Patent Publication Number: US-11035748-B2

Title: Pressure sensor attachment structure

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of priority to Japanese Patent Application No. 2016-153214 filed on Aug. 3, 2016. The entire contents of this application are hereby incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a sensor attachment structure that is suitable for use in, for example, a control valve of an automobile transmission. 
     2. Description of the Related Art 
     Automatic transmissions of vehicles include a control valve for controlling a transmission mechanism. The control valve controls the transmission mechanism by supplying or stopping supplying a predetermined oil pressure to the transmission mechanism by using a solenoid valve. Some existing control valves include a valve body in which an upper body is superposed on a lower body. An oil passage, in which hydraulic oil flows, is formed in the valve body. A solenoid valve for switching oil pressure and a sensor for detecting oil pressure in the oil passage are disposed in the valve body. 
     In most existing control valves, electronic devices, such as a sensor, are independently attached onto the valve body. As reduction in size has been needed in recent years, for example, control valves are required to have a built-in structure illustrated in  FIG. 8 , in which an oil pressure sensor  3  is held between an upper body  1  and a lower body  2 . 
     For example, such a structure is described in Japanese Unexamined Patent Application Publication No. 2010-174991, Domestic Re-publication of PCT International Publication for Patent Application No. 2010/058800, and Japanese Unexamined Patent Application Publication No. 2011-134801. 
       FIG. 9  illustrates a method used in existing technologies to hold the oil pressure sensor  3  between the upper body  1  and the lower body  2 . In this method, first, the upper body  1  is turned upside down so that a lower surface thereof faces upward, the oil pressure sensor  3  is turned upside down, and the oil pressure sensor  3  is inserted into an accommodation space  4  in the upper body  1 . Next, in a state in which the oil pressure sensor  3  is fitted into the accommodation space  4 , the upper body  1  is turned right side up and superposed on the lower body  2 , and the upper body  1  and the lower body  2  are fixed to each other. 
     If the oil pressure sensor  3  is first placed on the lower body  2  and then the upper body  1  is superposed on the lower body  2 , the oil pressure sensor  3  and the accommodation space  4  are hidden by the upper body  1 , it is difficult to adjust the positions of the oil pressure sensor  3  and the accommodation space  4  relative to each other, and it is difficult to insert the oil pressure sensor  3  into the accommodation space  4 . Therefore, as described above, the oil pressure sensor  3  is attached to the upper body  1  in a state in which the upper body  1  is turned upside down. 
     However, with such a method, after the oil pressure sensor  3  has been attached and when the upper body  1  is turned right side up to be superposed on the lower body  2 , the oil pressure sensor  3 , which has been fitted into the accommodation space  4 , may fall due to its own weight. Therefore, an operator needs to superpose the upper body  1  on the lower body  2  to adjust the positions of the upper body  1  and the lower body relative to each other while pressing the oil pressure sensor  3  so that the oil pressure sensor  3  may not fall. Thus, this method has a problem of very low workability. Moreover, there is a probability that the oil pressure sensor  3  becomes damaged, because an operator cannot avoid fall of the oil pressure sensor  3  from the upper body  1  even when the operator pays attention. 
     The present invention has been conceived to provide a sensor attachment structure which prevents an oil pressure sensor from falling from an upper body even when the upper body is turned upside down, and which allows installation of the oil pressure sensor and positioning of the upper body and a lower body to be accomplished by simple operations. 
     SUMMARY OF THE INVENTION 
     A sensor attachment structure according to a preferred embodiment of the present invention includes an oil pressure sensor including a sensor case and a pressure sensor element accommodated in the sensor case, the sensor case including a body portion having a circular horizontal section; and a valve body including an upper body and a lower body, the upper body including an accommodation space having a wall surface having a circular horizontal section, the accommodation space having the body portion inserted therein such that the body portion is capable of rotating about a central axis thereof extending in a vertical direction, the lower body including an oil passage arranged to extend therethrough toward the upper body. The sensor case includes a stopper arranged to project in a horizontal direction in an outer circumferential surface of the body portion. The accommodation space includes a guide groove arranged to extend in the vertical direction at the wall surface thereof, the guide groove being arranged to allow the stopper to move therein. The upper body includes a restricting portion arranged to restrict a vertical movement of the stopper in a situation in which the body portion is disposed in the accommodation space. A space portion allowing the stopper to move therein is arranged between the guide groove and the restricting portion. 
