JP2003031331A - Component for molding high voltage connector and manufacturing method of high voltage connector using it - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a component for molding a high voltage connector and a manufacturing method of the high voltage connector using it capable of reducing costs by simplifying a manufacturing process and improving usage efficiency of a molding machine. SOLUTION: The inner component (the component for molding the high voltage connector) 27 is attached to first and second electric wire assemblies 21 and 23 comprising a connection terminal 1, a resistive element 3 and an electric wire 5, and it is used for positioning in a mold for the electric wire assemblies 21 and 23 during molding of a resin sealed body. Terminal holding pieces 43a, 43b, 51a and 51b, resistance holding pieces 45a, 45b, 47a, 47b, 53a, 53b, 55a and 55b, and electric wire holding pieces 49a, 49b, 57a, 57b, 59a, 59b, 61a and 61b are provided on the inner component 27, and the holding pieces position and fix each portion of the electric wire assemblies 21 and 23 inserted from an upper end opening by holding them from both sides.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a high-voltage connector molding component and a method of manufacturing a high-voltage connector using the same.

[0002]

2. Description of the Related Art FIG. 11 is a plan view showing a simple configuration example of a high-voltage connector to which the present invention is applied. Since the structure of the high-voltage connector will be described in detail in the embodiments, only a brief description will be given here.

As shown in FIG. 11, the high voltage connector has a connection terminal (electrode sleeve) 1 and a resistance element (fixed resistance) 3
And an electric wire 5 electrically connected to the connection terminal 1 via the resistance element 3, and a resin sealing body 7. Resin sealing body 7
Encloses at least the first electrical connection portion 11 in which the connection terminal 1 and the resistance element 3 are electrically connected and the second electrical connection portion 13 in which the resistance element 3 and the electric wire 5 are electrically connected. Insulate.

Here, in the present specification, the connection terminal 1, the resistance element 3 and the electric wire 5 which are electrically connected in series are referred to as "electric wire assembly". In the illustrated example of FIG. 11, the resin sealing body 7 completely covers the section from the terminal end of the electric wire 5 in the electric wire assembly to the connection portion of the connection terminal 1 with the resistance element 3.

Since the high-voltage connector constructed as described above is integrally formed by embedding the resistance element 3 and the electrical connecting portions 11 and 13 in the resin sealing body 7, it can be manufactured in a small size and at low cost. There is an advantage that high insulation performance can be obtained.

In the manufacture of this high-voltage connector, how to position the resistance element 3 and the like in the mold when molding the resin encapsulation body 7 is a problem.

In this regard, the following manufacturing method has been proposed. First, as shown in FIG. 12, a resin molding 15 for positioning is formed on the outer peripheral portion of the resistance element 3 or the like of the electric wire assembly. The resin molded body 15 is formed by placing a portion such as the resistance element 3 of the wire assembly in a mold for molding the resin molded body 15 and injecting resin into the mold. Subsequently, a portion of the electric wire assembly where the resin sealing body 7 is formed is shown in FIG.
It is installed in the mold 17 as shown in FIG. At this time, the resin molded body 15 comes into contact with the inner surface of the mold 17, and thereby the resistance element 3 and the like are positioned in the mold 17. In this state, resin is injected into the mold 17 to form the resin sealing body 7.

[0008]

However, in the manufacturing method according to the above-mentioned proposal example, the electric wire assembly is made into the resin molding 1.
It is necessary to install the mold twice in the mold for molding 5 and for molding the resin encapsulant 17, which complicates the manufacturing process.

In this respect, since the wire assembly is generally installed manually in the mold, it is necessary to put a hand in a narrow mold at high temperature during the installation work, which is a heavy work load. Further, since the manual work is involved, the molding machine is occupied for a long time, and the use efficiency of the molding machine is reduced. Therefore, it is necessary to reduce the work of installing the wire assembly in the mold as much as possible.

In view of the above problems, therefore, the present invention simplifies the manufacturing process and improves the use efficiency of the molding machine, which results in cost reduction, and a high-voltage connector molding component and a high-voltage connector using the same. It aims at providing the manufacturing method of.

