Patent Description:
Conventionally, brake systems for vehicles such as two-wheel vehicles and four-wheel vehicles have been known to include a brake control device that controls the brake hydraulic pressure acting on a wheel brake. The brake control device includes a base body with brake fluid paths formed therein, solenoid valves attached to one surface of the base body, coil assemblies each surrounding the solenoid valves, a housing that covers the solenoid valves and the coil assemblies, and a control board functioning as an electrical component installed in the housing.

In such a brake control device, the control board controls the energization to the coil assemblies to open and close the solenoid valves, and thereby changes the brake hydraulic pressure in the brake fluid paths to control the braking force applied to the wheel brake.

The coil assembly includes a yoke, a bobbin disposed in the yoke, and a coil wound around the bobbin.

As for connection terminals connected to the coil, press-fit terminals have been known as described in Patent Literature <NUM>, for example. The press-fit terminals are press-mounted into mounting holes of the control board, thereby electrically connecting the coil assembly to the control board. Further, the coil assembly is attached around the solenoid valve in such a way that the solenoid valve is inserted through a center hole of the bobbin, and the coil is energized from the control board, thereby opening and closing the solenoid valve.

Patent Literature <NUM> discloses a coil assembly comprising: a bobbin comprising a cylindrical portion and a flange portion formed at an axial end of the cylindrical portion, the flange portion having a yoke housing portion formed therein; a coil including a winding around the bobbin; a yoke attached to the bobbin, wherein an end portion of the yoke is housed in the yoke housing portion; and a connection terminal electrically connected to the winding, wherein the end portion of the yoke, housed in the yoke housing portion, is arranged with the flange portion between the terminal portion and the end portion of the yoke in an axial direction of the terminal portion.

In the above-mentioned conventional coil assembly, each press-fit terminal has a plurality of bent portions and extends toward the control board. When the press-fit terminal is press-fitted into the mounting hole formed in the control board, a tool provided at an equipment side is placed on a lower side of the bent portions and is pressed in such a way that the press-fit terminals are pressed toward the control board side. Therefore, a space for placing the tool needs to be formed on a lateral side of the coil assembly.

The present invention provides a coil assembly and a brake control device that solve the above-mentioned problem, is capable of being assembled to an electrical component without using a tool for assembly, and is capable of enhancing the downsizing and the flexibility of layout by eliminating a space for placing the tool.

To solve the above problems, in an aspect of the present invention there is provided a coil assembly comprising: a bobbin comprising a cylindrical portion and a flange portion formed at an axial end of the cylindrical portion, the flange portion having a yoke housing portion formed therein; a coil including a winding around the bobbin; a yoke attached to the bobbin wherein an end portion of the yoke is housed in the yoke housing portion; and a connection terminal electrically connected to the winding, wherein the connection terminal is a press-fit terminal that includes a terminal portion, for forming a press-fit connection to an external contact portion, said terminal portion extending perpendicularly outward from the flange portion of the bobbin in an axial direction of the bobbin; and wherein the end portion of the yoke, housed in the yoke housing portion, is arranged with the flange portion between the terminal portion and the end portion of the yoke in an axial direction of the terminal portion, such that the end portion of the yoke supports the press-fit terminal via the flange portion in said axial direction of the terminal portion.

According to the structure of the coil assembly in the present invention, the press-fit terminal is supported by the yoke located on a side of the bobbin that is opposite to the terminal portion in the axial direction of the terminal portion. Thus, the yoke can receive a load applied in the axial direction when the terminal portion is press-fitted into the mounting hole of the control board. This enables the coil assembly to be electrically connected to the control board without using a tool for assembly or the like. Therefore, it is possible to eliminate a tool space that has been necessary for the connection operation and to enhance the downsizing and the flexibility of layout accordingly.

The bobbin of the above-mentioned coil assembly may preferably be formed of a resin and thus serving as an insulator. According to this structure, the yoke supports the press-fit terminal via the resin portion of the bobbin, so that it is possible to suitably insulate the yoke from the press-fit terminal.

In another aspect of the present invention there is provided a brake control device that includes the coil assembly according to the aspect mentioned above, the brake control device comprising: a base body in which a fluid path is formed; a solenoid valve which is attached to one surface of the base body and on which the coil assembly is mounted around; a housing fixed to the one surface of the base body, the housing covering the solenoid valve and the coil assembly; and a control board housed in the housing, the control board being configured to control the energization of the coil assembly to control an operation of the solenoid valve, wherein the terminal portion is press-fitted into a mounting hole formed in the control board.

