JP2013232367A - Waterproof structure of connector and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a waterproof structure which is free from an increase in the number of components, is capable of simplifying an assembling process, and does not enlarge a connector.SOLUTION: A molded waterproof part 6 for preventing water intrusion from the periphery of an electric wire 11 is integrally molded at least on the periphery of the electric wire 11. The electric wire 11 including the molded waterproof part 6 is integrally molded with a rear housing 14.

Description

  The present invention relates to a waterproof structure for a connector that requires waterproofness and a method for manufacturing the same.

  In a connector used for an automobile or the like, when water is transmitted along the outer periphery of an electric wire and enters the inside of the connector, insulation is lost.

  Patent Document 1 describes a conventional connector with waterproofness. This connector has a packing structure in which a terminal connected to an end of an electric wire and a terminal of the electric wire are accommodated in a pair of upper and lower shield members.

JP 2010-272404 A

  In the conventional connector, since it is necessary to assemble a pair of upper and lower seal members, the number of parts increases, the assembly process becomes complicated, and there is a problem that the connector becomes large. In particular, since a large current flows through the electric wire connected to the power source, there is a problem that the structure for waterproofing is complicated because it is necessary to ensure waterproofing.

  Therefore, an object of the present invention is to provide a waterproof structure in which the assembly process can be simplified without increasing the number of parts and the connector does not increase in size.

  The invention described in claim 1 is a waterproof structure for a connector that is used in a connector for connecting an electric device for power control and a terminal of an electric wire, and prevents water from entering the connector. A plate-like terminal connected to the plate, a rear connector having a rear housing in which the plate-like terminal is accommodated, and a mating terminal connected to the plate-like terminal and connected to the plate-like terminal on the power control electric device side And a front connector that accommodates a box-shaped female terminal connected to the cable, and a molded waterproof part that prevents water from entering from around the electric wire is integrally formed around at least the electric wire. The electric wire including is integrally formed with the rear housing.

  The invention according to claim 2 is the waterproof structure of the connector according to claim 1, wherein the molded waterproof part is formed with a restricting engagement part for restricting relative movement with the rear housing. And

  The invention according to claim 3 is the waterproof structure of the connector according to claim 1 or 2, wherein the plate-like terminal connected to the electric wire and the female terminal are welded.

  The invention according to claim 4 is a connector manufacturing method that is used in a connector that connects an electric power control device and a terminal of an electric wire, and prevents water from entering the connector. A molded waterproof part that prevents water from entering from the periphery of the electric wire is integrally formed around it, and then the molded waterproof part is molded integrally with the rear housing, and the plate terminal and the female terminal are welded together. And the front housing which accommodates the said female terminal is assembled | attached to the said rear housing.

  According to the first aspect of the present invention, since the molded waterproof part for preventing water from entering from the periphery of the electric wire is integrally formed at least around the electric wire, the molded waterproof part is in an integrated state in close contact with the electric wire. The molded waterproof part blocks water that is firmly coupled and transmitted through the electric wire, and can reliably prevent water from entering. In addition, since the electric wire including the molded waterproof part is integrally formed with the rear housing, the molded waterproof part is embedded in the rear housing so that the molded waterproof part can be kept in close contact with the electric wire. The invasion preventing power of water by the waterproof part increases.

  According to the first aspect of the present invention, the molded waterproof portion is integrally formed around the electric wire terminal, and the electric wire including the molded waterproof portion is integrally formed with the rear housing to form a waterproof structure. Therefore, the number of parts does not increase, and the connector does not increase in size. In addition, since the molded waterproof part is integrally formed with the electric wire and the rear housing is integrally formed, the assembly process is reduced and the manufacture is facilitated.

  According to the second aspect of the present invention, since the restriction engaging portion for restricting the relative movement with the rear housing is formed in the molded waterproof portion, the molded waterproof portion is displaced during holding and cooling of the rear housing. Can be prevented. As a result, the molded waterproof portion can be restricted from moving relative to the rear housing, and can be prevented from deviating from the fixed position of the electric wire.

  According to the invention of claim 3, since the plate-like terminal and the female terminal are welded, the plate-like terminal and the female terminal are firmly connected, and the reliability of the electrical connection is improved.

  According to the fourth aspect of the present invention, the molded waterproof part for preventing water from entering from the periphery of the electric wire is integrally formed around the electric wire, and then the molded waterproof part is integrally formed with the rear housing. In addition, a waterproof structure that prevents water from entering without increasing the number of parts and the assembly process can be obtained.