     The sensor attachment structure according to the above preferred embodiment of the present invention preferably has the following features: the accommodation space is a through hole defined in the upper body; the restricting portion is a portion of an upper edge of the through hole, the portion including no portion of the guide groove; and the space portion is a space adjoining the upper edge of the through hole and connected to an upper portion of the guide groove. 
     A sensor attachment structure according to another preferred embodiment of the present invention includes an oil pressure sensor including a sensor case and a pressure sensor element accommodated in the sensor case, the sensor case including a body portion having a circular horizontal section; and a valve body including an upper body and a lower body, the upper body including an accommodation space having a wall surface having a circular horizontal section, the accommodation space having the body portion inserted therein such that the body portion is capable of rotating about a central axis thereof extending in a vertical direction, the lower body including an oil passage arranged to extend therethrough toward the upper body. The sensor case includes a stopper arranged to project in a horizontal direction toward an interior of the accommodation space at the wall surface of the accommodation space. An outer circumferential surface of the body portion includes a guide groove arranged to extend in the vertical direction and allow the stopper to move therein. The outer circumferential surface of the body portion includes a restricting portion arranged to restrict a vertical movement of the stopper in a situation in which the body portion has been inserted in the accommodation space. A space portion allowing the stopper to move therein is arranged between the guide groove and the restricting portion. 
     The sensor attachment structure according to the other preferred embodiment of the present invention preferably has the following features: the space portion is a horizontal groove arranged to extend in a circumferential direction at the outer circumferential surface of the body portion, the horizontal groove being connected to the guide groove extending in the vertical direction; and the restricting portion is defined by a lower edge of the horizontal groove. 
     The sensor attachment structure according to each of the above preferred embodiments of the present invention may additionally have the following features: the sensor case includes a lower case and an upper case fixed above the lower case; the upper case is made of a resin, and is arranged to have the pressure sensor element disposed inside thereof; and the lower case is made of a metal, has arranged inside thereof an oil introducing space connected to the oil passage defined in the lower body, includes a collar portion at an outer circumference thereof, and is held with the collar portion being held between the upper body and the lower body. 
     The above and other elements, features, steps, characteristics and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments with reference to the attached drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a first preferred embodiment of the present invention. 
         FIG. 2  is a vertical sectional view of the first preferred embodiment. 
         FIG. 3  is a plan view illustrating engagement between stoppers and restricting portions according to the first preferred embodiment. 
         FIG. 4  is a perspective view of a second preferred embodiment of the present invention. 
         FIG. 5  is a vertical sectional view of the second preferred embodiment. 
         FIG. 6  is a plan view illustrating engagement between stoppers and restricting portions according to the second preferred embodiment. 
         FIG. 7  is a vertical sectional view of a modification of the second preferred embodiment. 
         FIG. 8  is a vertical sectional view illustrating a situation in which an oil pressure sensor is attached to a valve body. 
         FIG. 9  is a perspective view illustrating how oil pressure sensors fall from a valve body. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Hereinafter, preferred embodiments of the present invention will be described. In the figures for each preferred embodiment, members or portions that have their equivalents in a related-art structure illustrated in  FIGS. 8 and 9  are denoted by the same reference numerals as those of their equivalents in the related-art structure, and redundant descriptions of such members and portions will be omitted. In a description of each preferred embodiment, the term “vertical direction” refers to a direction in which an upper body and a lower body are placed one upon the other, and the term “axis” refers to a central axis of an oil pressure sensor extending in the vertical direction. In addition, an inner side and an outer side are defined with reference to the central axis of the oil pressure sensor, and the terms “circumferential direction” and “axial direction” refer to a circumferential direction about the central axis and an axial direction of the central axis, respectively, unless otherwise noted. 
