Durakool, Inc.

Craig R Graf

Ronald J Wolf

The present invention relates to a variable reluctance sensor which includes a coil of wire defining a pair of output terminals, one or more stators or pole pieces, and an injection molded bobbin formed from a magnetic material and a polymer binder for carrying the coil wire. The injection molded bobbin magnet enables the size and, thus, the strength of the magnet to be increased while not increasing the overall space requirements of the sensor. In addition, the injection molding enables the inner diameter of the bobbin to be formed in the image of the toothed target wheel relatively easily and inexpensively to additionally improve the output voltage of the sensor. In order to facilitate assembly of the sensor, the bobbin can be formed with integral tabs adapted to be received in corresponding notches formed in the stators, which allows for relatively quick and easy orientation of the stator relative to the bobbin. The output terminals are overmolded relative to the bobbin and stators, which secures the assembly together and also seals one side of the sensor. Axially extending members are radially spaced about an inner diameter of the bobbin to facilitate orientation of the sensor relative to a target wheel in a wheel hub by an automated manufacturing process.

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Elkhart, IN, United States of America

Craig R Graf