21(arrow B inFIG. 13(b)). The longitudinal end of the terminal support portion41opposite to where the guide portion43is provided (that is, the longitudinal end on which the second connection pieces53are arranged) protrudes from the adhesion surface22atoward the outer circumference of the hollow insulating body22, which is the front side of the adhesion surface22a(below the adhesion surface22ainFIG. 13(b)). The longitudinal direction of the terminal support portion41is a direction orthogonal to the longitudinal direction of the sensor section21, and more specifically, is a direction orthogonal to the adhesion surface22a(arrow C inFIG. 13(b)). Part of the terminal support portion41at the front side of the adhesion surface22ais longer than the part of the terminal support portion41at the back side of the adhesion surface22a. Thus, the two element connecting terminals152supported on the terminal support portion41are arranged adjacent to the first end22dof the hollow insulating body22such that the transverse direction of the element connecting terminals152corresponds to the longitudinal direction of the sensor section21, and the longitudinal direction of the element connecting terminals152is orthogonal to the longitudinal direction of the sensor section21. That is, the two element connecting terminals152are arranged to be adjacent to one of the longitudinal ends of the sensor section21opposite to the end on which the terminals33(seeFIG. 5(b)) are arranged, that is, the first end21d. The longitudinal direction of the element connecting terminals152is a direction orthogonal to the longitudinal direction of the sensor section21(in this example, the direction orthogonal to the adhesion surface22a). Part of the element connecting terminals152on the front side of the adhesion surface22ais longer than part of the element connecting terminals152on the back side of the adhesion surface22a.

The core electrodes25of the electrode wires23,24are drawn out from the first end22dof the hollow insulating body22. The core electrodes25of the two electrode wires23,24drawn out from the first end22dof the hollow insulating body22are arranged on both sides of the terminal support portion41in the thickness direction. After the core electrodes25of the electrode wires23,24are each sandwiched between the associated first connection piece52and the terminal main body51on both sides of the terminal support portion41in the thickness direction, the core electrodes25are electrically connected to the element connecting terminals152by soldering. InFIG. 13(h), a solder161, which electrically connects each core electrode25to the associated element connecting terminal152is shown by a broken line in which a long dash alternates with a pair of short dashes. The connecting portions between the element connecting terminals152and the core electrodes25of the electrode wires23,24, which are element-side electrode connecting portions P14, are formed on the ends of the element connecting terminals152that are adjacent to the first end21dof the sensor section21(the end close to the first end22d) in the longitudinal direction of the sensor section21.

The resistive element153includes a pair of connecting legs153afor connecting the resistive element153to the element connecting terminals152.FIG. 13(b) shows only one of the pair of connecting legs153a. The resistive element153is arranged at a position closer to the sensor section21than one of the transverse ends of each element connecting terminal152opposite to the sensor section21(the left end inFIG. 13(b)). In this example, part of the resistive element153other than the connecting legs153ais arranged to be closer to the sensor section21than the element connecting terminals152. The pair of connecting legs153ais arranged on both sides of the terminal support portion41in the thickness direction such that the terminal support portion41is located, in between. After the pair of connecting legs153ais each sandwiched between the associated second connection piece53and the terminal main body51on both sides of the terminal support portion41in the thickness direction, the connecting legs153aare electrically connected to the element connecting terminals152by soldering. InFIG. 13(b), a solder162, which electrically connects each connecting leg153ato the associated element connecting terminal152, is shown by a broken line in which a long dash alternates with a pair of short dashes. The connecting portions between the element connecting terminals152and the resistive element153, which are element connecting portions P15, are formed at positions on the element connecting terminals152displaced from the element-side electrode connecting portions P14in a direction orthogonal to the longitudinal direction of the sensor section21toward the outer circumference of the hollow insulating body22. The element connecting portions P15are formed on the longitudinal ends opposite to the ends of the element connecting terminals152on which the element-side electrode connecting portions P14are provided, and are formed at positions on the element connecting terminals152at the front side of the adhesion surface22a.

The element-side sealing member154is formed of insulating plastic material. The element-side sealing member154embeds and seals the element connecting terminals152, the resistive element153, the element connecting portions P15, the element-side electrode connecting portions P14, and the first end22dof the hollow insulating body22adjacent to the element connecting terminals152. The element-side sealing member154includes an element-side terminal, coating section171, which is adjacent to the first end22dof the hollow insulating body22in the longitudinal direction of the sensor section21, and an element-side mounting leg172, which is integrally formed with the element-side terminal coating section171.