According to the structure of the brake control device of the present invention, when fixing the housing to the one surface of the base body, it is possible to press-fit the press-fit terminals by sandwiching the coil assembly with the base body and the control board in the axial direction of the bobbin. In other words, the press-fit terminal is supported by the yoke located on a side of the bobbin that is opposite to the terminal portion in the axial direction of the terminal portion. Moreover, the yoke is supported by the base body located spaced apart from the terminal portion in the axial direction thereof than the side of the bobbin. This enables the base body to receive the load applied when the terminal portion of the press-fit terminal is press-fitted into the mounting hole of the control board. This enables the coil assembly to be electrically connected to the control board without using a tool for assembly or the like. Therefore, the brake control device having an excellent assembling property can be obtained.

The coil assembly and the brake control device of the present invention can be assembled to an electrical component without using a tool for assembly. Further, with the structure of the coil assembly and the brake control device of the present invention, it is possible to eliminate a space for disposing a tool and enhance the downsizing and the flexibility of layout.

Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings as appropriate. In the following description, when front, rear, left, right, upper, and lower sides of a coil assembly are referred to, directions illustrated in <FIG> are used as references. It should be noted that the description is not intended to limit the direction in which the coil assembly is assembled into a brake control device.

The embodiment is described with exemplifying a case where the coil assembly in the present invention is applied to the brake control device.

Firstly, the brake control device will be described. [Configuration of Brake Control Device] A brake control device U includes a base body <NUM> to which a pressure sensor, solenoid valves V1 and V2, a motor M, a reciprocation pump P, and the like are assembled, as illustrated in <FIG>. Moreover, the brake control device U includes an electronic control unit <NUM> including a control board <NUM> serving as an electrical component that detects the motion of a vehicle body, controls opening and closing of the solenoid valves V1 and V2, and controls operations of the motor M.

A not-shown brake fluid path (oil path) is formed in the base body <NUM>. The brake control device U is configured such that the control board <NUM> causes the solenoid valves V1 and V2 and the motor M to operate on the basis of the motion of the vehicle body, thereby causing the brake hydraulic pressure in the brake fluid path to change.

The base body <NUM> is a metal component formed in a substantially rectangular parallelepiped, and the brake fluid path (oil path) is formed therein.

Of the surfaces of the base body <NUM>, a surface <NUM> on a front side, referred to as one surface, has a plurality of bottomed attaching holes <NUM> and the like formed therein in which the solenoid valves V1 and V2 and a pressure sensor (not illustrated) are mounted. Note that, the number of the solenoid valves V1 and V2 and the pressure sensors to be used differs between cases where the vehicle is a four-wheel vehicle and cases where the vehicle is a two-wheel vehicle, and the number differs depending on the difference in the function of the brake control device, for example. Coil assemblies <NUM> are respectively mounted on the solenoid valves V1 and V2 of the embodiment. The solenoid valve V1 is, for example, a normally open solenoid valve. The solenoid valve V2 is, for example, a normally closed solenoid valve. The coil assemblies <NUM> are electrically connected to the control board <NUM> using press-fit terminals <NUM>, respectively, as described later.

The base body <NUM> has an outlet port <NUM> or the like formed on a side of an upper surface <NUM> of the base body <NUM>, to which outlet port <NUM> a piping leading to a wheel brake (not illustrated) is connected.

Moreover, base body <NUM> has a reservoir hole or the like formed on a side of a lower surface of the base body <NUM>, to which reservoir hole a reservoir component (not illustrated) constituting a reservoir is assembled.

Moreover, base body <NUM> has a pump hole <NUM> or the like formed on a side of a side surface <NUM> of the base body <NUM>, to which pump hole <NUM> the reciprocation pump P is attached.

Note that, the holes formed in the base body <NUM> are communicated with one another directly or via a not-illustrated brake fluid path formed in the base body <NUM>.

The motor M is an electrical component serving as a driving power source of the reciprocation pump P. The motor M is integrally fixed to a surface <NUM> on a rear side of the base body <NUM>, referred to as other side of the base body <NUM>. The motor M drives the reciprocation pump P.

A motor bus bar M1 for supplying electric power to a not-shown rotor is connected to the motor M. The motor bus bar M1 is inserted through a terminal hole (not shown) of the base body <NUM> and is electrically connected to the control board <NUM>.

