JP2005166347A - Waterproof connector and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To manufacture inexpensively a waterproof connector the size of which can be reduced. <P>SOLUTION: The waterproof connector 1 includes first and second housings 10, 20, first and second connecting terminals 30, 40 housed in these housings, and a plurality of electric wires 80 connected to them. The ends of the plurality of the electric wires 80 are sealed integrally with a first resin molding part 50, and housed in terminal insert mouths 13, 23. The terminal insert mouths 13, 23 and a communicating hole 17 formed on these side walls are sealed by the second resin molding part 60 filled in the terminal insert mouths 13, 23 and the communicating hole 17. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a waterproof connector having a waterproof capability and a method for manufacturing the same mounted on an automobile or the like, and more particularly to a waterproof connector that can be reduced in size and manufactured at low cost and a method for manufacturing the same.

  Conventionally, connectors are used for connecting electrical wirings such as wire harnesses for automobiles, etc., but waterproof connectors (particularly for connecting electrical wirings in places where connectors such as engine rooms are exposed to water) Waterproof connector) is used.

  In this waterproof connector, generally, the fitting portion between the housings of the connector is waterproofed by a sealing material made of rubber material, and the terminal insertion side (back side) of the housing is made of a strong elastic material such as silicon rubber. The contact portion between the electric wire and the wire seal material and the contact portion between the wire seal material and the housing are each waterproofed by the wire seal material (see, for example, Patent Document 1).

JP-A-9-289057 (page 2-4, FIG. 1-6)

  However, in the waterproof connector described in Patent Document 1, since it is necessary to provide a partition between the seal insertion holes of the wire seal in addition to the dimension of the wire seal material, the arrangement pitch between the connection terminals accommodated in the housing is small. In some cases, the housing becomes larger as compared with a normal connector. In addition, since a highly elastic material such as silicon rubber used for the wire seal material is expensive, the cost may increase.

  The present invention has been made in view of such problems, and an object of the present invention is to provide a waterproof connector that can be reduced in size and can be manufactured at low cost, and a manufacturing method thereof.

  The waterproof connector according to the present invention includes a plurality of electric wires having a structure in which a core wire is covered with an insulating coating, and a connection portion that can be connected to a counterpart connection terminal is formed on the distal end side, and is connected to the core wire of the electric wire on the proximal end side. A connector having a plurality of connection terminals formed with a wire connection portion and a wire fixing portion for fixing and holding the wire, and a housing having a plurality of terminal accommodation chambers for accommodating the plurality of connection terminals therein. The housing has a terminal insertion port that communicates with each terminal accommodation chamber on the rear end side of the plurality of terminal accommodation chambers, and a communication hole that communicates with the outside of the housing on the side wall of the terminal insertion port, The terminal portions of the plurality of electric wires are integrally sealed by a first resin mold portion and are accommodated on the front end side of the communication hole forming position in the terminal insertion port, and the terminal insertion port and the front of the housing Hole is characterized in that it is sealed by the second resin mold portions filled in these internal.

  The method for manufacturing a waterproof connector according to the present invention includes a plurality of electric wires having a structure in which a core wire is covered with an insulating coating, and a connecting portion that can be connected to a mating connection terminal on a distal end side, and a core wire of the electric wire on a proximal end side. A plurality of connecting terminals formed with a wire connecting portion to be connected to and a wire fixing portion for fixing and holding the wire, and a plurality of terminal accommodating chambers for accommodating the plurality of connecting terminals inside, A method of manufacturing a connector, comprising: a terminal insertion port communicating with each terminal accommodation chamber on a rear end side of the terminal accommodation chamber; and a housing having a communication hole communicating with the outside on a side wall of the terminal insertion chamber, A terminal connecting step of connecting the core wire of the electric wire and the wire connecting portions of the plurality of connecting terminals and fixing the plurality of electric wires to the plurality of connecting terminals at the wire fixing portion, and the terminal connecting step Connecting terminal A wire sealing step for integrally sealing the terminal portions of the plurality of connected wires with the first resin mold portion, and the terminal portion sealed with the first resin mold portion in the wire sealing step. A terminal portion housing step of housing the plurality of connection terminals in the plurality of terminal housing chambers and housing the connection terminals closer to the distal end side than the communication hole forming position in the terminal insertion port of the housing; And a housing sealing step of filling the terminal insertion port of the housing in which the portion is accommodated with mold resin and sealing the terminal insertion port and the communication hole with a second resin mold portion.

