Patent ID: 8770017

Claim:
A method ( 100 ) of manufacturing a molded sensor subassembly ( 1 ) having at least one sensor ( 3 , 4 ) supported on a first side ( 2 a ) of a circuit board ( 2 ) of the sensor assembly ( 1 ), the method comprising the steps of: inserting a plurality of individual pins ( 6 ), during a first step, into through-bores in the circuit board until either a head or a flange of the pins contacts the first side of the circuit board such that the plurality of pins pass through the circuit board ( 2 ) and extend beyond the first side and an opposite second side of the circuit board in a direction transverse to a plane defined by the circuit board, axially opposite ends of the pins having a respective first and second tool contact surface; arranging, during a second step, the circuit board ( 2 ) including the at least one sensor element ( 3 , 4 ) and the plurality of pins ( 6 ) into a two-part insert mold tool ( 10 ) such that the first and the second tool contact surfaces ( 7 a , 8 a ) of the plurality of pins ( 6 ) engage with the insert mold tool ( 10 ), and the plurality of pins ( 6 ) define a spacing distance between a surface of the sensor ( 3 , 4 ) and the insert mold tool ( 10 ); and filling the insert mold tool ( 10 ), during a third step, with insert molding material ( 14 ).