[0011]

[Means for Solving the Problems] Technical means for achieving the above object include a connection terminal, a resistance element, an electric wire electrically connected to the connection terminal through the resistance element, and the connection terminal. A first electrical connection portion electrically connected to the resistance element, and a resin sealing body that at least surrounds and insulates a second electrical connection portion electrically connected to the resistance element and the electric wire; In the manufacturing process of a high-voltage connector equipped with
A high-voltage connector molding part made of resin, which is installed in a mold for molding the resin encapsulant and is used for molding the resin encapsulant, and which is provided in a base part and the base part. And at least one pair of resistance sandwiching pieces that sandwich and hold the inserted resistance element from both sides, and that are provided on the base portion,
A positioning structure on the mold side, which cooperates with a positioning structure on the mold side provided on the inner surface of the mold and positions this high-voltage connector molding part at a predetermined position in the mold. And

[0012] Preferably, the high-voltage connector molding component is provided in the base part, and at least one pair of terminal clamping pieces for clamping and holding the inserted connection terminal from both sides, and the base part. It is preferable to further include at least one pair of electric wire holding pieces that are provided and that hold the inserted electric wire by sandwiching it from both sides.

Further, it is preferable that the positioning structure on the component side is a recess or a projection fitted with a projection or a recess provided as the positioning structure on the mold side.

Further, preferably, the high-voltage connector molding component is formed of the same resin as the resin sealing body.

The technical means for achieving the above object is a method of manufacturing a high voltage connector using the high voltage connector molding component according to claim 1, wherein the connection terminal and the resistance element are electrically connected. A step of connecting, a step of electrically connecting the resistance element and the electric wire, a step of inserting the resistance element between the resistance clamping pieces of the high-voltage connector molding component, and the high-voltage connector molding component It is characterized by including a step of installing in a mold and a step of injecting a resin into the mold to mold the resin sealing body.

[0016]

1 is an external view of a high-voltage connector to which an inner part, which is a high-voltage connector molding part, according to an embodiment of the present invention is applied, and FIG. 2 is a cross-sectional view of the high-voltage connector of FIG. FIG. 3 and FIG. 4 are plan views of the first and second electric wire assemblies used in the high voltage connector of FIG.

As shown in FIGS. 1 and 2, the high voltage connector includes first and second electric wire assemblies 21 and 23 and a resin sealing body 25. An inner part 27 (see FIG. 7) described later is embedded in the resin sealing body 25.

First and second electric wire assemblies 21, 23
As shown in FIGS. 3 and 4, includes a connection terminal 1 electrically connected in series in the order described, a resistance element 3, and an electric wire 5 that is a covered electric wire.

The connection terminal 1 is made of metal and, as shown in FIGS. 5 and 6, has a resistance connection portion 1a to which one lead 3b of the resistance element 3 is connected, and a resistance connection portion 1a opposite to the resistance connection portion 1a. The formed spring mounting portion 1b and the resistance connection portion 1
A flange portion 1c formed so as to project outward is provided between a and the spring mounting portion 1b.

The resistance connecting portion 1a has a substantially semi-cylindrical shape extending in the direction of arrow A in FIG. 5, and its outer peripheral portion corresponding to the chord having a substantially semi-circular cross-section has a shape in the direction of arrow A. A groove 1d extending along the groove is formed. A bottomed stop hole 1e is formed at the downstream end of the resistance connecting portion 1a in the direction of arrow A so as to be continuous with the end of the groove 1d.

The spring mounting portion 1b has a substantially columnar shape extending in the direction of arrow A, and the coil spring 29 is screwed and mounted in the coil groove 1f provided on the outer peripheral portion thereof. The coil spring 29 is made of metal and is used for connecting the high-voltage connector to the electrical connection portion to be connected.

The flange portion 1c is a spring mounting portion 1b.
A small-diameter portion 1g located on the side and a large-diameter portion 1h located between the small-diameter portion 1g and the resistance connecting portion 1a and having a larger diameter than the small-diameter portion 1g are provided. It is used to prevent the resin from flowing into the retracting portion 31a for the coil spring 29 provided in the molding die 31 at the time of molding. Therefore, the outer diameter of the small diameter portion 1g is
The size of the small diameter portion 1g is set so as to fit inside the opening of the retracting portion 31a.