     1. First Preferred Embodiment 
     1.1 Structure 
     A first preferred embodiment of the present invention will now be described below with reference to  FIGS. 1, 2, and 3 . In the first preferred embodiment, stoppers are included in a sensor case, while restricting portions are included in an upper body. 
     A valve body includes an upper body  1  and a lower body  2 . The upper body  1  includes an accommodation space  4  in which a portion of an oil pressure sensor  3  is accommodated. The lower body  2  includes an oil passage  21  arranged to extend therethrough and upward toward the upper body  1 , and the oil pressure sensor  3  is fixed at an opening portion of the oil passage  21 . 
     The accommodation space  4  is a through hole arranged to pass through the upper body  1  from an upper surface to a lower surface of the upper body  1 . A case of the oil pressure sensor  3  is inserted upwardly through the accommodation space  4  along a central axis thereof. An upper edge of the through hole, which defines the accommodation space  4 , in the upper surface of the upper body  1  defines restricting portions  52  arranged to prevent stoppers  50 , which are included in an upper case  32 , from moving downwardly along the central axis of the oil pressure sensor  3 . 
     A decreased diameter portion  41 , which is shaped such that an outer circumferential surface of the upper case  32  of the oil pressure sensor  3  can be tightly fitted therein, is arranged in an upper portion of the accommodation space  4 . A horizontal section, that is, a section perpendicular to the axis of the oil pressure sensor  3 , of the decreased diameter portion  41  is smaller than a horizontal section of a lower case  31  of the oil pressure sensor  3 , and the lower case  31  cannot entirely enter into the decreased diameter portion  41 . An increased diameter portion  42 , in which an outer circumferential surface of the lower case  31 , that is, a collar portion  7  of the lower case  31 , is fitted, is arranged in a lower portion of the accommodation space  4 . A shoulder portion  43  is defined at a boundary between the decreased diameter portion  41  and the increased diameter portion  42 . 
     The oil pressure sensor  3  is a columnar member having a central axis extending in the vertical direction, and includes the lower case  31  and the upper case  32 , which is fixed above the lower case  31 . The lower case  31  and the upper case  32  correspond to a sensor case of the present invention. An outer circumference of the lower case  31  is arranged to project radially outward, i.e., in a horizontal direction in  FIG. 2 , beyond an outer circumference of the upper case  32  to assume the shape of a flange, and defines the collar portion  7 . 
     An oil introducing space  34  is defined in the lower case  31 . The oil introducing space  34  is arranged to open into the oil passage  21  at one end, and is closed at another end with a flexible plate  33  which is to be deformed in accordance with oil pressure. A groove  35 , which is recessed upward from a lower surface of the lower case  31 , is defined in the lower case  31 . The groove  35  is arranged radially outside of the oil passage  21 . A sealant  35   a , such as, for example, an O-ring, is fitted in the groove  35 . A surface of contact between the lower case  31  and the lower body  2  is sealed with the sealant  35   a.    
     A pressure measuring space  36 , which is arranged to surround an upper surface of the flexible plate  33 , is defined in the upper case  32 . A support member  37 , a periphery of which is fixed to the upper case  32 , is arranged in the pressure measuring space  36 . A pressure sensor element  38  is arranged on a lower surface of the support member  37 . The pressure sensor element  38  is arranged on an opposite side of the flexible plate  33  with respect to the oil introducing space  34 . When the flexible plate is deformed by oil pressure from the oil passage  21 , the pressure sensor element  38  detects a change in pressure by sensing a deformation of the flexible plate  33 . 
     The upper case  32  is provided with terminal pins  39 , each of which has spring-like elasticity and is connected to the pressure sensor element  38 . An upper portion of the upper case  32  and the terminal pins  39  provided thereat are arranged to project from the accommodation space  4 , which is defined in the upper body  1 , and are exposed from the upper surface of the upper body  1 . 
     At a surface of the upper case  32 , the stoppers  50 , which are two in number and each of which is arranged to project in a horizontal direction outwardly away from the central axis of the oil pressure sensor  3 , are arranged at regular intervals, that is, at intervals of 180 degrees with the axis of the oil pressure sensor  3  as a center. Referring to  FIG. 2 , each stopper  50  is arranged at a level higher than that of a lower surface of the oil pressure sensor  3  by a thickness of the upper body  1 . A lower surface of each stopper  50  is arranged at a level substantially the same as that of a lower surface of the upper case  32 . 