As illustrated in <FIG>, the electronic control unit <NUM> includes: the control board <NUM>; a housing <NUM> that houses the control board <NUM>, the solenoid valves V1 and V2 that protrude from the base body <NUM>, the pressure sensor and the like; and a cover <NUM> that closes an opening of the housing <NUM>.

The control board <NUM> is a substantially rectangular substrate main body on which an electric circuit is printed and to which electronic components such as semiconductor chip are attached. The control board <NUM> controls, by computer programs stored in advance, energization of the coil assembly <NUM> (see <FIG>) and the motor M on the basis of information obtained from various kinds of sensors such as a pressure sensor, an angular velocity sensor and an acceleration sensor, which are not illustrated, in order to control opening and closing operations of the solenoid valves V1 and V2 and driving of the motor M.

As illustrated in <FIG>, the housing <NUM> is a resin box body that is integrally fixed to the surface <NUM> on the front side of the base body <NUM> in such a way as to cover the solenoid valves V1 and V2 protruding from the surface <NUM> of the base body <NUM> on the front side thereof and the pressure sensor or the like.

The housing <NUM> is open-sided on the side opposite to the base body <NUM> and is open-sided on the side of the base body <NUM>. The solenoid valves V1 and V2, the coil assembly <NUM>, the pressure sensor, and the like are housed in an inner space of the housing <NUM>.

The cover <NUM> is a lid which is made of a resin and which seals the opening of the housing <NUM> on the side thereof opposite to the base body <NUM>. The cover <NUM> is fixed to an end face of the housing <NUM> by means of welding, bonding, screw-fastening, or the like.

As illustrated in <FIG> and <FIG>, the coil assembly <NUM> includes a bobbin <NUM>, a coil <NUM> constituted by a winding <NUM> wound around the bobbin <NUM>, a yoke <NUM> attached to the bobbin <NUM>, and press-fit terminals <NUM> electrically connected to the winding <NUM> (coil <NUM>) and serving as connection terminals. The coil assembly <NUM> is an electrical component to be housed in the housing <NUM> in a state of surrounding the solenoid valve V1 or V2 as shown in <FIG>. The coil assemblies <NUM> are electromagnetic coils that respectively generate a magnetic field around the solenoid valves V1 and V2 by the respective coils <NUM> being energized from the control board <NUM> via the press-fit terminals <NUM>.

As illustrated in the views in <FIG>, the bobbin <NUM> is a resin component (insulating component) with a cylindrical portion <NUM> having upper and lower end portions on which flange portions <NUM> and <NUM> are respectively formed. As illustrated in <FIG>, the cylindrical portion <NUM> has a circular insertion hole 21a centrally penetrating therethrough as a bobbin-side insertion hole. As illustrated in <FIG>, the insertion hole 21a communicates with the later-described upper yoke housing portion 22c formed in the upper flange portion <NUM> and with a hole 22a of the flange portion <NUM>. As illustrated in <FIG>, the insertion hole 21a also communicates with a lower yoke housing portion 23a formed in the lower flange portion <NUM>. The insertion hole 21a has an inside diameter D1. As illustrated in <FIG>, each of the flange portions <NUM> and <NUM> has a front portion that is formed in a semi-circular shape in plan view corresponding to the shape of the winding of the coil <NUM>, and has a rear portion that is formed in a substantially rectangular shape in plan view corresponding to the shape of the yoke.

The hole 22a of the flange portion <NUM> has an inside diameter larger than the inside diameter D1 of the insertion hole 21a.

As illustrated in <FIG>, the upper flange portion <NUM> is formed with a larger thickness in an up-and-down direction than the lower flange portion <NUM>. As illustrated in <FIG>, formed on an inner side of the upper flange portion <NUM> is the upper yoke housing portion 22c, which can house the later-described upper portion <NUM> of the yoke <NUM>. The upper yoke housing portion 22c has openings respectively on the rear surface and the front surface of the upper flange portion <NUM>. The upper portion <NUM> of the yoke <NUM> is housed in the upper yoke housing portion 22c from the rear surface side of the upper flange portion <NUM> (see <FIG>).

The upper yoke housing portion 22c includes a predetermined clearance with respect to the housed upper portion <NUM> of the yoke <NUM> in a direction orthogonal to an axial direction of the bobbin <NUM> (in the horizontal direction). This allows the upper portion <NUM> of the yoke <NUM> to move in the horizontal direction by the clearance provided, in the upper yoke housing portion 22c.

Note that, the flange portion <NUM> covers the substantially entire upper portion <NUM> of the yoke <NUM>, and thus has an excellent insulation property.