The resistance element 3 is interposed between the connection terminal 1 and the electric wire 5, and two leads 3b and 3c are drawn out from both ends of the substantially columnar element body 3a. The resistance value of the resistance element 3 is set to, for example, 10 kΩ. Each lead 3b,
The length of 3c is set to a predetermined length, for example, about 3 to 5 mm, and bending is performed if necessary.

The electric wire 5 is a pressure-resistant electric wire, and the end portion is peeled off in advance before connection with the resistance element 3 to expose the conductor portion by a predetermined length, for example, about 3 to 5 mm.

The electrical connection between the connection terminal 1 and the resistance element 3 is
For example, as shown in FIGS. 3 and 4, one lead 3b of the resistance element 3 is inserted into the groove 1d of the resistance connecting portion 1a, and the tip end of the lead 3b is inserted into the stop hole 1e. 3b is soldered to the resistance connecting portion 1a. At this time, since the lead 3b is soldered in a state where the lead 3b is inserted in the groove 1d provided in the substantially semi-cylindrical resistance connection portion 1a, the soldering can be easily performed.

For electrical connection between the resistance element 3 and the electric wire 5, as shown in FIGS. 3 and 4, for example, the exposed conductor portion at the end of the electric wire 5 and the other lead 3c of the resistance element 3 are soldered. It is done by doing.

The main differences between the first electric wire assembly 21 and the second electric wire assembly 23 are the difference in the diameter of the electric wire 5 used and the difference in the bent shape of the electric wire assemblies 21, 23. Regarding the diameter of the electric wire 5, the outer diameter of the electric wire 5 used in the first electric wire assembly 21 is, for example, 3.4 mm, and the outer diameter of the electric wire 5 used in the second electric wire assembly 23 is, for example, 2 mm. 0.2 mm
Is. Regarding the bent shape, the first electric wire assembly 21 has the lead 3 connected to the connection terminal 1 of the resistance element 3.
The second electric wire assembly 2 is bent in an L shape at the portion b.
Reference numeral 3 denotes a portion of the lead 3c connected to the electric wire 5 of the resistance element 3 and bent in an L shape.

The resin encapsulant 25 is an electrical connection portion (first electrical connection portion) between the connection terminal 1 and the resistance element 3 in the first and second electric wire assemblies 21 and 23 thus configured.
37, and an electrical connection portion between the resistance element 3 and the electric wire 5 (second
The electrical connection part 39) is at least surrounded and insulated. In the present embodiment, the resin sealing body 25 completely covers the section from the terminal end of the electric wire 5 in the first and second electric wire assemblies 21, 23 to the resistance connecting portion 1a of the connecting terminal 1. , Constituting a connector housing. The resin encapsulant 25 as described above is attached to the electric wire assemblies 21, 23 from above the inner part 27, which will be described later.
It is molded with resin so as to cover a predetermined portion of 1, 23 and is integrated with the inner part 27.

FIG. 7 is a plan view of an inner part according to an embodiment of the present invention, FIG. 8 is a side view of the inner part when viewed from the direction of arrow B in FIG. 7, and FIG. 9 is a view of FIG. It is a side view of the inner part when it sees from the arrow C direction.

The inner part 27 is a resin molded product formed of the same resin (for example, PBT) as the resin encapsulant 25, and as shown in FIGS. 7 to 9, the base part 41 and the first part. Of the pair of terminal clamping pieces 43a, 43b, two sets of resistance clamping pieces 45a, 45b, 47a, 47b, and one pair of electric wires protrudingly provided on the base 41 for positioning the electric wire assembly 21 of FIG. Clamping pieces 49a, 49b and first electric wire assembly 2
One pair of terminal sandwiching pieces 51a, 51b projectingly provided on the base portion 41 for positioning the three, and two pairs of resistor sandwiching pieces 53.
a, 53b, 55a, 55b and three sets of wire holding pieces 57a, 57b, 59a, 59b, 61a, 61b,
As a positioning structure on the component side, two are provided on the base portion 41, and two projections 63 and 65 and holes (recesses) 67 and 69 are provided.