The element-side terminal coating section171is integrally formed on the end face of the hollow insulating body22at the first end22dwhile embedding the first end22dof the hollow insulating body22. The element-side terminal coating section171embeds and seals part of the terminal support portion41adjacent to the first end22dof the hollow insulating body22in the longitudinal direction of the sensor section21, part of the two element connecting terminals152adjacent to the first end22dof the hollow insulating body22in the longitudinal direction of the sensor section21(approximately half the element connecting terminals152in the longitudinal direction where the electrode wires23,24are connected), the guide portion43, and the element-side electrode connecting portions P14. The outer shape of the element-side terminal coating section171is a size larger than the outer shape of the hollow insulating body22, and the shape of the cross-section of the element-side terminal coating section171orthogonal to the longitudinal direction of the sensor section21is substantially D-shaped. The end of the element-side terminal coating section171close to the first end22dof the hollow insulating body22is in close contact with the first end22dto be liquid-tight and air-tight.

The element-side mounting leg172is integrally formed with the end of the element-side terminal coating section171closer to the resistive element153and with the adhesion surface22aat the first end22dof the hollow insulating body22. The element-side mounting leg172protrudes further outward than the outer circumferential surface of the hollow insulating body22, and is a substantially rectangular solid. The element-side mounting leg172has a width slightly greater than the adhesion surface22a. The measurement of the element-side mounting leg172in the longitudinal direction of the sensor section21is substantially equal to the measurement of the element-side terminal coating section171in the longitudinal direction of the sensor section21. The element-side mounting leg172embeds and seals part of the terminal support portion41that protrudes further outward than the outer circumferential surface of the hollow insulating body22, parts of the two element connecting terminals152that protrude further outward than the outer circumferential surface of the hollow insulating body22(approximately half the element connecting terminals152in the longitudinal direction where the resistive element153is connected), the resistive element153, and the element connecting portions P15. Thus, the longitudinal direction of the element-side sealing member154is a direction orthogonal to the longitudinal direction of the sensor section21(in this embodiment, the direction orthogonal to the adhesion surface22a). Part of the element-side sealing member154at the front side of the adhesion surface22ais longer than part of the element-side sealing member154at the back side of the adhesion surface22a.

A pair of element-side mounting engagement portions173are formed on the element-side mounting leg172.FIG. 13(b) shows only one of the two element-side mounting engagement portions173. The pair of element-side mounting engagement portions173are formed on both sides of the element-side mounting leg172in the widthwise direction (the direction that is the same as the widthwise direction of the adhesion surface22a), that is, on both sides of the element-side mounting leg172in the thickness direction of the terminal support portion41. The pair of element-side mounting engagement portions173are grooves extending in the longitudinal direction of the sensor section21through the element-side mounting leg172in the longitudinal direction of the sensor section21. The pair of element-side mounting engagement portions173is formed at positions between the element-side electrode connecting portions P14and the element connecting portions P15in the longitudinal direction of the terminal support portion41. The pair of element-side mounting engagement portions173is formed at positions on the element connecting terminals152between the first connection pieces52and the second connection pieces53in the longitudinal direction of the terminal support portion41. The width of part of the element-side mounting leg172at which the pair of element-side mounting engagement portions173are formed (the width in the direction that is the same as the widthwise direction of the adhesion surface22a) is reduced. However, parts of the two element connecting terminals152are embedded in the element-side mounting leg172at the back side of the element-side mounting engagement portions173.

The above-mentioned element-side mounting leg172is engaged with the bracket12by inserting the part of the element-side mounting leg172between the pair of element-side mounting engagement portions173in the engaging groove12aformed in the longitudinal end of the bracket12. Parts on both sides of the engaging groove12aof the bracket12are inserted in the pair of element-side mounting engagement portions173. Thus, the longitudinal end of the foreign matter detection sensor13close to the element-side sealing member154is secured to the bracket12by the element-side mounting leg172.

In this manner, since the element connecting portions P15are displaced relative to the element-side electrode connecting portions P14on the element connecting terminals152in the direction orthogonal to the longitudinal direction of the sensor section21, the resistive element153is easily arranged at a position closer to the sensor section21than the one of the transverse ends of each element connecting terminal152opposite to the sensor section21. Since the resistive element153is arranged at the position closer to the sensor section21than one of the transverse ends of each element connecting terminal152opposite to the sensor section21, the site of the element-side sealing member154is reduced in the longitudinal direction of the sensor section21as compared to a case in which the resistive element153is arranged to protrude from the element connecting terminals152in the direction opposite to the sensor section21in the longitudinal direction of the sensor section21. Thus, the measurement of the sensor section21is increased in the longitudinal direction on the longitudinal end of the sensor section21at which the element connecting terminals152are arranged. As a result, the detection range of the foreign matter is increased in the longitudinal direction of the sensor section21.