As illustrated in <FIG>, the upper flange portion <NUM> has a rear edge portion on which two protrusions 22e, 22e are formed spaced apart from each other in the left-right direction with a predetermined distance therebetween. Each protrusion 22e is a plate-like portion that protrudes rearward from the rear edge portion of the upper flange portion <NUM> and is formed in a rectangular shape in plan view.

The upper flange portion <NUM> has left and right rear portions with terminal support portions 22b, 22b formed thereon that respectively support base portions <NUM>, <NUM> of the two press-fit terminals <NUM>, <NUM>. The press-fit terminals <NUM>, <NUM> are partially embedded in the terminal support portions 22b, 22b by insert-molding, respectively (see <FIG>). In other words, the terminal support portions 22b, 22b (upper flange portion <NUM>) function as an insulator of the press-fit terminals <NUM>, <NUM>.

As illustrated in <FIG>, the upper portion <NUM> of the yoke <NUM>, housed in the upper yoke housing portion 22c, is located below the terminal support portions 22b, 22b. In other words, the two press-fit terminals <NUM>, <NUM> are supported by the upper portion <NUM> of the yoke <NUM> via the terminal support portions 22b, 22b. The terminal support portions 22b, 22b cover portions of the upper portion <NUM> of the yoke <NUM> that respectively support the press-fit terminals <NUM>, <NUM>. This provides insulation between the press-fit terminals <NUM>, <NUM> and the yoke <NUM>.

As illustrated in <FIG>, formed on an inner side of the lower flange portion <NUM> is the lower yoke housing portion 23a, which can house a lower portion <NUM> (see <FIG>) of the yoke <NUM>. The lower yoke housing portion 23a has openings respectively on the rear surface and the lower surface of the lower flange portion <NUM>. In other words, the lower portion <NUM> of the yoke <NUM> is exposed from the lower surface of the coil assembly <NUM> (see <FIG>). The lower portion <NUM> of the yoke <NUM> is housed in the lower yoke housing portion 23a from the rear surface side of the lower flange portion <NUM> (see <FIG>).

As illustrated in <FIG>, the lower yoke housing portion 23a has an inner face on which convex portions 23b, 23b having a curved shape and protruding inward are formed opposite to each other on left and right sides (see <FIG>). The lower yoke housing portion 23a includes, like the above-described upper yoke housing portion 22c, a predetermined clearance with respect to the housed lower portion <NUM> of the yoke <NUM> in a direction orthogonal to the axial direction of the bobbin <NUM> (in the horizontal direction). This allows the lower portion <NUM> of the yoke <NUM> to move in the horizontal direction by the clearance in the lower yoke housing portion 23a.

The lower flange portion <NUM> has quadrangular column-shaped protrusions <NUM>, <NUM> formed on left and right-side surfaces of the lower flange portion <NUM> on a rear side thereof. The protrusions <NUM>, <NUM> each serve as a bonding surface for fixing to the base body <NUM> by an adhesive and serve as a positioning portion for assembling the coil assembly <NUM> to the brake control device U. Specifically, the protrusions <NUM>, <NUM> can each be locked with a not-shown positioning member (rib, protrusion, or the like) provided on the front surface <NUM> (surface on which the solenoid valves V1 and V2 are mounted) of the base body <NUM>, for example. By this locking, the coil assembly <NUM> mounted on the solenoid valve V1 or V2 is positioned so as to be unable to turn around an axis of the bobbin <NUM>. Moreover, the protrusions <NUM>, <NUM> can be locked with a not-shown wall portion provided on the inner side of the housing <NUM>, for example. This wall portion is arranged around the coil assembly <NUM> and has grooves with which the protrusions <NUM>, <NUM> are locked by press-insertion or the like.

The bobbin <NUM> described above is produced by injection-molding or the like. When the bobbin <NUM> is injection-molded, the press-fit terminals <NUM>, <NUM> are insert-molded at the same time in such a way as to be integrally joined to the flange portion <NUM>.

The yoke <NUM> is formed of a metal material having magnetic properties. As illustrated in the views in <FIG>, the yoke <NUM> is configured to include the upper portion <NUM> as an end portion, the lower portion <NUM> as an end portion, and a side portion <NUM> that connects between the upper portion <NUM> and the lower portion <NUM>. The yoke <NUM> is formed to have a vertical cross section with a substantially concave shape (see <FIG>).

The upper portion <NUM> is a part that is housed in the upper yoke housing portion 22c of the upper flange portion <NUM> of the bobbin <NUM> (see <FIG>). The upper portion <NUM> has an outer shape similar to that of the upper flange portion <NUM> of the bobbin <NUM>, and has a front portion formed in a semi-circular shape and a rear portion formed in a substantially rectangular shape, as illustrated in <FIG>. The upper portion <NUM> is configured so as to be housed in the upper yoke housing portion 22c with the above-described clearance therebetween and is movable in the horizontal direction with respect to the upper yoke housing portion 22c.

Note that, the upper portion <NUM> is formed to have an outer shape that is slightly smaller than that of the lower portion <NUM>, as illustrated in <FIG>.

The upper portion <NUM> is housed in the upper yoke housing portion 22c, and thus is arranged below the press-fit terminals <NUM> with the upper flange portion <NUM> in between. In other words, the press-fit terminals <NUM> (terminal portions <NUM> and base portions <NUM>) are supported by the upper portion <NUM> located on a side of the upper flange portion <NUM> that is opposite to the terminal portions <NUM> in an axial direction thereof.

The lower portion <NUM> is a part that is housed in the lower yoke housing portion 23a of the lower flange portion <NUM> of the bobbin <NUM> (see <FIG>). The lower portion <NUM> has a front portion formed in a semi-circular shape and a rear portion formed in a substantially rectangular shape, like the outer shape of the upper portion <NUM> (see <FIG>).

As illustrated in <FIG>, the lower portion <NUM> has recessed portions 32b, 32b formed on portions of the lower portion <NUM> that face the convex portions 23b, 23b of the lower yoke housing portion 23a (see <FIG>). In a state where the lower portion <NUM> is housed in the lower yoke housing portion 23a, the convex portions 23b, 23b of the lower yoke housing portion 23a are loosely fitted (fitted with a gap) with the recessed portions 32b, 32b of the lower portion <NUM>. The lower portion <NUM> is configured so as to be housed in the lower yoke housing portion 23a with a clearance therebetween, and is movable in the horizontal direction with respect to the lower yoke housing portion 23a in a state where the convex portions 23b, 23b are loosely fitted with the recessed portions 32b, 32b as described above. In other words, the convex portions 23b are fitted with the recessed portions 32b in such a way as to allow the above-described movement in the horizontal direction.

The yoke <NUM> has a circular insertion hole 31a formed in the upper portion <NUM> as a yoke-side mounting hole and has a circular insertion hole 32a formed in the lower portion <NUM>. These insertion holes 31a, 32a have substantially the same inside diameter D2 as illustrated in <FIG> and <FIG>. The inside diameter D2 is selected such that the insertion holes 31a, 32a fit over the solenoid valve V1 (V2). Here, the relation between the above-mentioned inside diameter D1 of the insertion hole 21a of the bobbin <NUM> and the inside diameter D2 of the insertion holes 31a, 32a of the yoke <NUM> is such that the inside diameter D1 of the bobbin <NUM> is larger than the inside diameter D2 of the yoke <NUM>, i.e., D1 > D2.

As illustrated in <FIG>, the two press-fit terminals <NUM>, <NUM> are metal components partially insert-molded in the terminal support portions 22b, 22b (the bobbin <NUM>). As illustrated in <FIG>, the two press-fit terminals <NUM>, <NUM> are spaced apart from each other by a predetermined distance in the left-and-right direction.

As illustrated in the views in <FIG>, each press-fit terminal <NUM> includes a plate-like base portion <NUM>, a terminal portion <NUM> that protrudes upward from an upper portion of one end of the base portion <NUM>, and a connection portion <NUM> that protrudes downward from a lower portion of the other end of the base portion <NUM>.

As illustrated in <FIG>, the most part of the base portion <NUM> is embedded in the terminal support portion 22b. The upper portion of the base portion <NUM> is exposed from the terminal support portion 22b. As illustrated in <FIG>, the base portion <NUM> has an insertion hole 11a formed therein into which resin can enter when being molding. As illustrated in <FIG>, the base portion <NUM> is reinforced and supported by a reinforcing rib 22d provided on the terminal support portion 22b.

As illustrated in <FIG>, the terminal portion <NUM> projects upward (toward the outside in the axial direction of the bobbin <NUM>) from the upper portion of the one end of the base portion <NUM> and perpendicularly thereto. In other words, the terminal portion <NUM> extends upward from the upper flange portion <NUM>. The terminal portion <NUM> has a distal end portion with a loop-shaped bulge, which is press-fitted into a mounting hole <NUM> (see <FIG>) of the control board <NUM> (see <FIG>).

The connection portion <NUM> is connected to the winding <NUM> of the coil <NUM>. The connection portion <NUM> has a contact portion <NUM> with which the winding <NUM> comes into contact and which has a smaller plate thickness than other portion of the connection portion <NUM>. In other words, the press-fit terminal <NUM>, the plate thickness of which is likely to be limited due to the requirement for being press-fitted, is configured such that the connection portion <NUM> to which the winding <NUM> is connected is thin-walled to scrape off the coating of the winding <NUM> by the contact.

As illustrated in <FIG>, the contact portion <NUM> has a groove <NUM> formed therein having a substantially V-shaped cross section. The groove <NUM> has upper edge portions each extending in a rounded shape. The groove <NUM> has a pair of step portions <NUM>, <NUM> protruding inwardly (toward an inner side) of the groove <NUM>, at opposed portions of inner surfaces of the groove <NUM>. The step portions <NUM>, <NUM> define a groove 15b therebetween having a narrow width. The groove 15b defined by the step portions <NUM>, <NUM> of the groove <NUM> has a width L1 (width in the left-and-right direction) that is smaller than a wire diameter D3 of the winding <NUM> (wire diameter of the wire with coating). The groove <NUM> is formed so as to have a narrower width toward a deepest part 15c.

As illustrated in <FIG>, the connection portion <NUM> has a protrusion <NUM> formed on a lower lateral portion of the connection portion <NUM> to allow winding a wire of the winding <NUM> between the protrusion <NUM> and the groove <NUM>. In addition, the connection portion <NUM> has a hook portion 13b formed on a lower end portion of the connection portion <NUM> and protruding in a hook shape toward the terminal support portion 22b (see <FIG>). The hook portion 13b (not shown) is embedded in the terminal support portion 22b (see <FIG>).

The press-fit terminal <NUM> can be obtained by pressworking (press punching), for example. In the press punching, a flat, belt-like metal plate or the like having conductivity and a predetermined thickness is used to obtain a press punched material including the press-fit terminals <NUM>, as illustrated in <FIG>. The press punched material includes a frame-shaped connection plate <NUM> which serves as a carrier and to which press-fit terminals <NUM> are connected via connection plate connecting parts 19a. Each press-fit terminal <NUM> is molded according to the above-described terminal structure.

The thin-walled contact portion <NUM> is formed to have a thin thickness by performing an additional pressworking after the press punching has been performed. Thereafter, the groove <NUM> is formed by punching.

Note that, the contact portion <NUM> may be formed by pressworking at the same time as when the press punching is performed, or the contact portion <NUM> may be formed in advance by pressworking and then the punching-out may be performed.

The coil <NUM> is obtained by winding the wire of the winding <NUM> around the cylindrical portion <NUM> of the bobbin <NUM>, as illustrated in <FIG>. Two end portions of the winding <NUM> are respectively attached to the connection portions <NUM>, <NUM> of the press-fit terminals <NUM>, <NUM> by being wound therearound, and the coil <NUM> is electrically connected to each of the press-fit terminals <NUM>, <NUM>.

Firstly, as illustrated in <FIG>, the winding <NUM> is wound around the cylindrical portion <NUM> of the bobbin <NUM> to form the coil <NUM> around the bobbin <NUM>, as illustrated in <FIG>.

Thereafter, the end portions of the winding <NUM> of the coil <NUM> are wound around the connection portions <NUM>, <NUM> of the press-fit terminals <NUM>, <NUM> to connect the winding <NUM> to the connection portions <NUM>, <NUM>, respectively. In this operation, as illustrated in <FIG>, when the wire of the winding <NUM> is inserted into the groove <NUM> formed in the contact portion <NUM>, the winding <NUM> comes into contact with the inner surface of the groove <NUM> to scrape off the coating of the winding <NUM>. In other words, in the course of winding the wire of the winding <NUM> around the groove <NUM>, the coating of the winding <NUM> is automatically scraped off by the thin-walled contact portion <NUM> and the winding <NUM> is electrically connected to the connection portion <NUM>.

At this time, when the wire of the winding <NUM> comes into contact with the step portion <NUM> of the groove <NUM>, the scraping-off of the coating of the winding <NUM> is facilitated, and the electrical connection of the winding <NUM> is reliably established. Moreover, as the width L1 (width in the left-and-right direction) of the groove 15b defined by the step portions <NUM>, <NUM> of the groove <NUM> is smaller than the wire diameter D3 (wire diameter of the wire with coating) of the winding <NUM>, the coating of the wire of the winding <NUM> is scrapped off more suitably by inserting the wire of the winding <NUM> into the deepest part 15c in the winding operation.

Thereafter, as illustrated in <FIG>, the yoke <NUM> is mounted into the bobbin <NUM>. In this operation, the upper portion <NUM> of the yoke <NUM> is inserted into the upper yoke housing portion 22c of the bobbin <NUM>, and the lower portion <NUM> of the yoke <NUM> is inserted into the lower yoke housing portion 23a. When the lower portion <NUM> of the yoke <NUM> is housed in the lower yoke housing portion 23a, the convex portions 23b, 23b (see <FIG>) of the lower yoke housing portion 23a are loosely fitted with the recessed portions 32b, 32b of the lower portion <NUM>. This fitting causes the bobbin <NUM> to hold the yoke <NUM> and prevents the yoke <NUM> from falling off from the bobbin <NUM>.

Note that, when the yoke <NUM> is inserted in the mounting direction more than necessary, the side portion <NUM> of the yoke <NUM> abuts on the protrusions 22e, 22e provided on the upper flange portion <NUM> of the bobbin <NUM>. This prevents the yoke <NUM> from coming into contact with the coil <NUM>.

In this way, the assembling of the coil assembly <NUM> is completed.

According to the embodiment of the brake control device U, as illustrated in <FIG>, the terminal portions <NUM> of the press-fit terminals <NUM> of the coil assemblies <NUM> disposed in the housing <NUM> are press-fitted into the mounting holes <NUM> of the control board <NUM>. In this manner, the coil assemblies <NUM> are electrically connected to the control board <NUM> by press-fitting the press-fit terminals <NUM> in the control board <NUM>.

When attaching the coil assembly <NUM> to the brake control device U, firstly, the coil assemblies <NUM> are mounted on the solenoid valves V1 and V2 having been attached to the base body <NUM>. In this operation, if not-shown positioning members such as ribs are provided on the surface <NUM> on the front side of the base body <NUM>, the protrusions <NUM>, <NUM> of the bobbin <NUM> of the coil assembly <NUM> are locked with the positioning members. This positions the coil assembly <NUM> so as to be unable to turn around the axis of the bobbin <NUM>. Accordingly, the press-fit terminals <NUM> are disposed at predetermined positions of the base body <NUM>.

Thereafter, the housing <NUM> is attached to the base body <NUM>. Subsequently, the control board <NUM> is brought closer to the housing <NUM>, the press-fit terminals <NUM> are placed into mounting holes <NUM> of the control board <NUM>, and the control board <NUM> is pressed toward the base body <NUM>.

In this situation, as illustrated in <FIG>, the yoke <NUM> (upper portion <NUM>) supports the press-fit terminals <NUM>, at a location spaced apart from the terminal portions <NUM> in the axial direction of the terminal portions <NUM>. Specifically, the upper portion <NUM> of the yoke <NUM> is arranged in such a way that a flat surface of the upper portion <NUM> is spaced apart from the terminal portions <NUM> in the axial direction of the terminal portions <NUM> and that the flat surface is orthogonal to the axial direction. Thus, the load applied in the axial direction when the terminal portion <NUM> is press-fitted into the mounting hole <NUM> of the control board <NUM> is received by the flat surface of the yoke <NUM> (upper portion <NUM>) in a direction perpendicular to the flat surface.

The lower portion <NUM> of the yoke <NUM> is abutted on the surface <NUM> of the front side of the base body <NUM>. This enables the base body <NUM> (product) to receive the load that is applied in the axial direction when the terminal portion <NUM> is press-fitted into the mounting hole <NUM> of the control board <NUM>.

The inside diameter D1 of the insertion hole 21a of the bobbin <NUM> is larger than the inside diameter D2 of the insertion holes 31a, 32a of the yoke <NUM>. This allows, when placing the press-fit terminals <NUM> into mounting holes <NUM> of the control board <NUM>, sliding of the bobbin <NUM> in a direction orthogonal to the axial direction of the solenoid valves V1 and V2 relative to the yoke <NUM> attached to the solenoid valves V1 and V2. Accordingly, the positioning of the press-fit terminals <NUM> with respect to the mounting holes <NUM> of the control board <NUM> is easy.

After the positioning has been completed, the control board <NUM> is pressed toward the base body <NUM>, so that the terminal portions <NUM> are press-fitted into the mounting holes <NUM> of the control board <NUM>. This electrically connects the coil assembly <NUM> to the control board <NUM> via the press-fit terminals <NUM>.

According to the above-described structure of the coil assembly <NUM> of the embodiment, the yoke <NUM> supports the press-fit terminals <NUM>, at a location spaced apart from the terminal portions <NUM> in the axial direction of the terminal portions <NUM>. Thus, the yoke <NUM> can receive the load that is applied in the axial direction when the terminal portions <NUM> are press-fitted into the mounting holes <NUM> of the control board <NUM>. This enables the coil assembly <NUM> to be electrically connected to the control board <NUM> without using a tool for assembly or the like. Therefore, it is possible to eliminate a space for placing a tool that was necessary for connection and to enhance the downsizing and the flexibility of layout accordingly.

The yoke <NUM> supports the press-fit terminals <NUM> via the bobbin <NUM> (upper flange portion <NUM>) serving as an insulator. Therefore, it is possible to suitably insulate the yoke <NUM> from the press-fit terminals <NUM>. Note that, the bobbin <NUM> is entirely made of resin, and thus insulation is easily achieved.

As the terminal support portions 22b, 22b (resin portions) of the bobbin <NUM> cover portions of the yoke <NUM> that support the press-fit terminals <NUM> (portions of the upper portion <NUM> that support the press-fit terminals <NUM>), it is possible to suitably insulate the yoke <NUM> from the press-fit terminals <NUM>.

According to the structure of the brake control device U of the embodiment, when fixing the housing <NUM> to the one surface of the base body <NUM>, it is possible to press-fit the press-fit terminals <NUM> by sandwiching the coil assembly <NUM> with the base body <NUM> and the control board <NUM> in the axial direction of the bobbin <NUM>. In other words, the press-fit terminals <NUM> are supported by the yoke <NUM> located on a side of the bobbin <NUM> that is opposite to the terminal portions <NUM> in the axial direction of the terminal portions <NUM>. Moreover, the yoke <NUM> is supported by the base body <NUM> located spaced apart from the terminal portions <NUM> in the axial direction of the terminal portions <NUM> than the side of the bobbin <NUM>. This enables the base body <NUM> to receive the load applied when the terminal portions <NUM> of the press-fit terminals <NUM> are press-fitted into the mounting holes <NUM> of the control board <NUM>. This enables the coil assembly <NUM> to be electrically connected to the control board <NUM> without using a tool for assembly or the like. Therefore, the brake control device U having an excellent assembling property can be obtained.

The present invention has been described in the foregoing on the basis of the embodiment. However, the present invention is not limited to the configuration of the embodiment described. The configuration can be changed as appropriate in a range without departing the scope of the present invention. Moreover, a part of the configuration of the embodiment can be added, removed, and replaced.

For example, although the bobbin <NUM> is described as being entirely formed of a resin, the embodiment is not limited thereto. At least portions that support the press-fit terminals <NUM> may be formed of a resin to cause this resin portion to function as an insulator.

Moreover, the terminal portion <NUM> of each press-fit terminal <NUM> only needs to protrude upward from the bobbin <NUM>, and the connection portion <NUM> and the like of the press-fit terminal <NUM> may be disposed on a lateral side and the like of the bobbin <NUM>.

Moreover, although the press-fit terminals <NUM> have been described as being insert-molded in the bobbin <NUM>, the press-fit terminals <NUM> are not limited thereto and may be adapted to be attached to the bobbin <NUM> later.

Claim 1:
A coil assembly (<NUM>) comprising:
a bobbin (<NUM>) comprising a cylindrical portion (<NUM>) and a flange portion (<NUM>) formed at an axial end of the cylindrical portion, the flange portion having a yoke housing portion (22c) formed therein;
a coil (<NUM>) including a winding (<NUM>) around the bobbin;
a yoke (<NUM>) attached to the bobbin, wherein an end portion (<NUM>) of the yoke is housed in the yoke housing portion; and
a connection terminal (<NUM>) electrically connected to the winding,
wherein the connection terminal is a press-fit terminal (<NUM>) that includes a terminal portion (<NUM>), for forming a press-fit connection to an external contact portion, said terminal portion extending perpendicularly outward from the flange portion of the bobbin in an axial direction of the bobbin, and
wherein the end portion of the yoke, housed in the yoke housing portion, is arranged with the flange portion between the terminal portion and the end portion of the yoke in an axial direction of the terminal portion, such that the end portion of the yoke supports the press-fit terminal via the flange portion in said axial direction of the terminal portion.