  In addition, the 1st and 2nd resin mold part of the waterproof connector of this invention is good to consist of any one mold resin of a polyamide type, a polyurethane type, and polyolefin hot-melt resin, for example, respectively.

  Moreover, the terminal part of the some electric wire integrally sealed by the 1st resin mold part may include the connection part of the core wire of a some electric wire, and the electric wire connection part of a some connecting terminal, for example.

  The housing is preferably provided with a wedge-shaped anchor portion that is continuous with the second resin mold portion outside the communication hole and for attaching the housing to an external attachment member.

  As this anchor portion, for example, (1) a molded resin forming a second resin mold portion that leaks to the outside from the terminal insertion port of the housing through the communication hole, or (2) the housing A resin obtained by attaching a resin molding member previously formed in a predetermined shape to the mold resin constituting the second resin mold part reaching the communication hole from the terminal insertion port, or (3) a resin formed in a predetermined shape It is preferable that the molded member is attached to the mold resin constituting the second resin mold part through the communication hole.

  In the waterproof connector manufacturing method of the present invention, the anchor portion is formed to form a wedge-shaped anchor portion for connecting the housing to an external mounting member, which is continuous with the second resin mold portion outside the housing via the communication hole. You may make it further provide a process.

  According to the present invention, the terminal portions of the plurality of electric wires connected to the plurality of connection terminals are integrally sealed by the first resin mold portion, and each connection terminal is accommodated in each terminal accommodating chamber of the housing. A waterproof connector is realized in which the terminal insertion port and the communication hole are sealed by the second resin mold portion after being accommodated on the tip side from the communication hole forming position in the terminal insertion port. For this reason, the arrangement pitch between the connection terminals can be reduced as compared with the conventional one, and the waterproof connector can be downsized. In addition, it is possible to automate the operation of housing the connection terminals in the housing as compared with the case where the terminal portions of the plurality of electric wires are respectively connected to the connection terminals and these are manually housed in the housing. Furthermore, since the mold resin constituting the first and second resin mold parts is a cheaper material than silicon rubber or the like, the cost of the waterproof connector can be reduced. Thereby, a small waterproof connector can be manufactured at low cost.

  Further, according to the present invention, in order to realize a structure in which the communication hole communicating with the outside of the housing is provided on the side wall of the terminal insertion port of the housing, and the terminal insertion port and the communication hole are sealed by the second resin mold part. The portion in the communication hole of the second resin mold part serves as a wedge of the second resin mold part with respect to the housing, and the second resin mold part is never peeled off or detached from the housing. Thereby, it is possible to reliably maintain high waterproof performance.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.

1 is a partial cross-sectional view showing a waterproof connector according to an embodiment of the present invention, FIG. 2 is a partial cross-sectional view showing a first housing of the waterproof connector, and FIG. 3 is AA ′ of FIG. It is sectional drawing.
As shown in FIG. 1, the waterproof connector 1 includes a first housing 10 as a so-called male housing (plug type housing) made of, for example, a resin-molded member, and a so-called resin-molded member that fits into the first housing 10. The second housing 20 as a female housing (receptacle type housing), the metal first connection terminal 30 and the second connection terminal 40 accommodated in the first and second housings 10 and 20, the first and second The electric wire 80 connected to each of the two connection terminals 30 and 40 is provided.

  In this example, the plurality of connection terminals 30 and 40 include a cylindrical connection portion 31 and a plate-like connection portion 41 that are directly connected to each other, and a plurality of electric wires 80 in which the core wires 81 are exposed (extracted) at the terminal portion. Wire connecting portions 32, 42 connected to the core wire 81 by crimping, etc., wire fixing portions 33, 43 for fixing and holding the wire 80 by caulking, etc., these connecting portions 31, 41, wire connecting portions 32, 42, and It comprises plate-like connecting portions 34 and 44 that connect the wire fixing portions 33 and 43.

  For example, in the cylindrical connection portion 31 of the first connection terminal 30, the contact piece 35 for contacting the plate-like connection portion 41 of the second connection terminal 40 when connecting to the second connection terminal 40. Is formed.

  On the other hand, each of the first and second housings 10 and 20 has a convex fitting portion 11 and a concave fitting portion 21 on the distal end side, and the first housing 10 is provided inside the fitting portion 11. The two housings 20 have a plurality of terminal accommodating chambers 12 and 22 for accommodating a plurality of first and second connection terminals 30 and 40, respectively, inside the base end side of the fitting portion 21. In each of the terminal accommodating chambers 12 and 22 of both the housings 10 and 20, for example, the first and second connection terminals 30 and 40 respectively accommodated are engaged, and these are engaged in the terminal accommodating chambers 12 and 22, respectively. Lance portions 18 and 28 are formed for stopping and fixing.