Each set of clamping pieces 43a, 43b, 45a, 45b, 47a, 47b for the first electric wire assembly 21.
49a and 49b are the shapes of the electric wire assembly 21, here L
It is arranged according to the bent shape of the character. In addition, similarly, each pair of holding pieces 51a, 5a for the second electric wire assembly 23 is
1b, 53a, 53b, 55a, 55b, 57a, 57
b, 59a, 59b, 61a, 61b are also the electric wire assembly 2
It is arranged according to the shape of No. 3, here, the L-shaped bent shape.

Clamping pieces 43a, 43b, 45a, 4 of each set
5b, 47a, 47b, 49a, 49b, 51a, 51
b, 53a, 53b, 55a, 55b, 57a, 57
b, 59a, 59b, 61a, 61b (the reference numeral "D" (refer to FIG. 7 is used when these are collectively referred to) are provided so that paired members face each other with a space therebetween, As shown representatively for the sandwiching pieces 43a, 43b and the like in FIGS. 8 and 9, the tip ends are curved in a direction in which they approach each other. Therefore, when the corresponding portions of the wire assemblies 21, 23 are pushed into the clamping pieces D of the respective sets through the upper end openings thereof and are inserted, the clamping pieces D of the respective sets are bent at their tip portions. Depending on the shape, the corresponding parts of the electric wire assemblies 21, 23 are sandwiched so as to be held from both sides, positioned and fixed, and prevented from coming off. The opening width E of the distal end opening of each pair of the sandwiching pieces D is, as shown representatively for the sandwiching pieces 43a and 43b in FIG. 8, the width of the corresponding portion of each wire assembly 21, 23 to be positioned and fixed. Is also narrowly set.

More specifically, the terminal clamping pieces 43a, 43
b, 51a, 51b are for positioning and fixing the connection terminal 1 of each electric wire assembly 21, 23. Resistor holding pieces 45a, 45b, 47a, 47b, 53a, 53
b, 55a, 55b are for positioning and fixing the resistance element 3 of each electric wire assembly 21, 23. Electric wire holding pieces 49a, 49b, 57a, 57b, 59a, 59
b, 61a, 61b are for positioning and fixing the electric wire 5 of each electric wire assembly 21, 23.

Here, the resistance holding pieces 45a, 45b, 4
The opening width E of the upper end opening of 7a, 47b, 53a, 53b, 55a, 55b is such that the outer diameter of the resistance element 3 is 3.5, for example.
If it is mm, it is set to 2.4 mm. The opening width E of the upper end opening of the wire holding pieces 49a and 49b is 2.4 m when the outer diameter of the corresponding wire 5 is 3.4 mm, for example.
set to m. Electric wire holding pieces 57a, 57b, 59
a, 59b, 61a, 61b opening width E of the upper end opening
Is set to 1.2 mm when the outer diameter of the corresponding electric wire 5 is 2.2 mm, for example.

The protrusions 63 and 65 and the holes 67 and 69 are
The inner component 27 is for positioning the inner component 27 in the mold 31 when the inner component 27 is installed in the mold 31 for molding the resin sealing body 25. In the mold 31, not-shown recesses and protrusions for fitting the projections 63 and 65 and the holes 67 and 69 to position the inner component 27 are provided as a positioning structure on the mold 31 side.

The base portion 41 has a window-pierced portion other than a portion that serves as a framework for connecting the sandwiching pieces D and the like. As a result, when the resin encapsulant 25 is molded, the base portion 4
1 prevents the resin flow from being obstructed.

Next, a manufacturing process of a high voltage connector using the inner part 27 will be described. First, as shown in FIGS. 3 and 4, the connection terminal 1, the resistance element 3, and the electric wire 5 are connected in series by soldering or the like to form first and second electric wire assemblies 21 and 23. Then, FIG.
As shown in, the corresponding parts of the electric wire assemblies 21, 23 are inserted into the sandwiching pieces D of each set of the inner parts 27, and the inner parts 27 are attached to the electric wire assemblies 21, 23. Then, the inner part 27 is installed in the mold 31 together with the electric wire assemblies 21 and 23. At the time of this installation, the protrusions 63, 65 and the holes 67, 69 of the inner part 27 are attached to the mold 31.
The inner part 27 and the electric wire assemblies 21 and 23 are positioned by fitting into the recesses and protrusions inside. Subsequently, resin is injected into the mold 31 to mold the resin sealing body 25.