     A distance from the central axis of the oil pressure sensor  3  to a projecting end of each stopper  50  is arranged to be smaller than a radius of the increased diameter portion  42  of the accommodation space  4 , so that the stopper  50  can freely move in the vertical direction and in the circumferential direction within the increased diameter portion  42  without making contact with a wall surface of the increased diameter portion  42 . 
     The distance from the central axis of the oil pressure sensor  3  to the projecting end of each stopper  50  is arranged to be greater than a radius of the decreased diameter portion  41 . Accordingly, a wall surface of the decreased diameter portion  41  of the accommodation space  4  is provided with guide grooves  51  each of which is arranged to extend in the vertical direction, and the stoppers  50  are fitted into the guide grooves  51  such that the stoppers  50  are movable in the vertical direction. Each guide groove  51  is arranged to open into the increased diameter portion  42  of the accommodation space  4  at a lower end thereof, and is arranged to be open at the upper surface of the upper body  1  at an upper end thereof. 
     The upper body  1  includes the restricting portions  52 , each of which is arranged to restrict a vertical movement of a corresponding one of the stoppers  50  in a situation in which the oil pressure sensor  3  is disposed in the accommodation space  4 . In the present preferred embodiment, each restricting portion  52  is a portion of an upper edge of the accommodation space  4 , the portion including no portion of any guide groove  51 . A space portion, which is arranged to allow the stopper  50  to move therein when the oil pressure sensor  3  is rotated about the axis thereof extending in the vertical direction in the accommodation space  4 , is arranged between each guide groove  51  and the corresponding restricting portion  52 . The space portion, which allows the stopper  50  to move therein, is a portion of a space above the upper surface of the upper body  1 , the portion adjoining the upper edge of the accommodation space  4  and being connected to an upper-end opening portion of the guide groove  51 . 
     The first preferred embodiment, which has the above-described structure, has the following advantages. 
     When the oil pressure sensor  3  is attached to the upper body  1 , the upper body  1  is turned upside down, and then, the oil pressure sensor  3 , with the terminal pins  39  thereof taking the lead, is inserted into the accommodation space  4 . At this time, the oil pressure sensor  3  is rotated about the axis thereof to allow the stoppers  50  to be fitted into the guide grooves  51  and to move along the guide grooves  51 . Thus, the entire oil pressure sensor  3  can be inserted through the accommodation space  4 , even with the stoppers  50  projecting outwardly relative to the wall surface of the decreased diameter portion  41 . 
     When insertion of the oil pressure sensor  3  into the accommodation space  4  has been completed, the stoppers  50  have passed through the guide grooves  51  to be located above the upper body  1  as illustrated in (a) of  FIG. 3 . If the oil pressure sensor  3  is rotated about the axis thereof in this situation, each stopper  50  leaves the opening portion of the corresponding guide groove  51 , and slides in the circumferential direction along the upper edge of the accommodation space  4 . The stopper  50  is able to move in the circumferential direction at this time because the space portion, which allows the stopper  50  to move therein and which is connected to the opening portion of the guide groove  51 , is provided at the upper surface of the upper body  1 . 
     If each stopper  50  is rotated by 90 degrees as illustrated in (b) of  FIG. 3 , for example, the stopper  50  is engaged with the corresponding restricting portion  52 , which is defined at the upper edge of the accommodation space  4 , and is restrained from moving toward the lower body  2 . At the same time, a portion of the upper case  32  is disposed in the decreased diameter portion  41  of the accommodation space  4 , and a portion of the lower case  31  is disposed in the increased diameter portion  42 , and thus, the oil pressure sensor  3  is held in the accommodation space  4  with a portion of the upper body  1  lying between the stoppers  50  and the shoulder portion  43 . 