In the example shown inFIG. 13, after being sandwiched between the first connection piece52and the terminal main body51, each of the electrode wires23,24is electrically connected to the associated element connecting terminal152by soldering. After being sandwiched between the second connection piece53and the terminal main body51, each of the connecting legs153aof the resistive element153is electrically connected to the associated element connecting terminal152by soldering. However, each of the electrode wires23,24does not need to be soldered, but may be electrically connected to the corresponding element connecting terminal152by only being sandwiched and crimped between the associated first connection piece52and the terminal main body51. Similarly, each of the connecting legs153aof the resistive element153does not need to be soldered, but may be electrically connected to the corresponding element connecting terminal152by being sandwiched and crimped between the associated second connection piece53and the terminal main body51. Also, the electrode wires23,24and the resistive element153may be electrically connected to the element connecting terminals152by welding.

In the first embodiment, the sensor section21includes the two electrode wires23,24. However, the number of the electrode wires of the sensor section21is not limited to two but may be any number more than one.

In the first embodiment, the electrode wires23,24helically extend in the longitudinal direction of the hollow insulating body22. However, the electrode wires23,24may extend straight in the longitudinal direction of the hollow insulating body22.

In the first embodiment, the electrode wires23,24each include the flexible core electrode25, which is formed by twisting conductive thin wire, and the cylindrical conductive coating layer26, which has conductivity and elasticity and covers the outer circumference of the core electrode25. However, each of the electrode wires23,24may be a single flexible metal wire.

In the first embodiment, the foreign matter detection sensors13are arranged on the edges of the door panel5(mounting positions). However, the foreign matter detection sensors13may be arranged on the edges (mounting position) of the tail opening4opposing the edges of the door panel5. Also, the foreign matter detection sensors13do not necessarily have to be used in the foreign matter detection apparatus11of the motor-driven back door device2, but may be used in a foreign matter detection apparatus of a motor-driven slide door device that selectively opens and closes the exit provided on a side of the vehicle by sliding a door panel. Also, the foreign matter detection sensor13may be used in an apparatus for detecting contact of foreign matter besides the foreign matter detection apparatus of a door opening and closing apparatus that selectively opens and closes the door panel by driving force of, for example, a motor.

In the second embodiment, the mounting engagement portions183are recesses that are formed to reduce the width of the mounting leg182. However, the shape of the mounting engagement portions183is not limited to this. For example, the mounting engagement portions183may protrude in the widthwise direction of the mounting leg182. In this case, the longitudinal end of each bracket12has a shape that can be engaged with the mounting engagement portions183.

In the second embodiment, parts of the power supply members130are located at the rear portion of the mounting engagement portions183in the mounting leg182. However, parts of the power supply members130embedded in the mounting leg182do not necessarily have to be located at the rear portion of the mounting engagement portions183.

In the second embodiment, the mounting leg182includes the pair of mounting engagement portions183. However, the mounting leg182may include only one mounting engagement portion183. Also, the mounting leg182does not necessarily have to include the mounting engagement portion183.

In the second embodiment, part of the sealing member34that protrude further outward than the outer circumferential surface of the hollow insulating body22forms the mounting leg182mounted on the bracket12. However, part of the sealing member34that protrudes further outward than the outer circumferential surface of the hollow insulating body22(the part that protrudes forward of the adhesion surface22a) does not necessarily have to be mounted on the bracket12.

In the second embodiment, the foreign matter detection sensors13are adhered to the edges (mounting positions) of the door panel5via the brackets12. However, the foreign matter detection sensors13may be adhered directly to the edges of the door panel5without using the brackets12. Also, the foreign matter detection sensors13may be mounted on the brackets12or the edges of the door panel5by method other than adhesion by the double-sided tape15, such as sticking with an adhesive.

In the second embodiment, the lead wires171,172are connected to the positions on the terminals51that are the same as the positions where the core electrodes25of the electrode wires23,24are connected. However, the lead wires171,172may be connected to positions on the terminals51displaced in the longitudinal direction of the sensor section21from the positions where the core electrodes25of the electrode wires23,24are connected.

In the second embodiment, one of the power supply members130is configured by one of the terminals51and one of the lead wires (the lead wire171), but may be formed of only the lead wire171. Similarly, the other one of the power supply members130is configured by the other one of the terminals51and the other one of the lead wires (the lead wire172), but may be configured by only the lead wire172. In this case, the distal end of the core electrode25of the electrode wire23is electrically connected to the distal end of the metal wire173of the lead wire171directly, and the distal end of the core electrode25of the electrode wire24is electrically connected to the distal end of the metal wire173of the lead wire172directly. Thus, the terminal processing section31does not include the support member32and the terminals51. Since the number of components of the foreign matter detection sensor13is reduced, the manufacturing costs are reduced.