As described above, according to the present embodiment, the inner part 27 is preliminarily manufactured in a step different from the step of manufacturing the high voltage connector, and the inner part 27 is formed at the time of molding the resin sealing body 25. First and second electric wire assemblies 21, 23
Part of the electric wire assembly 21 or 23 sealed by the resin encapsulant 25 such as the resistance element 3 of the electric wire assembly 21 or 23. Is positioned, and in that state, the resin sealing body 2
5 is molded. Therefore, the number of times the electric wire assemblies 21 and 23 are installed in the mold 31 can be set to once when the resin sealing body 25 is molded, which simplifies the manufacturing process of the high-voltage connector and allows the molding machine to be manufactured. The occupancy time of the molding machine can be reduced and the use efficiency of the molding machine can be improved, which can reduce the manufacturing cost of the high voltage connector.

Further, the electric wire assembly 2 of the inner part 27
The attachment to the wires 1 and 23 can be easily performed by inserting corresponding portions of the wire assemblies 21 and 23 between the sandwiching pieces D of the respective sets.

Further, the first and second electric wire assemblies 2
Since the connection terminals 1 and the resistance elements 3 and the electric wires 5 of the electric wires 1 and 23 are held by the sandwiching pieces D of each set of the inner part 27, the connection terminals 1 and the resistance elements of the electric wire assemblies 21 and 23 in the die 31 3 and the electric wire 5 can be reliably positioned.

The first and second electric wire assemblies 21,
When the inner part 27 is attached to the wire 23, both the wire assemblies 21, 23 and the inner part 27 can be handled as one part, and these parts can be easily installed in the mold 31. .

Furthermore, when the inner part 27 is installed in the mold 31, the inner part 27 and the two-wire assembly 2 are installed.
1, 23 are positioned by the protrusion 63 of the inner part 27,
This can be easily performed by fitting the 65 and the holes 67, 69 into the recesses and protrusions in the mold 31.

Further, the inner part 27 is made up of the resin sealing body 25.
Since it is formed of the same resin as the above, the resin sealing body 25 and the inner component 27 can be integrated when the resin sealing body 25 is molded, and the boundary portion between the resin sealing body 25 and the inner component 27 can be formed. It is possible to prevent the insulation property from being lowered.

In this embodiment, the case of applying to the high voltage connector provided with the two electric wire assemblies 21 and 23 has been described, but the high voltage connector provided with one electric wire assembly 21 and 23 (for example, FIG. 11). The high-voltage connector shown in 1) may be applied.

[0045]

According to the invention described in claims 1 to 5, the high-voltage connector molding component according to the present invention is manufactured in advance in a step different from the manufacturing step of the high-voltage connector, and At the time of molding, the high-voltage connector molding component is mounted on the resistance element of the wire assembly consisting of the connection terminal, the resistance element, and the wire that are electrically connected in series, and is installed in the mold together with the wire assembly. The resistance element is positioned inside, and the resin sealing body is molded in that state. As a result, the number of times the wire assembly is installed in the mold can be set to once when molding the resin encapsulant, which simplifies the manufacturing process of the high-voltage connector and reduces the time occupied by the molding machine. As a result, the use efficiency of the molding machine can be improved, and thus the manufacturing cost of the high-voltage connector can be reduced.

Further, the high-voltage connector molding component can be easily attached to the electric wire assembly by inserting the resistance element of the electric wire assembly between the resistance holding pieces.

According to the second aspect of the present invention, not only the resistance element of the electric wire assembly but also the connection terminal and the electric wire are held by the high-voltage connector molding component. The connection terminal, the resistance element, and the electric wire can be reliably positioned inside.

According to the third aspect of the present invention, since the positioning structure on the die side and the positioning structure on the component side are formed by the protrusion and the recess, or the recess and the protrusion which are fitted to each other, the high-voltage connector molding is performed. It is possible to easily position the high-voltage connector molding component and the electric wire assembly at the time of installing the component for use in the mold simply by fitting the protrusion and the recess.