     After the oil pressure sensor  3  is temporarily fixed to the upper body  1  in the above-described manner, the upper body  1  is turned upside down, and is fitted on an upper surface of the lower body  2 , and the upper and lower bodies  1  and  2  are fixed to each other. In this case, the oil pressure sensor  3  does not fall away from a lower surface of the upper body  1  because the oil pressure sensor  3  is temporarily fixed to the upper body  1 . 
     After the upper and lower bodies  1  and  2  are fixed to each other, the collar portion  7  of the lower case  31  of the oil pressure sensor  3  is held between the shoulder portion  43  of the upper body  1  and a surface of the lower body  2 . Accordingly, even if each stopper  50  is disengaged from the corresponding restricting portion  52 , the oil pressure sensor  3  remains fixed between the upper body  1  and the lower body  2 . 
     The following advantageous effects can be expected from the first preferred embodiment. 
     (1) Provision of the stoppers  50  and the restricting portions  52 , which are arranged to hold the oil pressure sensor  3  in the accommodation space  4 , prevents the oil pressure sensor  3  from falling off the upper body  1  in an operation stage before the oil pressure sensor  3  is fixed in a built-in manner between the upper and lower bodies  1  and  2  of a control valve. This contributes to preventing damage to the oil pressure sensor  3 , and simplifying an assembling operation, and leads to improved productivity. 
     (2) Provision of projections as the stoppers  50  at the surface of the upper case  32  allows a simpler structure of the stoppers  50 , a simpler structure of a mold for molding, and higher strength than in a case where the upper case  32  is provided with a stopper defined by an elastic member, and elasticity thereof is used to temporarily fix the oil pressure sensor  3  and the upper body  1  to each other. 
     (3) Since an edge of the accommodation space  4 , which is an opening portion defined in the upper body  1 , is used as each restricting portion  52 , it is not particularly necessary to machine a wall surface of the accommodation space  4  or the like to form a protrusion or a recess therein when the accommodation space  4  is defined in the valve body. 
     (4) Since the collar portion  7  is arranged to extend over the entire circumferential extent of the lower case  31 , the collar portion  7  has a large area, and can receive a pressing force of the upper body  1  with the large area. Thus, the lower case  31  can be securely fixed. In particular, the upper case  32  is made of a resin, and it is therefore easy to define the stoppers  50 . The lower case  31 , which is held between the upper and lower bodies  1  and  2 , may be made of a metal having a high strength, and in this case, the oil pressure sensor  3  can be securely fixed by the upper and lower bodies  1  and  2 . 
     2. Second Preferred Embodiment 
     A second preferred embodiment of the present invention will now be described below with reference to  FIGS. 4, 5, and 6 . In a description of the second preferred embodiment, members or portions that have their equivalents in the first preferred embodiment are denoted by the same reference numerals as those of their equivalents in the first preferred embodiment, and descriptions of those members or portions are omitted. The second preferred embodiment is different from the first preferred embodiment in that stoppers  50  are included in an upper body  1 , while guide grooves  51  and restricting portions  52  are included in an upper case  32  of an oil pressure sensor  3 . 
     At an inner circumferential surface of an upper edge portion of an accommodation space  4 , the stoppers  50 , which are two in number and each of which is arranged to project in a horizontal direction toward an interior of the accommodation space  4 , are arranged at regular intervals in the circumferential direction. Each guide groove  51  is arranged to extend in the vertical direction at an outer circumferential surface of the upper case  32 , and a horizontal groove  53 , which is connected to the guide groove  51  and is arranged to extend in the circumferential direction, is arranged at an upper-end opening portion of the guide groove  51 . The stopper  50  is able to move in the guide groove  51  and the horizontal groove  53 . A lower edge of the horizontal groove  53  defines the restricting portion  52 , which is arranged to restrict a vertical movement of the stopper  50  in a situation in which the oil pressure sensor  3  has been inserted in the accommodation space  4 . A space in the horizontal groove  53  defines a space portion allowing the stopper  50  to move therein between the guide groove  51  and the restricting portion  52 . 