It is a disassembled perspective view of the connector used for the waterproof structure of 1st Embodiment of this invention. It is a perspective view which shows the electric wire before shape | molding a shaping | molding waterproof part integrally. It is a perspective view which shows the electric wire which the female terminal connected after integrally forming a shaping | molding waterproof part. It is a perspective view which shows the state which shape | molded the rear housing in the state which shape | molded the shaping | molding waterproof part. It is a disassembled perspective view which shows the housing front used for a front connector. It is a perspective view of the electric wire which integrally formed the forming waterproof part in a 2nd embodiment of the present invention. FIG. 7 is a front view of FIG. 6. FIG. 7 is a side view of FIG. 6. It is a disassembled perspective view of the connector used for the waterproof structure of 3rd Embodiment of this invention. It is a disassembled perspective view of the deformation state of 3rd Embodiment.

  Hereinafter, the present invention will be described in detail with reference to the illustrated embodiments.

[First Embodiment]
1 to 5 show a waterproof structure 1 for a connector according to a first embodiment of the present invention. The connector 2 used in the waterproof structure 1 connects an electric power control device (inverter: not shown) and an electric wire (power line) 11, and is connected between the electric power control device and the electric wire 11. By being provided, the power from the power source is supplied to the power control electric device. The connector 2 includes a plate-like terminal 3, a rear connector 4, a front connector 5, and a molded waterproof part 6.

  The plate-like terminal 3 is connected to the terminal of the electric wire 11 from the power source. In this embodiment, the electric wire 11 is formed of a two-core wire, and the plate terminal 3 is connected to the terminal of each electric wire 11. As shown in FIG. 2, the plate-like terminal 3 has a plate-like terminal main body portion 3 a and a wire-side connection portion that is bent at a right angle from the terminal main body portion 3 a and connected to the terminal of the inner conductor of the electric wire 11 by crimping. 3b and a female terminal side connection portion 3c that is integrally formed at the end of the terminal main body portion 3a opposite to the electric wire side connection portion 3b and is connected to the female terminal 12 to be described later by caulking and welding. Yes.

  The rear connector 4 includes a rear housing 14 in which the plate terminal 3 and the terminal portion of the electric wire 11 connected to the plate terminal 3 are accommodated. The rear housing 14 is made of an insulating resin. The rear housing 14 is integrally provided with an attachment portion 14a having a long cylindrical shape to which the front connector 5 is assembled on the front side, and a member for assembling the front connector 5 on the outer surface of the attachment portion 14a. The stop convex part 14b is formed. Such a rear housing 14 is not molded in advance, but is integrally molded in a mold together with a molded waterproof portion 6 to be described later when the connector 2 is manufactured. By this integral molding, the shape shown in FIG. 1 is obtained.

  The integrally formed rear housing 14 is accommodated in the shield shell 21. The shield shell 21 is formed in a box shape from a metal such as aluminum, and performs electromagnetic wave shielding on the accommodated rear housing 14.

  The front connector 5 is formed by a front housing body 15 (front housing) and a housing front 17.

  The front housing body 15 accommodates a pair of female terminals 12. The female terminal 12 is formed in a box shape, and is accommodated in the front housing body 15 while being connected to each of the plate terminals 3. In order to accommodate the female terminal 12, the front housing body 15 is formed with a terminal accommodating chamber 15c. The terminal accommodating chamber 15c is partitioned by the partition wall portion 15a, and mutual contact of the female terminals 12 inserted into the respective terminal accommodating chambers 15c is prevented. The front housing body 15 is assembled to the mounting portion 14 a of the rear housing 14, and a hook portion 15 b corresponding to the locking projection 14 b of the mounting portion 14 a protrudes toward the rear housing 14.

  The housing front 17 is for receiving a mating terminal of an electric power control device. As shown in FIG. 5, the housing front 17 has a lower front portion 17a and an upper front portion 17b, which can be assembled to each other. A rectangular mating terminal insertion port 19 into which a plate-like mating terminal (not shown) from the power control electric device side is inserted is formed in the lower front portion 17a. The mating terminal inserted into the mating terminal insertion port 19 is electrically connected to the box-shaped female terminal 12 housed in the terminal housing chamber 15 of the front housing body 15.

  The molded waterproof part 6 is integrally formed around the electric wire 11. The molded waterproof part 6 is provided so as to surround the periphery of the electric wire 11 made of a two-core wire, and blocks the water moving to the plate-like terminal 3 side through the insulating sheath 11a of the electric wire 11. Thereby, the penetration | invasion of the water from the circumference | surroundings of the electric wire 11 can be prevented.

  The molded waterproof portion 6 is not molded in advance, and is integrally molded in the mold when the connector 2 is manufactured. FIG. 1 shows the shape of a molded waterproof part formed by integral molding. Since the molded waterproof portion 6 is integrated with the electric wire 11 by being integrally molded in this way, it is more firmly coupled to the electric wire 11 than when a seal ring such as rubber is simply wound around the electric wire 1. For this reason, waterproofness improves remarkably.

  A thermosetting elastomer is used as the material of the molded waterproof portion 6. As the thermosetting elastomer, a vulcanized rubber or a thermosetting resin-based elastomer can be used, and as the thermosetting resin-based elastomer, urethane rubber, silicone rubber, fluorine rubber, or the like can be appropriately selected.

  Next, a manufacturing method of the connector 2 of this embodiment will be described with reference to FIGS. FIG. 2 shows a state before the molded waterproof part 6 is integrally molded, and the plate-like terminal 3 is connected to the end of each electric wire 11 composed of two core wires.

  FIG. 3 shows a state after the molded waterproof part 6 is integrally molded. A terminal portion of the electric wire 11 to which the plate-like terminal 3 is attached is set in a mold, and a thermosetting elastomer is injected into the mold to be thermally cured. Thereby, the molded waterproof part 6 is integrally molded around the terminal portion of the electric wire 11.

After the molded waterproof part 6 is integrally molded, the box-shaped female terminals 12 are connected to the respective plate-shaped terminals 3. As shown in FIGS. 1 and 3, the female terminal 12 is formed by a box-shaped female box connection portion 12a and a thin plate-shaped connection portion 12b extending from the female box connection portion 12a. The female terminal side connection portion 3c of the plate-like terminal 3 is crimped and crimped to the connection portion 12b. Then, the plate-shaped connection part 12b and the female terminal side connection part 3c are combined by welding. By performing the welding, the plate-like terminal 3 and the female terminal 12 are firmly connected. This improves the reliability of the electrical connection. FIG. 4 shows a state in which the rear housing 14 is integrally formed. The integral molding shown in FIG. 4 is performed after integral molding of the molded waterproof portion 6 to the terminal portion of the electric wire 11 and connection of the plate-like terminal 3 and the female terminal 12 by welding.

  In the integral molding of the rear housing 14, the terminal portion of the electric wire 11 in which the molded waterproof portion 6 is formed and the plate-like terminal 3 connected to the terminal portion of the electric wire 11 are set in the mold. It is performed by injecting an insulating resin into the interior and curing. By this molding, the molded waterproof portion 6 and the terminal portion of the electric wire 11 provided with the molded waterproof portion 6 are embedded in the rear housing 14. Therefore, the molded waterproof part 6 is fixed in the rear housing 14, and the molded waterproof part 6 is prevented from separating from the electric wire 11. Therefore, since the molded waterproof part 6 can be kept in close contact with the periphery of the electric wire 11, water can be reliably prevented from entering by the molded waterproof part 6.

  After the molded waterproof part 6 is integrally formed at the end of the electric wire 11 and the rear housing 14 is integrally molded with the molded waterproof part 6, the front housing body 15 is assembled to the rear housing 14. In this case, the housing front 17 is assembled and inserted into the front housing body 15 to form the front connector 5. A seal ring 7 made of rubber is disposed between the front housing main body 15 and the housing front 17.

  Thereafter, the front housing body 15 is assembled to the mounting portion 14 a of the rear housing 14 while the female terminal 12 is inserted into the terminal accommodating chamber 15 c of the front housing body 15. At this time, the hook portion 15b is locked to the locking convex portion 14b while sandwiching the seal ring 8 made of rubber, and the assembly is completed.

  In such an embodiment, since the molded waterproof portion 6 is integrally formed around the end of the electric wire 11, the molded waterproof portion 6 is in close contact with the insulating outer skin 11 a of the electric wire 11 and is firmly coupled to the electric wire 11. For this reason, since the shaping | molding waterproof part 6 interrupts | blocks the water which transmits the electric wire 11, invasion of water can be prevented reliably. Further, since the electric wire 11 including the molded waterproof portion 6 is integrally formed with the rear housing 14, the molded waterproof portion 6 is embedded integrally with the rear housing 14, and the molded waterproof portion 6 is kept in close contact with the electric wire 11. This can increase the prevention of water penetration by the molded waterproof part 6.

  In such an embodiment, the molded waterproof portion 6 is integrally formed around the end of the electric wire 11 and the electric wire 11 including the molded waterproof portion 6 is integrally formed with the rear housing 14 to form a waterproof structure. The number of parts does not increase, and the connector 2 does not increase in size. Moreover, since the molded waterproof portion 6 is integrally formed with the electric wire 11 and the rear housing 14 is integrally formed, the assembly process is reduced and the manufacture is facilitated.

[Second Embodiment]
6 to 8 show a second embodiment of the present invention. In this embodiment, the restriction engaging part 23 is formed with respect to the molded waterproof part 6 integrally molded around the terminal portion of the electric wire 11. The restricting engagement portion 23 includes an engagement groove 24 formed in a concave shape on the outer surface of the molded waterproof portion 6.

  The engaging groove 24 as the restricting engaging portion 23 is formed in a direction intersecting the length direction of the electric wire 11. In this embodiment, the molded waterproof portion 6 is orthogonal to the length direction of the electric wire 11. It is formed on the outer surface. Further, the engaging groove 24 is formed in an intermediate portion in the length direction (vertical direction in FIGS. 6 to 8) of the molded waterproof part 6, and the molded waterproof part 6 is in a state of sandwiching the engaging groove 24. Yes. The engagement groove 24 is formed to a depth that reaches the insulating outer skin 11 a of the electric wire 11.

  When the rear housing 14 is integrally formed using the molded waterproof part 6 in which the engaging groove 24 as the restriction engaging part 23 is formed, the molded waterproof part 6 is displaced at the time of holding or cooling the rear housing 14. Can be prevented.

  That is, since the elastomer (thermosetting elastomer) of the molded waterproof portion 6 and the resin of the rear housing 14 are made of different materials and have different coefficients of thermal expansion, the shrinkage rate at the time of molding the rear housing 14 is different. Since stress acts on the molded waterproof part 6 due to the difference in shrinkage rate, the molded waterproof part 6 may be displaced with respect to the electric wire 11 when the rear housing 14 is integrally formed. When such a shift | offset | difference of the shaping | molding waterproof part 6 arises, waterproofness will fall. On the other hand, when the engaging groove 24 is formed in the molded waterproof part 6 as in this embodiment, the resin for molding the rear housing 14 enters the engaging groove 24 and is cured in the resin entering state. Therefore, the molded waterproof part 6 is in a fixed state at a fixed position. Accordingly, since the molded waterproof portion 6 is restricted from moving relative to the rear housing 14 and is not displaced from the fixed position of the electric wire 11, it is possible to prevent the waterproof property from being lowered.

  In addition, as the restricting engagement portion 23, a protrusion may be formed on the molded waterproof portion 6 instead of the groove 24.

[Third Embodiment]
FIG. 9 shows the connector 2 used in the waterproof structure of the third embodiment of the present invention.

  In the connector 2 of this embodiment, a concentric wire is used as the electric wire 11. Other configurations are the same as those of the first embodiment, and the same members as those in FIG.

  The electric wire 11 made of concentric wires is formed by arranging an inner conductor 31 and an outer conductor 32 on the outer periphery of the inner conductor 31 via an insulating inner skin, and covering the outer periphery of the outer conductor 32 with an insulating outer shell 33. . In this electric wire 11, the inner conductor 31 and the outer conductor 32 are drawn out by being peeled off, and the plate-like terminals 3 are connected to the ends of the inner conductor 31 and the outer conductor 32, respectively.

  In this way, the molded waterproof portion 6 is integrally molded with respect to the portion including the ends of the inner conductor 31 and the outer conductor 32. Since the inner conductor 31 and the outer conductor 32 are drawn out in directions away from each other, the molded waterproof portion 6 has a conductor covering portion 35 surrounding them, and a lead-out portion (terminal) of the inner conductor 31 and the outer conductor 32 in the electric wire 11. ) Is formed into a shape in which the terminal cover portion 36 surrounding the periphery of is integrally formed.

  The molded waterproof part 6 is an integral body in which a thermosetting elastomer is injected and cured in a state where the inner conductor 31 and the outer conductor 32, their lead portions (terminals), and the plate-like terminal 3 are set in a mold. It is formed by molding. After the molded waterproof part 6 is molded, the rear housing 14 is formed integrally with the portion of the electric wire 1 including the molded waterproof part 6 as in the first embodiment.

  Also in such an embodiment, since the molded waterproof portion 6 is integrally formed around the end of the electric wire 11 made of a two-core wire, the molded waterproof portion 6 is firmly bonded in an integrated state in close contact with the electric wire 11. For this reason, since the shaping | molding waterproof part 6 interrupts | blocks the water which transmits the electric wire 11, invasion of water can be prevented reliably. Further, since the electric wire 11 including the molded waterproof portion 6 is integrally formed with the rear housing 14, the molded waterproof portion 6 is embedded integrally with the rear housing 14, and the molded waterproof portion 6 is kept in close contact with the electric wire 11. This can increase the prevention of water penetration by the molded waterproof part 6.

  Also in this embodiment, the molded waterproof portion 6 is integrally formed around the end of the electric wire 11 and the electric wire 11 including the molded waterproof portion 6 is integrally formed with the rear housing 14 to form a waterproof structure. The number of parts does not increase and the connector 2 does not increase in size. Moreover, since the molded waterproof portion 6 is integrally formed with the electric wire 11 and the rear housing 14 is integrally formed, the assembly process is reduced and the manufacture is facilitated.

  In this embodiment as well, the restriction engagement portion 23 of the second embodiment may be formed on the molded waterproof portion 6, thereby preventing the molded waterproof portion 6 from being displaced, thereby preventing a decrease in waterproofness. be able to.

  FIG. 10 shows various modifications when a concentric wire is used as the electric wire 11. In FIG. 10, a cylindrical connection end 37 is integrally formed with the plate-like terminal 3 connected to the outer conductor 32. The connection end 37 is extrapolated to the exposed outer conductor 32 which is peeled off, and the connection end 37 is connected to the outer conductor 32 by caulking or ultrasonic bonding. As a result, the inner conductor 31 and the outer conductor 32 are drawn out in substantially the same direction. The molded waterproof part 6 surrounding the periphery of the terminal of the electric wire 11 is formed to have a large diameter such that the terminal cover part 36 surrounds the connection end 37.

  The present invention is not limited to the above embodiment, and various modifications are possible. In the above embodiment, the molded waterproof part 6 is integrally formed around the terminal of the electric wire 11, but the molded waterproof part 6 may be formed longer with respect to the electric wire 11 than the terminal part. Moreover, after crimping the female terminal connection part 3c of the plate-shaped terminal 3 to the female terminal 12, these are welded, However, These may be welded only without crimping.

DESCRIPTION OF SYMBOLS 1 Connector waterproof structure 2 Connector 3 Plate terminal 4 Rear connector 5 Front connector 6 Molding waterproof part 11 Electric wire 12 Female terminal 14 Rear housing 15 Front housing main body (front housing)
23 Restriction engagement part

Claims (4)

It is used for a connector that connects an electrical device for power control and the end of an electric wire, and is a waterproof structure for a connector that prevents water from entering the connector,
A plate-like terminal connected to the end of the electric wire, a rear connector having a rear housing in which the plate-like terminal is accommodated, an electric device for power control that is assembled to the rear connector and connected to the plate-like terminal A front connector that houses a box-shaped female terminal connected to the mating terminal on the side,
A waterproof connector according to claim 1, wherein a molded waterproof part for preventing water from entering from the periphery of the electric wire is integrally formed at least around the electric wire, and the electric wire including the formed waterproof part is integrally formed with the rear housing. Construction. The waterproof structure of the connector according to claim 1,
A waterproof structure for a connector, wherein a restriction engaging portion for restricting relative movement with the rear housing is formed in the molded waterproof portion.   The waterproof structure for a connector according to claim 1 or 2, wherein a plate-like terminal connected to the electric wire and the female terminal are welded. A method for manufacturing a connector that is used for a connector that connects an electric device for power control and a terminal of an electric wire, and prevents water from entering the connector,
After integrally forming a molded waterproof part that prevents water from entering from around the electric wire at least around the electric wire, the molded waterproof part is molded integrally with the rear housing,
Welding the plate terminal and the female terminal;
A method for manufacturing a connector, comprising: assembling a front housing for housing the female terminal to the rear housing.

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