  A fitting wall 19 that fits on the outer peripheral surface side of the fitting portion 21 of the second housing 20 is formed outside the outer peripheral surface of the fitting portion 11 of the first housing 10. Further, a recessed portion 29 is formed on the inner peripheral surface of the fitting portion 21 of the second housing 20, and the outer peripheral surface of the fitting portion 11 of the first housing 10 is made of, for example, a rubber member. The fitting portion seal material 88 mounted and disposed on the fitting portion seal material 88 is fitted, and the fitting portion seal material 88 allows the outer peripheral surface of the fitting portion 11 of the first housing 10 to 2 A contact portion with the inner peripheral surface of the fitting portion 21 of the housing 2 is sealed.

  The first and second housings 10 and 20 communicate with the terminal accommodating chambers 12 and 22 at the rear end sides of the plurality of terminal accommodating chambers 12 and 22, respectively, and open at the proximal end sides of the housings 10 and 20, respectively. Terminal insertion ports 13 and 23 to be used. On the side walls of these terminal insertion openings 13 and 23, communication holes to be described later are formed to communicate with the outside of the housings 10 and 20, respectively.

  And the terminal part of each electric wire 80 is integrally sealed by the 1st resin mold part 50, and is shape | molded in the shape fitted to each terminal insertion port 13 and 23. FIG. Thus, the terminal part sealed by the 1st resin mold part 50, when accommodating each connection terminal 30 and 40 in each terminal accommodating chamber 12 and 22, the back side (each each in each terminal insertion port 13 and 23) The housings 10 and 20 are housed without gaps, for example, by press fitting.

  In addition, although description is omitted here, as the terminal portion of each electric wire 80 sealed by the first resin mold portion 50, the core wire 81 of each electric wire 80 and the electric wire connection portions 32 and 42 of each connection terminal 30 and 40 are used. The connection part may be included. This is because if these are collectively sealed with the first resin mold portion 50, the strength of the connection portion can be improved at the same time.

  Thus, the terminal insertion ports 13 and 23 of the respective housings 10 and 20 in which the first resin mold part 50 is accommodated are further sealed by the second resin mold part 60. At this time, the first resin mold part 50 and the second resin mold part 60 are in close contact with each other, and no air remains in the terminal insertion ports 13 and 23. In this way, waterproof processing by the first and second resin mold portions 50 and 60 is performed on the base end side of each housing 10 and 20.

  These resin mold portions 50 and 60 are, for example, polyamide-based hot melt resins, polyurethane-based hot melt resins, and polyolefin-based hot melt resins. In particular, the second resin mold portion 60 is relatively made of a crystalline resin. It consists of hot-melt resin with high rigidity.

Next, although this waterproof connector 1 is demonstrated based on the 1st housing 10, it is assumed that the part which is not mentioned especially is applicable also in the 2nd housing 20 with the same structure.
As shown in FIG. 2, in the first housing 10, a plurality of connection terminals 30 connected to a plurality of electric wires 80 are respectively accommodated in the terminal accommodating chamber 12, and terminal portions of the plurality of electric wires 80 are first resin mold portions 50. And is housed in the terminal insertion port 13 of the first housing 10, and the terminal insertion port 13 is sealed by the second resin mold part 60.

  Here, as shown in FIG. 3, the first resin mold portion 50 is accommodated on the distal end side of the first housing 10 with respect to the position where the communication hole 17 is formed in the terminal insertion port 13. For this reason, the second resin mold part 60 is provided in the first housing 10 in a state where the mold resin filled in the terminal insertion port 13 closes and seals the terminal insertion port 13 and the communication hole 17.

  If the second resin mold part 60 is formed in this way, the part that seals the communication hole 17 of the second resin mold part 60 serves as a wedge of the second resin mold part 60 with respect to the first housing 10. The second resin mold part 60 is never peeled off or detached from the terminal insertion opening 13. Therefore, it is possible to reliably prevent moisture from entering the terminal housing chamber 12 together with the first resin mold portion 50, to have high waterproof performance, and to maintain the waterproof performance. The second resin mold part 60 of the second housing 20 can also have the same structure.

