Flap position sensing device of active air flap system and method of manufacturing the same

1. A flap position sensing device of an active air flap system comprising a housing having an air inlet which allows outside air entering through a radiator grille to pass, a flap which rotates to reciprocate between an open position for opening the air inlet of the housing and a closed position for closing the air inlet of the housing, and a flap actuator for rotating the flap, the flap position sensing device comprising:

a rotating body which is formed of a resin material, and rotates the flap by receiving torque while the rotating body is coaxially fixed to a rotation shall of the flap;

a sensor casing which is formed of a resin material, and is fixed to the housing to rotatably support the rotating body;

a first hall sensor and a second hall sensor which are integrally formed with the sensor casing, and are disposed corresponding to the open position and the closed position, respectively, of the flap; and

a first permanent magnet and a second permanent magnet which are integrally formed with the rotating body, are spaced apart from each other by an opening and closing angle of the flap, and are disposed to interact with the first hall sensor and the second hall sensor according to opening and closing of the flap, so as to sense the open position, the closed position, and other positions of the flap.

2. The flap position sensing device of claim 1 , wherein power terminals of the first hall sensor and the second hall sensor are connected as a group to one connector terminal, and grounding terminals of the first hall sensor and the second hall sensor are connected as a group to another connector terminal.

3. A method of manufacturing a flap position sensing device of an active air flap system comprising a housing having an air inlet which allows outside air entering through a radiator grille to pass, a flap which rotates to reciprocate between an open position for opening the air inlet of the housing and a closed position for closing the air inlet of the housing, and a flap actuator for rotating the flap, the method comprising:

during injection molding of a sensor casing, while a first hall sensor and a second hall sensor are spaced apart from each other by an opening and closing angle of the flap, the first hall sensor and the second hail sensor are inserted to be integrally formed with the sensor casing; and

during injection molding of a rotating body, while a first permanent magnet and a second permanent magnet are spaced apart from each other by an opening and closing angle of the flap, and are disposed to interact with the first hall sensor and the second hall sensor to sense the open position, the closed position, and other positions of the flap, the first permanent magnet and the second permanent magnet are inserted to be integrally formed with the rotating body.

4. The method of claim 3 , wherein the integrally forming of the first hall sensor and the second sensor with the sensor casing comprises:

connecting the first hall sensor and the second hall sensor to connector terminals;

during injection molding of a pre-molding body, inserting the first hall sensor and the second hall sensor, connected to the connector terminals, to be molded into the pre-molding body; and

overmold injection molding of the sensor casing with respect to the pre-molding body, so that the pre-molding body is integrally formed with the sensor casing.

5. The method of claim 4 , wherein the connecting of the first hall sensor and the second hall sensor to the connector terminals comprises connecting power terminals of the first hall sensor and the second hall sensor as a group to one connector terminal, and connecting grounding terminals of the first hall sensor and the second hall sensor as a group to another connector terminal.