In the second embodiment, the bent portions176are bent such that, parts of the power supply members130on the opposite side of the bent portions176relative to the electrode connecting portions P1extend toward the first end22dof the hollow insulating body22in parallel to the sensor section21. However, the bent portions176may have any shape as long as the direction in which the parts of the power supply members130on the opposite side of the bent portions176relative to the electrode connecting portions P1extend is in the direction toward the first end of the sensor section21.

In the second embodiment, the direction changing sections175include the bent portions176, but do not necessarily have to include the bent portions176. In this case, the direction changing sections175may extend straight from the electrode connecting portions P1to the end face182aof the mounting leg182inside the sealing member34such that, for example, the direction changing sections175extend from the electrode connecting portions P1in a direction intersecting the longitudinal direction of the sensor section21and further extend in the direction toward the first end21d(first end22d) of the sensor section21.

In the second embodiment, the direction changing sections175extend from the electrode connecting portions P1in the direction orthogonal to the longitudinal direction of the sensor section21, and further extend toward the first end22dof the hollow insulating body22to be parallel to the sensor section21. However, the direction in which the direction changing sections175extend is not limited to this. The direction changing sections175may have any form as long as the direction changing sections175extend from the electrode connecting portions P1in the direction intersecting the longitudinal direction of the sensor section21and further extend in the direction toward the first end21dof the sensor section21. In this case also, an advantage that is the same as the advantage (1) of the second embodiment is obtained.

In the second embodiment, parts of the insulating coatings174of the lead wires171,172are embedded in the sealing member34. However, the parts of the insulating coatings174do not need to be embedded in the sealing member34, and only the metal wires173may be embedded in the sealing member34. The insulating coatings174are generally formed of plastic material. Therefore, since the parts of the insulating coatings174are embedded in the sealing member34formed of plastic material, for example, even in a case in which the terminal processing section31is exposed to a high temperature and the plastic material expands, the sealing performance between the sealing member34and the lead wires171,172is prevented from being reduced due to the difference in the coefficient of linear expansion (coefficient of cubic expansion). The number of the power supply members130provided in the foreign matter detection sensor13may be changed as required in accordance with the number of electrode wires23,24.

The shape of the sealing member34is not limited to that illustrated in the second embodiment. The sealing member34may have any shape as long as the sealing member34seals the electrode connecting portions P1, the direction changing sections175, the bent portions176, and one longitudinal end of the hollow insulating body22. For example, the sealing member34may be a cover that is mounted on the outer circumference of the support member32so as to accommodate the electrode connecting portions P1, the direction changing sections175, the bent portions176, and one longitudinal end of the hollow insulating body22.

In the second embodiment, the straight line L1that passes through the centers of the electrode wires23,24is parallel to the widthwise direction of the adhesion surface22a. However, the straight line L1does not necessarily have to be parallel to the widthwise direction of the adhesion surface22a. For example, the straight line L1may be parallel to the direction orthogonal to the longitudinal direction of the sensor section21. That is, the electrode wires23,24may be drawn out from the second end22eof the hollow insulating body22such that the straight line L1is parallel to the direction orthogonal to the longitudinal direction of the sensor section21on the end face22f.

In the second embodiment, the sensor section21includes the two electrode wires23,24. However, the number of the electrode wires of the sensor section21is not limited to two but may be any number more than one.

In the second embodiment, the electrode wires23,24helically extend in the longitudinal direction of the hollow insulating body22. However, the electrode wires23,24may extend straight in the longitudinal direction of the hollow insulating body22.

In the second embodiment, each of the electrode wires23,24includes the flexible core electrode25, which is formed by twisting conductive thin wire, and the cylindrical conductive coating layer26, which has elasticity and covers the outer circumference of the core electrode25. However, each of the electrode wires23,24may be a single flexible metal wire.

In the second embodiment, the foreign matter detection sensors13are arranged on the edges (mounting positions) of the door panel5. However, the foreign matter detection sensors13may be arranged on the edges (mounting positions) of the tail opening4opposing the edges of the door panel5. Also, the foreign matter detection sensors13do not necessarily have to be used in the foreign matter detection apparatus11of the motor-driven back door device2, but may be used in a foreign matter detection apparatus of a motor-driven slide door device that selectively opens and closes the exit provided on a side of the vehicle by sliding a door panel. Also, the foreign matter detection sensor13may be used in an apparatus for detecting contact of foreign matter besides the foreign matter detection apparatus of a door opening and closing apparatus that selectively opens and closes the door panel by driving force of, for example, a motor.