  According to the waterproof connector 1 configured as described above, since the terminal portions of the plurality of electric wires 80 are integrally sealed by the first resin mold portion 50, the arrangement pitch between the connection terminals 30 is increased as compared with the conventional one. The size can be reduced and the size can be reduced. Moreover, the terminal part of the some electric wire 80 is connected to the connection terminal 30, respectively, and compared with the case where these several connection terminals 30 were accommodated in the 1st housing 10 by hand, to the 1st housing 10 of the connection terminal 30 Can be automated. In addition, since the mold resin constituting the first and second resin mold parts 50 and 60 is a relatively inexpensive material, the cost of the waterproof connector can be reduced as compared with the case where silicon rubber or the like is used for waterproofing. Can do. Thereby, a small and inexpensive waterproof connector can be realized.

  FIG. 4 is a partial cross-sectional view for explaining another embodiment of the second resin mold part 60 of the first housing 10 of the waterproof connector 1, and FIG. 5 is a cross-sectional view taken along the line BB ′ of FIG. . In the following, explanations that overlap with the parts that have already been explained will be omitted, and the parts that have already been mentioned can be applied to parts that are not mentioned.

  The second resin mold part 60 of the first housing 10 includes a wedge-shaped anchor part 61 in which a mold resin filled from the terminal insertion port 13 and leaking to the outside through the communication hole 17 is molded into a predetermined shape. This is different from the previous example. For example, the first housing 10 and the waterproof connector 1 can be attached to the attachment panel 90 by inserting and fitting the anchor portion 61 into the attachment hole 91 of the attachment panel 90 as an external attachment member. Since the anchor portion 61 is formed of the mold resin constituting the second resin mold portion 60, the connector 61 is inexpensive compared to the case where a component such as an anchor portion is separately attached to the housing and the connector is attached to the attachment member. The mounting structure can be realized.

6 and 7 are partial cross-sectional views showing the structure of another anchor portion.
As shown in FIG. 6, the anchor portion 62 has a resin molded part separately formed in advance in a predetermined shape arranged outside the communication hole 17, and the arranged resin molded part is filled from the terminal insertion port 13 and communicated with the communication hole 17. It has a structure provided in the first housing 10 in a state of being continuous with the second resin mold part 60 by being bonded to the mold resin filled therein, and has the same effect as the anchor part 61. Further, the anchor part 63 shown in FIG. 7 further improves the adhesion between the resin molded part and the second resin mold part 60. The anchor portion 63 has a structure in which a resin molded part formed in a predetermined shape in advance is attached to a mold resin constituting the second resin mold portion 60 through the communication hole 17.

Next, the manufacturing process of this waterproof connector 1 will be described using the first housing 10 in the same manner.
FIG. 8 is a flowchart showing the manufacturing process of this waterproof connector.
First, in the terminal connection step, the core wires 81 of the plurality of wires 80 and the wire connection portions 32 of the plurality of first connection terminals 30 are connected by crimping, and the wire fixing portions 33 are crimped on the plurality of wires 80. To each first connection terminal 30 (S1). Next, in the wire sealing step, the terminal portions of the plurality of electric wires 80 connected to the plurality of first connection terminals 30 in the terminal connection step are integrally sealed with the first resin mold portion 50 formed by molding resin. (S2).

  In the terminal portion housing step, the terminal portions of the plurality of electric wires 80 that are integrally sealed by the first resin mold portion 50 in the wire sealing step are used as the first connection terminals 30 as the terminals of the first housing 10. It accommodates in the accommodation chamber 12, and accommodates in the front end side rather than the communication hole 17 formation position in the terminal insertion port 13 of the 1st housing 10 (S3). Finally, in the housing sealing step, the terminal insertion port 13 in which the terminal portions of the plurality of electric wires 80 are accommodated in the terminal portion accommodation step is filled with mold resin, and cooled, dried, etc., to perform the terminal insertion port 13 and the communication hole 17. Is sealed with the second resin mold part 60 (S4). According to this manufacturing method, a small and inexpensive waterproof connector 1 can be manufactured.

  In addition, in this manufacturing method, it is provided with the anchor part formation process which forms the above-mentioned anchor parts 61-63 continuous with the 2nd resin mold part 60 in the 1st housing 10 in parallel with the housing sealing process of step S4. Anyway.

  INDUSTRIAL APPLICABILITY The present invention can be used for various applications in which electrical connection is performed in places where moisture is applied.

It is a partial sectional view showing a waterproof connector concerning one embodiment of the present invention. It is a partial sectional view showing the 1st housing of the waterproof connector. It is AA 'sectional drawing of FIG. It is a partial sectional view for explaining other embodiments of the 2nd resin mold part of the 1st housing of the waterproof connector. It is BB 'sectional drawing of FIG. It is a partial cross section figure which shows the structure of the other anchor part of the waterproof connector. It is a partial cross section figure which shows the structure of the other anchor part of the waterproof connector. It is a flowchart which shows the manufacturing process of the waterproof connector which concerns on one Embodiment of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Waterproof connector, 10 ... 1st housing, 11, 21 ... Fitting part, 12, 22 ... Terminal accommodating chamber, 13, 23 ... Terminal insertion port, 20 ... 2nd housing, 30 ... 1st connection terminal, 31, 41 ... Connection part, 32, 42 ... Electric wire connection part, 33, 43 ... Electric wire fixing part, 34, 44 ... Connection part, 35 ... Contact piece, 40 ... Second connection terminal, 50 ... First resin mold part, 60 ... 2nd resin mold part, 61-63 ... anchor part, 80 ... electric wire.

Claims (9)

A plurality of electric wires having a structure in which a core wire is covered with an insulating coating;
A plurality of connection terminals in which a connection portion connectable to the counterpart connection terminal is formed on the distal end side, and a wire connection portion connected to the core wire of the electric wire on the proximal end side and an electric wire fixing portion for fixing and holding the electric wire;
A connector comprising a housing having a plurality of terminal accommodating chambers for accommodating the plurality of connection terminals therein,
The housing has a terminal insertion port that communicates with each terminal accommodation chamber on the rear end side of the plurality of terminal accommodation chambers, and a communication hole that communicates with the outside of the housing on the side wall of the terminal insertion port,
The terminal portions of the plurality of electric wires are integrally sealed by the first resin mold portion and accommodated on the tip side from the communication hole forming position in the terminal insertion port,
The waterproof connector, wherein the terminal insertion port and the communication hole of the housing are sealed by a second resin mold part filled therein. 2. The waterproof connector according to claim 1, wherein the first and second resin mold parts are each made of any one of a polyamide-based resin, a polyurethane-based resin, and a polyolefin-based hot melt resin. The terminal portions of the plurality of wires integrally sealed by the first resin mold portion include connection portions between the core wires of the plurality of wires and the wire connection portions of the plurality of connection terminals. The waterproof connector according to claim 1 or 2. The said housing is provided with the wedge-shaped anchor part for continuing the said 2nd resin mold part on the exterior of the said communicating hole, and attaching the said housing to an external attachment member. The waterproof connector according to any one of claims. The said anchor part shape | molds the mold resin which comprises the said 2nd resin mold part which leaks outside from the said terminal insertion port through the said communicating hole, and is formed in a predetermined shape. Waterproof connector. The anchor portion is formed by attaching a resin molding member formed in a predetermined shape to a mold resin constituting the second resin mold portion that reaches the communication hole from the terminal insertion port. The waterproof connector according to claim 4. The said anchor part attaches the resin molding member formed in the predetermined shape beforehand to the mold resin which comprises the said 2nd resin mold part through the said communicating hole, The said resin part is characterized by the above-mentioned. Waterproof connector. A plurality of electric wires having a structure in which a core wire is covered with an insulating coating;
A plurality of connection terminals in which a connection portion connectable to the counterpart connection terminal is formed on the distal end side, and a wire connection portion connected to the core wire of the electric wire on the proximal end side and an electric wire fixing portion for fixing and holding the electric wire, and
A plurality of terminal accommodating chambers for accommodating the plurality of connection terminals therein, a terminal insertion port communicating with each terminal accommodating chamber on the rear end side of the plurality of terminal accommodating chambers, and a side wall of the terminal insertion port A method of manufacturing a connector comprising a housing having a communication hole communicating with the outside,
A terminal connection step of connecting the core wires of the plurality of electric wires and the wire connection portions of the plurality of connection terminals and fixing the plurality of electric wires to the plurality of connection terminals at the wire fixing portion;
A wire sealing step of integrally sealing the terminal portions of the plurality of electric wires to which the plurality of connection terminals are connected in this terminal connection step with a first resin mold portion;
The terminal portion sealed by the first resin mold portion in the wire sealing step accommodates the plurality of connection terminals in the plurality of terminal accommodation chambers and the communication hole forming position in the terminal insertion port of the housing. A terminal part accommodation step of accommodating the tip side more than,
A housing sealing step of filling the terminal insertion port of the housing in which the terminal portion is accommodated in the terminal portion accommodation step with mold resin and sealing the terminal insertion port and the communication hole with a second resin mold portion. A method for manufacturing a waterproof connector. An anchor part forming step of forming a wedge-shaped anchor part for attaching the housing to an external attachment member, which is continuous with the second resin mold part through the communication hole, outside the housing; The manufacturing method of the waterproof connector of Claim 8.