According to the fourth aspect of the present invention, since the high-voltage connector molding component is formed of the same resin as the resin encapsulant, the resin encapsulant and the high-voltage connector are molded at the time of molding the resin encapsulant. Therefore, it is possible to prevent the deterioration of the insulating property at the boundary between the resin sealing body and the high-voltage connector molding component.

[Brief description of drawings]

FIG. 1 is an external view of a high-voltage connector to which an inner component according to an embodiment of the present invention is applied.

2 is a cross-sectional view of the high voltage connector of FIG.

3 is a plan view of a first electric wire assembly used in the high voltage connector of FIG. 1. FIG.

4 is a plan view of a second electric wire assembly used in the high voltage connector of FIG. 1. FIG.

5 is a diagram showing a configuration of a connection terminal used in the high-voltage connector of FIG. 1 and an installation state of the connection terminal in the mold.

6 is a diagram showing the configuration of a connection terminal when viewed in the direction of arrow A in FIG.

FIG. 7 is a plan view of the inner component according to the embodiment of the present invention.

FIG. 8 is a side view of the inner component when viewed from the direction of arrow B in FIG.

9 is a side view of the inner component when viewed from the direction of arrow C in FIG.

FIG. 10 is a plan view showing a state where inner parts are attached to the first and second electric wire assemblies.

FIG. 11 is a plan view showing a simple configuration example of a high-voltage connector to which the present invention is applied.

FIG. 12 is a diagram showing a manufacturing process of a method for manufacturing a high-voltage connector according to a proposed example.

FIG. 13 is a diagram showing a manufacturing process of a method for manufacturing a high-voltage connector according to a proposed example.

[Explanation of symbols]

1 Connection Terminal 3 Resistance Element 5 Electric Wires 21,23 Electric Wire Assembly 25 Resin Sealing Body 27 Inner Part 31 Mold 37, 39 Electric Connection Part 41 Bases 43a, 43b Terminal Holding Pieces 45a, 45b, 47a, 47b Resistance Clamping pieces 49a, 49b Electric wire clamping pieces 51a, 51b Terminal clamping pieces 53a, 53b, 55a, 55b Resistance clamping pieces 57a, 57b, 59a, 59b, 61a, 61b Electric wire clamping pieces 63, 65 Protrusions 67, 69 Hole

Claims (5)

[Claims] 1. A connection terminal, a resistance element, an electric wire electrically connected to the connection terminal via the resistance element, and a first electric connection portion electrically connecting the connection terminal and the resistance element. A resin encapsulation body that at least surrounds and insulates a second electrical connection portion to which the resistance element and the electric wire are electrically connected. Is a resin high-voltage connector molding component that is installed in a mold for use in molding the resin encapsulant, and includes a base portion and the resistance element that is provided and inserted in the base portion. At least one pair of resistance clamping pieces for sandwiching and holding the above-mentioned material from both sides, and a positioning structure on the die side provided on the base part and provided on the inner surface of the die, cooperate with each other, and this high-voltage connector molding Position the parts for use in the prescribed position in the mold A high-voltage connector molding component, comprising: a component-side positioning structure to be determined. 2. The high-voltage connector molding component is provided in the base part, and is provided in the base part, and at least one pair of terminal clamping pieces for clamping and holding the inserted connection terminal from both sides. And at least one set of wire holding pieces for holding the inserted electric wire by sandwiching it from both sides,
The high-voltage connector molding component according to claim 1, further comprising: 3. The high-voltage connector according to claim 1, wherein the component-side positioning structure is a recess or a protrusion that fits with a protrusion or a recess provided as the mold-side positioning structure. Molding parts. 4. The high-voltage connector molding component according to claim 1, wherein the high-voltage connector molding component is formed of the same resin as the resin sealing body. 5. A method of manufacturing a high-voltage connector using the high-voltage connector molding component according to claim 1, the step of electrically connecting the connection terminal and the resistance element, the resistance element and the electric wire. A step of electrically connecting the resistor element, a step of inserting the resistance element between the resistance clamping pieces of the high-voltage connector molding component, a step of installing the high-voltage connector molding component in the mold, the mold A step of injecting a resin into the interior of the resin to form the resin encapsulant.