     The circumferential dimension of each horizontal groove  53  may be just large enough to allow the stopper  50  to be engaged with the restricting portion  52  of the horizontal groove  53 , that is, approximately as large as a circumferential dimension of the stopper  50 , for example. In the second preferred embodiment, however, the horizontal groove  53  is arranged to extend over an angular range of 90 degrees in the circumferential direction so that the oil pressure sensor  3  can be rotated by 90 degrees in the accommodation space  4 . 
     In the second preferred embodiment, as illustrated in (a) of  FIG. 6 , the oil pressure sensor  3  is inserted into the accommodation space  4  with the stoppers  50  entering into the guide grooves  51 . If the oil pressure sensor  3  is rotated by 90 degrees in the accommodation space  4  in a situation in which each stopper  50  has reached an upper end of the corresponding guide groove  51 , the stopper  50  enters into the corresponding horizontal groove  53 . Then, if the stopper  50  reaches an end portion of the horizontal groove  53 , the stopper  50  is engaged with the corresponding restricting portion  52  as illustrated in (b) of  FIG. 6  to prevent the oil pressure sensor  3  from falling off the upper body  1 . Thus, advantageous effects similar to those of the first preferred embodiment can be achieved. 
     In the second preferred embodiment, the guide grooves  51  and the horizontal grooves  53  are defined in the upper case  32 , which is made of a resin. Therefore, it is possible to define the guide grooves  51  and the horizontal grooves  53  at one time by a resin molding process using a mold, which allows easier manufacture than in the case where the upper body  1  is made of a metal and the guide grooves  51  are defined in the upper body  1  made of the metal. 
     3. Other Preferred Embodiments 
     The present invention is not limited to the above-described preferred embodiments. The above-described preferred embodiments have been presented by way of example only, and the present invention can be embodied in a variety of other forms. Various omissions, substitutions, and changes may be made without departing from the scope of the invention. These preferred embodiments and modifications thereof fall within the scope and spirit of the invention and the scope of equivalents thereof. Examples thereof will now be described below. 
     (1) A low-profile, so-called button-type oil pressure sensor may be used as a columnar sensor having a central axis in a preferred embodiment of the present invention. In this case, an accommodation space  4  may be a recessed portion defined in a lower surface of an upper body  1  as illustrated in  FIG. 7 . In  FIG. 7 , stoppers  50  are included in the upper body  1 . Note, however, that, in the case where the accommodation space  4  is the recessed portion, the stoppers  50  may alternatively be defined in an outer circumference of a sensor case, while guide grooves  51  and horizontal grooves  53  may be defined in a wall surface of the accommodation space  4 , with a lower edge of each horizontal groove  53  defining a restricting portion  52 . 
     (2) The number of stoppers  50  included in the sensor case or the upper body  1  is not limited to two, but may be more than two, as long as the stoppers  50  are arranged at regular intervals in the circumferential direction. The number of stoppers may be one as long as the one stopper is so shaped as to be capable of securely fixing the sensor case to the upper body  1 . 
     (3) Each stopper  50  may alternatively be defined by a member separate from the case of the oil pressure sensor  3  and the upper body  1 , and may be fixed to the sensor case or the upper body  1  through, for example, screwing, fitting, or adhesion. 
     (4) The structure of the oil pressure sensor  3  is not limited to those of the preferred embodiments illustrated in the figures. Each stopper may be defined in the lower case  31 , the support member  37 , or another portion of a body portion of the oil pressure sensor, instead of in the upper case  32  as in the first preferred embodiment. 
     (5) Materials of the upper case  32  and the lower case  31  are not limited to those of the preferred embodiments illustrated in the figures. The upper case  32  may be made of, for example, a metal instead of a resin, as long as the stopper  50  can be defined in the upper case  32 . The lower case  31  may alternatively be made of a resin. 
     (6) The collar portion  7 , which is defined in the lower case  31 , does not need to be in the shape of a flange extending over the entire circumferential extent of the lower case  31 . Projecting portions may be defined at the outer circumference of the lower case  31  at regular intervals or at appropriate intervals, and upper surfaces of the projecting portions may be used as the collar portion  7 . 
     Features of the above-described preferred embodiments and the modifications thereof may be combined appropriately as long as no conflict arises. 
     While preferred embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims.