JP3174270B2 - Connector for connecting electric wire and flat cable and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rotating body and a fixed body for transferring electric signals between a rotating body connected to a steering wheel and a fixed body connected to a steering column in, for example, a steering mechanism of a vehicle. The present invention relates to a connector for connecting an electric wire and a flat cable, and a method for manufacturing the connector, which is used for an electrical connection device of the above.

[0002]

2. Description of the Related Art Japanese Patent Application Laid-Open No. 7-69219 discloses an electrical connection device to which this type of connection connector is applied.

[0003] As shown in FIG. 7, this electrical connection device includes a cylindrical rotary body 1 into which a steering wheel shaft (not shown) is inserted, and a rotatably supporting rotary body 1 shown in FIG. Upper cover 3A and under cover 3 constituting housing 2 fixed to the steering column not to be mounted
B, a flexible space which is fixed at both ends to the rotating body 1 and the housing 2 and is folded back in the annular space 4 is provided in the annular space 4 between the rotating body 1 and the housing 2. A flat cable 6 and a guide roller 7 are provided.

[0004] The flat cable 6 is
The connectors 8 and 9 provided on both sides of the inner surface of the rotating body 1 are wound around the inner surface of the rotating body 1 and the outer surface is wound on the inner surface of the under cover 3B in a direction opposite to the inner direction. It is fixedly accommodated in the rotating body 1 and the housing 2.

Both ends of the flat cable 6 are connected to electric wires 5 and 10 in connectors 8 and 9, respectively. For example, the inner end of the flat cable 6 is connected to various switches (not shown) on the steering wheel side via the electric wire 5. ), And the outer end thereof is connected to a control circuit (not shown) on the steering column side via an electric wire 10.

At this time, the connector 8 (9) for connecting the electric wire and the flat cable is pressed into a groove 12 formed on one side surface of the mounting plate 11 as shown in FIGS.
And the flat cable 6 is temporarily fixed by passing through a bridge 13 formed on the other side surface of the mounting plate 11 (see FIG. 8A), and protrudes from the mounting plate 11 in the same direction. The exposed conductors 5A and 6A of the flat electric cable 5 and the flat cable 6 are ultrasonically bonded to each other (see FIG. 8B).
Thereafter, the mounting plate 11 is covered with the synthetic resin material 14 including the joint between the conductor exposed portions 5A and 6A (see FIG. 9).
It is configured by insert molding.

The connector 8 (9) thus constructed
The joint between the conductor exposed portions 5A and 6A is protected by the synthetic resin material 14 coated by insert molding, and the tensile strength of the electric wire 5 and the flat cable 6 can be secured together. I have.

[0008] A similar technique relating to the connector 8 (9) is disclosed in Japanese Utility Model Laid-Open No. 4-76257 and Japanese Patent Laid-Open No. 5-627.
No. 54 discloses this.

[0009]

However, in the conventional connector 8 (9) for connecting an electric wire and a flat cable, the synthetic resin material directly hits the conductor exposed portion 6A of the flat cable 6 at the time of insert molding. Depending on the injection pressure of the molding machine and the direction of flow of the synthetic resin material, excessive stress may be applied to the conductor exposed portion 6A. In this case, the conductor is formed thin and brittle, which may cause a disconnection situation. As a result, there is a problem that reliability is reduced.

That is, as shown in FIG. 10, a conventional connector 8 (9) has a mounting plate 11 and conductor exposed portions 5A, 6A.
It can be obtained by setting in the cavity C including the joining portion of A and performing insert molding. The synthetic resin material flowing into the cavity C from the gate G during the insert molding generally has a flow R1 on the holding surface side of the flat cable 6 of the mounting plate 11 and a flow R2 on the holding surface side of the electric wire 5 of the mounting plate 11. Into the cavity C. At this time, the synthetic resin material flowing along the flow R1 out of the flows R1 and R2 of the synthetic resin material is exposed to the conductor exposed portions 6 of the flat cable 6.
A, and excessive stress is applied to the root A, which is the unsupported portion of the exposed conductor 6A.
May be disconnected from the root A.

The conductor exposed portion 6 of the flat cable 6
A and when the conductor exposed portion 5A of the electric wire 5 is ultrasonically welded,
Since the horn or anvil serving as a welding jig directly hits the conductor exposed portion 6A on the flat cable 6 side, stress is applied to the thin and weak conductor exposed portion 6A on the flat cable 6 side, and stable joining may not be performed. .

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problem, and an object of the present invention is to provide a connector for connecting an electric wire and a flat cable and a method for manufacturing the same, which can stably obtain a product having improved reliability. To offer.

[0013]

According to a first aspect of the present invention, an electric wire and a flat cable each having a conductor exposed portion at its tip are held along a plate surface of a mounting plate, and the conductor exposed portions are joined to each other. And a connector for connecting an electric wire and a flat cable, which is insert-molded with a synthetic resin material so as to cover at least a part of the mounting plate and a joint portion of the conductor exposed portion, wherein the mounting plate has a conductor pitch of the flat cable. A plurality of bus bars are formed corresponding to each other, and a plurality of bus bars having both front and back surfaces exposed and the both ends buried in the mounting plate are arranged for each of the window portions, and a flat cable is provided on one surface of each bus bar. The conductor exposed portion of the conductor and the conductor exposed portion of the electric wire are sequentially overlapped, and in that state, a bus bar and the two conductor exposed portions are joined, and the insert molding is performed including the bus bar. There.

In this connector, since the bus bar protects the exposed portion of the conductor of the flat cable, the exposed portion of the conductor on the flat cable side is not exposed, and the flow of the insert molding resin can be blocked by the bus bar. In addition, the flat cable and the exposed conductor of the wire are pushed to the busbar side by the insert molding resin flowing into the exposed conductor of the wire, but the force can be received by the busbar, and stress is applied to the base of the joint on the flat cable side. Can be prevented. Further, since the bus bar is interposed, the horn or the anvil, which is a joining jig, is not directly applied to the exposed conductor of the flat cable. Further, since the bus bar is present in the synthetic resin material in a state of covering the conductor exposed portion of the flat cable, heat conduction from the outside can be blocked by the bus bar.

According to a second aspect of the present invention, there is provided a connector for connecting an electric wire and a flat cable according to the first aspect, wherein both the flat cable and the electric wire have one exposed surface of the conductor facing the same direction and one surface of a mounting plate. And is held between the mounting plate and a cover by a cover detachably fitted to one plate surface of the mounting plate.

In this connector, the flat cable and the electric wire can be securely held by fitting the cover to the mounting plate and insert-molding a synthetic resin material.

According to a third aspect of the present invention, there is provided the connector for connecting an electric wire and a flat cable according to the second aspect, wherein a flat cable holding surface for holding the flat cable in a straight line is provided on one plate surface of the mounting plate. An L-shaped wire receiving portion is formed on the back surface of the cover and holds the distal end side of the electric wire in parallel with the flat cable and holds the base end side of the electric wire in a direction perpendicular to the flat cable. It is characterized by having.

In this connector, the flat cable is set on the flat cable holding surface, the electric wire is set in the electric wire receiving portion, and the cover is fitted to the mounting plate in that state, thereby securely holding the flat cable and the electric wire. can do. In addition, the direction in which the flat cable and the wire are drawn out can be kept orthogonal.

According to a fourth aspect of the present invention, there is provided a connector for connecting an electric wire and a flat cable according to the third aspect, wherein the L-shaped electric wire receiving portion is fitted with the distal end side of each electric wire, respectively. A plurality of wire holding grooves for holding the flat cable at the conductor pitch of the flat cable in parallel with the flat cable,
And a bent portion accommodating portion for accommodating together the bent portions of all the electric wires bent in an L-shape from the distal end side to the proximal end side.

In this connector, the electric wire can be held by fitting the distal end of the electric wire into the electric wire holding groove and housing the bent portion in the bent portion housing portion. In that case, the bent portion is housed together with all the wires, but the distal ends are each held by the wire holding groove, so the wires can be held comfortably, and the distal end of the wires is flat and parallel to the flat cable. It can be held in accordance with the conductor pitch of the cable. Further, in this connector, since there is a portion (bent portion accommodating portion) for holding the bent portion of the electric wire, the base end side of the electric wire can be pulled out in a direction orthogonal to the flat cable.

According to a fifth aspect of the present invention, there is provided the connector for connecting an electric wire and a flat cable according to the fourth aspect, wherein an insert molding resin filled from the outside is guided to the wire holding groove on the plate surface of the cover. It is characterized in that a formed resin introduction hole is formed.

In this connector, since the insert molding resin enters the wire holding groove through the resin introduction hole, the gap around the electric wire and the gap around the flat cable can be reliably filled with the resin.

According to a sixth aspect of the present invention, there is provided the connector for connecting an electric wire and a flat cable according to the fourth or fifth aspect, wherein the resin is introduced into the cover to guide the insert molded resin externally filled into the bent portion accommodating portion. It is characterized in that a passage is provided.

In this connector, since the insert-molded resin enters the bent portion accommodating portion of the electric wire from the resin introduction passage, the gap around the electric wire and the gap around the flat cable can be reliably filled with the resin.

According to a seventh aspect of the present invention, there is provided a connector for connecting an electric wire and a flat cable according to any one of the third to sixth aspects, wherein the mounting plate guides and holds the electric wire extending in a direction perpendicular to the flat cable. An electric wire drawing portion is provided, and an electric wire pressing piece for holding the electric wire between the electric wire drawing portion and the electric wire drawing portion is detachably fitted to the electric wire drawing portion.

In this connector, the electric wire can be securely held by fitting the electric wire pressing piece to the electric wire drawing portion, and the tensile strength of the electric wire can be increased.

According to an eighth aspect of the present invention, there is provided the connector for connecting an electric wire and a flat cable according to any one of the first to seventh aspects, wherein the mounting plate has a locking claw for hooking a lug at an end of the flat cable. It is characterized by being provided.

In this connector, when the flat cable is set on the mounting plate, the ear, which is the non-removed portion of the insulator left at the tip of the flat cable, is set while being hooked on the locking claw. Then, the conductor exposed portion that is soft and easy to bend can be held straight along the bus bar by pulling the ear at the tip. Accordingly, the bus bar and the exposed conductor can be ultrasonically bonded in a stable state.

According to a ninth aspect of the present invention, there is provided a connector for connecting an electric wire and a flat cable according to any one of the first to eighth aspects, wherein a portion of the mounting plate around a bus bar is provided.
It is characterized in that a recess for filling the insert molding resin is formed.

In this connector, since there is a recess filled with the insert molding resin around the portion where the bus bar is provided, the periphery of the bus bar, that is, the joint portion of the exposed conductor is firmly solidified with the resin and protected. .

According to a tenth aspect of the present invention, there is provided the connector for connecting an electric wire and a flat cable according to any one of the first to ninth aspects, wherein the bus bar has both ends supporting portions embedded in the mounting plate; A central joint having a joint surface for exposing the flat cable and the exposed conductor of the electric wire, which is provided at the window of the mounting plate and joining the exposed portions of the flat cable and the electric wire, is integrally connected via a joint having a small heat transfer area. It is characterized by being.

In this connector, the joint energy at the time of joining the exposed portions of the conductor of the flat cable and the electric wire to the center joint of the bus bar can be prevented from being released to the portion other than the center joint by the connecting portion. Therefore, the bonding can be performed in a shorter time and with higher efficiency with smaller bonding energy. In addition, since heat is prevented from being transferred to the support portions at both ends by the connecting portions, the resin is prevented from being melted by the heat radiation of the support portions, so that the bus bar can be stably supported and a stable joint state can be secured.

According to an eleventh aspect of the present invention, there is provided a method of manufacturing a connector for connecting an electric wire and a flat cable according to any one of the first to tenth aspects, wherein the mounting plate having the busbar is insert-molded and then a conductor is provided at the tip. While holding the wire and the flat cable having the exposed portion along the plate surface of the mounting plate, the conductor exposed portion of the flat cable and the conductor exposed portion of the wire are sequentially overlapped on one surface of each bus bar, and in that state, After joining the bus bar and the exposed portions of both conductors,
It is characterized in that insert molding is performed so as to cover the bus bar, the joint of the conductor exposed portion, and a part of the mounting plate with a synthetic resin material.

According to this manufacturing method, insert molding is performed in a state where both conductor exposed portions of the electric wire and the flat cable are overlapped and joined to one surface of the bus bar, so that the injection pressure and the synthetic resin material at the time of insert molding are formed. Irrespective of the direction of flow into the cavity, excessive stress applied to the conductor exposed portion during insert molding can be avoided.

[0035]

DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 is an exploded perspective view showing a skeleton portion (before insert molding with a synthetic resin material) of a connector according to an embodiment of the present invention, FIG. 2 is a perspective view showing an assembled state of the skeleton portion, FIG. 3A is a sectional view taken along the line IIIa-IIIa of FIG. 1, and FIG. 3B is a sectional view taken along the line IIIb-IIIb of FIG. 2. 2 and 3 (b) show the outline of the resin molded product obtained by insert molding the skeleton portion of FIG. Here, this portion will be described as insert molding resin 70.

This connector has a conductor exposed portion 5 at its tip.
The connector 5 is a connector for connecting the electric wire 5 having the wires A and 6A and the flat cable 6 with sufficient strength. The components constituting the connector housing include a main holder 20 and a cover 40 fitted to the holder 20. , And an electric wire pressing piece 60. These are all made of resin moldings.

The holder 20 is disposed along the inner peripheral surface of the housing of the electrical connection device as shown in FIG.
The mounting plate 21 has a fixed width (vertical width) that is curved in an arc shape. Edge walls 22 are provided at both ends in the width direction of the mounting plate 21 so as to protrude inward. The inner surface of the mounting plate 21 sandwiched between the both edge walls 22 holds the flat cable 6 in a straight line. Cable holding surface 21a for the connection.

Further, the holder 20 has a gutter-shaped wire lead-out portion 23 protruding from one side of the mounting plate 21 in the width direction. The wire outlet 23 is disposed at the center in the length direction of the mounting plate 21, and the edge wall 2 at the position where the wire outlet 23 is provided.
2 are cut out, whereby the flat cable holding surface 21
The portion from a to the wire lead-out portion 23 is formed as a continuous recess.

A window 25 is provided at one longitudinal end of the mounting plate 21. This window portion 25 is divided into three, here, the number of connection wires by a partition wall 24 arranged in parallel to the longitudinal direction of the mounting plate 21. Each window portion 25 has a structure shown in FIGS. As shown in FIG. 2, bus bars 30 made of separated copper plates (or other metal plates) may be fitted. The bus bars 30 are insert-molded in the holder 20, and three bus bars 30 are arranged in parallel along the longitudinal direction of the mounting plate 21 at the same pitch as the conductor pitch of the flat cable 6. The front and back surfaces are exposed on the inner peripheral surface side and the outer peripheral surface side of the mounting plate 21.

In the edge wall 22 of the portion of the mounting plate 21 where the window portion 25 is formed, a recess is provided for improving the flow, filling property or connectivity of the resin when insert molding with a synthetic resin material later. 26 are provided. In addition, a locking claw 27 is provided at the tip of the partition wall 24 that partitions the window 25, as shown in detail in FIG. This locking claw 27
Is a lug 6B provided at the tip of the flat cable 6 (an insulator non-removed portion formed by leaving only the tip when the insulator of the flat cable 6 is removed to expose the conductor).
Is a part for hooking as shown by an arrow.

As shown in FIGS. 1 and 2, the wire pulling portion 23 is adjacent to the wire holding groove 31,
There is a lock portion 28 that locks with the engagement portion 61 on the wire holding piece 60 side when the wire 0 is fitted to the wire drawing portion 23, and the cover 40 is attached to the mounting plate 21 on the edge wall 22 of the mounting plate 21. There is a lock portion 29 that locks with the engagement portion 47 on the cover 40 side when fitted.

As shown in FIG. 5, the cover 40 is formed as an arc-shaped plate along the mounting plate 21, and has an L-shaped wire receiving portion 41 on the surface (back surface) on the mounting plate 21 side. are doing. The L-shaped wire accommodating portion 41 is a portion having a function of holding the wires 5 in a bent shape, and has wire holding grooves 42 into which the distal ends of the respective wires 5 are fitted, respectively, and an L extending from the distal side to the proximal side. And a bent portion accommodating portion 43 for accommodating together the bent portions of all the electric wires 5 bent in a letter shape. The bent portion accommodating portion 43 can guide the base end side of the electric wire 5 in a direction perpendicular to the flat cable 6, that is, toward the electric wire lead-out portion 23 side.

On the other hand, the wire holding grooves 42 are arranged in parallel at the same pitch as the conductor pitch of the flat cable 6 so that the leading end of the wire 5 can be held at the same pitch as the conductor pitch of the flat cable 6 in parallel. Has become. The wire holding groove 42 is provided with projections 42a and 42b for holding the fitted wire 5 so as not to come off. Further, the distal end of the wire holding groove 42 is open to the end wall of the cover 40.

As shown in FIGS. 1 and 2, a penetrating resin introduction hole for guiding the insert molding resin 70 filled from the outside into the wire holding groove 42 is provided at the position of the wire holding groove 42 of the cover 40. 44 are provided. Further, a resin introduction passage 45 for guiding the insert molding resin 70 to the bent portion housing portion 43 is provided at an end position of the bent portion housing portion 43 (see FIG. 5).

To manufacture this connector, first, the holder 20 having the above-described bus bar 30, the cover 40, and the wire pressing piece 60 are prepared. Also, as shown in FIG. 1, an electric wire 5 to be connected and a flat cable 6 are prepared, a conductor exposed portion 5A is formed at the end of the electric wire 5, and a conductor exposed portion 6A is formed at the end of the flat cable 6. At this time, the ear 6B is left at the tip of the flat cable 6 so that the conductor exposed portion 6A is not deformed. Then, the flat cable 6 is set on the flat cable holding surface 21a of the holder 20 with the ear 6B hooked on the locking claw 27 at the tip of the holder 20.

Next, the electric wire 5 is fitted into the electric wire holding groove 42 on the back surface of the cover 40, and the bent portion is inserted into the bent portion accommodation portion 4.
The cover 40 is fitted to the holder 20 while being housed in the holder 3, and is fixed so as not to come off by the engaging portion 47 and the lock portion 29. Thereby, the electric wire 5 and the flat cable 6 can be reliably held between the cover 40 and the mounting plate 21 with the conductor exposed portions 6A and 5A both oriented in the same direction.

At this time, the exposed conductor 6A at the tip of the flat cable 6 and the exposed conductor 5A at the tip of the electric wire 5 are connected to each other as shown in FIG.
As shown in (2), it is positioned so as to overlap on the surface of the bus bar 30 provided in the window 25 of the holder 20 in this order. Actually, the flat cable 6 has the ear 6B at the tip.
By simply setting while hooking on the locking claw 27, the positioning with respect to the bus bar 30 can be easily performed.
Further, the electric wire 5 can be easily positioned with respect to the bus bar 30 only by fixing the cover 40 to the holder 20 in a state of being fitted in the electric wire holding groove 42.

When the cover 40 is fitted to the holder 20, the base end of the flat cable 6 is pulled out from one end of the mounting plate 21, and the base end of the electric wire 5 is connected to an electric wire outlet. It is pulled out along the direction 23 and perpendicular to the flat cable 6 (see FIG. 2). Here, the wire holding piece 6
The base end side of the electric wire 5 can be securely pressed down by fitting 0 to the electric wire drawing portion 23.

Next, the overlapped portion of the bus bar 30, the exposed conductor 6A of the flat cable 6, and the exposed conductor 5A of the electric wire 5 is sandwiched between the horn and the anvil of the ultrasonic welding machine. People together. At the time of this joining, by interposing the bus bar 30 therebetween, the welding jig does not directly contact the exposed conductor 6A of the flat cable 6, so that stress acting on the exposed conductor 6A at the time of joining can be reduced, and the joining state can be reduced. Can be good.

After the joining is completed and an assembly as shown in FIG. 2 is made, the assembly is inserted into a mold, and is then insert-molded with a synthetic resin material. The window 25 including the joints of the portions 5A and 6A, the other recesses 26, and the like are filled and solidified with resin to obtain the connection connector of the embodiment.

At this time, the plurality of conductor exposed portions 5A and 6B
Are individually partitioned by the partition wall 24 provided in the window 25, so that the corresponding exposed conductors 5A and 6A are accurately joined without interfering with other adjacent exposed conductors 5A and 6A. You.

Further, at the time of insert molding, the conductor exposed portion 6A of the flat cable 6 is protected by the bus bar 30,
Since the exposed portion 6A of the conductor is not exposed, FIG.
(B) The flow of the resin as shown by the arrow S1 is interrupted,
Excessive stress does not act on the exposed conductor 6A of the flat cable 6. Also, the arrow S in FIG.
2, the flow of the resin toward the exposed conductor portion 5A of the electric wire causes the flat cable 6 and the exposed conductor portion 6 of the electric wire 5 to flow.
A and 5A are pushed toward the bus bar 30, but the force is reliably received by the bus bar 30, so that no extra stress is applied to the conductor exposed portion 6A of the flat cable 6. Therefore, disconnection at the time of welding or insert molding can be prevented.

Also, since the insert molding resin 70 enters the cover 40 through the resin introduction hole 44 and the resin introduction passage 45 provided in the cover 40, the gap around the electric wire 5 and the gap around the flat cable 6 can be reliably formed. It can be filled with resin, and the holding power of the electric wire 5 and the flat cable 6 can be increased.

Further, at the time of actual use, the bus bar 30
Is present in the synthetic resin material in a state of covering the conductor exposed portion 6A of the flat cable 6, so that heat conduction from the outside can be cut off by the bus bar 30, and the conductor exposed portion 6A is subjected to thermal stress in use. Can also be protected.

FIG. 6 shows a bus bar 80 (FIG. 6A) used in another embodiment and its assembled state (FIG. 6).
(B)) is shown. The other embodiment is different from the first embodiment only in that a bus bar 80 having a different shape is used. For this reason, the same components are denoted by the same reference numerals, and redundant description will be omitted.

The bus bar 80 has both ends supporting portions 81, 81 embedded in the mounting plate 21 and both exposed portions 6 A, 6 A of the flat cable 6 and the electric wire 5, which are provided so as to be exposed to the window 25 of the mounting plate 21. A central joint 82 having a joint surface 82a (indicated by oblique lines in the figure) for joining 5A is integrally connected via a connecting portion 83 having a small heat transfer area. That is, the bus bar 80 is insert-molded by embedding the connecting portions 83 and the supporting portions 81 at both ends in the mounting plate 21 and exposing the front and back surfaces of the central joint portion 82 to the window portion 25 when the holder 20 is formed. You. At this time, the mounting plate 21
The surface of the central joint 82 located on the inner peripheral side of
2a.

In the present embodiment having the bus bar 80, the joint energy at the time of joining the exposed portions 6A and 5A of the flat cable 6 and the electric wire 5 to the joint surface 82a is reduced by the connecting portion 83 to the portions other than the central joining portion 82. Can be prevented, the bonding can be performed with a smaller bonding energy, in a shorter time and with higher efficiency. In addition, the connection portion 83 prevents heat transfer to the both-end support portion 81 and prevents overheating of the support portion 81.
Dissolution of the resin constituting the mounting plate 21 burying the substrate 1 is prevented, so that the support state of the bus bar 80 is stabilized and a stable joint state is obtained.

Further, the takt time of the production line in this embodiment can be shortened by the above-mentioned short joining time,
Thereby, cost reduction can be achieved.

[0060]

As described above, according to the first aspect of the present invention, since the conductor exposed portion of the flat cable is insert-molded while being protected by the bus bar, an excessive stress is applied to the conductor exposed portion of the flat cable. Can be avoided, and disconnection during insert molding of the conductor can be prevented. As a result, a product with improved reliability can be stably obtained. In addition, since the bus bar is present in the synthetic resin in a state of covering the conductor exposed portion of the flat cable, heat conduction from the outside is blocked by the bus bar,
The exposed conductor can be protected from thermal stress in use, and the durability can be improved.

According to the second aspect of the present invention, the cover is fitted to the mounting plate and the synthetic resin material is insert-molded.
Flat cable and electric wire can be held securely,
The tensile strength of electric wires and flat cables can be increased.

According to the third aspect of the present invention, the flat cable and the electric wire can be more securely held. In addition, the direction in which the flat cable and the wire are drawn out can be kept orthogonal.

According to the fourth aspect of the present invention, the bent portions are housed together with all the electric wires, but the front ends are respectively held by the electric wire holding grooves, so that the electric wires can be held without difficulty. Particularly, since the front end side of the electric wire can be held in conformity with the flat cable, it becomes easy to join.

According to the fifth aspect of the present invention, the gap around the electric wire and the gap around the flat cable can be reliably filled with the insert molding resin, so that the holding force of the electric wire and the flat cable is increased, and the tensile strength is increased. Can be improved.

According to the sixth aspect of the present invention, the gap between the wire accommodating portions can be particularly filled by the insert molding resin, so that the holding force of the wire and the flat cable can be increased, and the tensile strength can be improved. .

According to the seventh aspect of the present invention, since the wire pressing piece is fitted to the wire drawing portion, the wire can be securely held and the tensile strength of the wire can be increased.

According to the eighth aspect of the present invention, since the locking claw for hooking the ear at the tip of the flat cable is provided, the conductor exposed portion of the flat cable which is soft and easy to be bent can be held straight along the bus bar. it can. Therefore, the bus bar and the exposed conductor can be ultrasonically bonded in a stable state, and the reliability of the bonding can be improved.

According to the ninth aspect of the present invention, the periphery of the bus bar, that is, the joining portion of the conductor exposed portion can be securely solidified with the resin, and the joining portion can be protected more reliably.

According to the tenth aspect of the present invention, the joint energy at the time of joining the exposed portions of the conductors of the flat cable and the electric wire to the joining surface of the bus bar can be prevented from being released to the portion other than the central joint by the connecting portion. The joining can be performed in a shorter time and with higher efficiency with a smaller joining energy, and the cost can be reduced by shortening the tact time of the production line. Moreover, since the resin around the support portion is not melted by preventing overheating of the support portion of the bus bar at the time of joining, the support portion is firmly fixed, so that the support state of the bus bar is stabilized and a stable joint state is obtained. Can be

According to the eleventh aspect of the invention, the insert molding is performed in a state where the conductor exposed portions of the electric wire and the flat cable are overlapped on one surface of the bus bar, so that the injection pressure and the synthetic resin material during the insert molding are formed. Irrespective of the flow direction of the conductor into the cavity, excessive stress applied to the conductor exposed portion during insert molding can be avoided to prevent disconnection of the conductor. Also, when joining the exposed conductors,
Since the joining is performed with the bus bar interposed, the welding jig or the like can be prevented from directly hitting the exposed conductor of the flat cable, and the reliability of the joining can be improved.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view showing a skeleton portion according to an embodiment of the present invention.

FIG. 2 is a perspective view showing an assembled state of a skeleton portion according to one embodiment of the present invention.

3A is a sectional view taken along the line IIIa-IIIa of FIG. 1, and FIG. 3B is a sectional view taken along the line IIIb-IIIb of FIG.

FIG. 4 is a rear view of an IV section of FIG. 1;

FIG. 5 is a rear view of the inner cover of FIG. 1;

6 (a) is a perspective view of a bus bar used in another embodiment of the present invention, and FIG. 6 (b) is a cross-sectional view corresponding to a view taken along the line IIIb-IIIb of FIG. 2 in which the bus bar is assembled. .

FIG. 7 is a cutaway perspective view of a conventional electrical connection device to which a connector for connecting an electric wire and a flat cable is applied.

8 shows a skeleton portion of the connection connector of FIG. 7, and (a)
Is an exploded perspective view, and (b) is a perspective view of the assembled state.

FIG. 9 is a perspective view of a conventional connector for connecting a flat cable and an electric wire incorporating the skeleton portion of FIG. 8;

FIG. 10 is an explanatory diagram of a flow of a synthetic resin material during insert molding of the connection connector of FIG. 9;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 5 Electric wire 5A Conductor exposed part 6 Flat cable 6A Conductor exposed part 6B Ear 21 Mounting plate 21a Flat cable holding surface 23 Electric wire lead-out part 26 Depression 25 Window 27 Locking claw 30, 80 Bus bar 40 Cover 41 Electric wire accommodation part 42 Electric wire Holding groove 43 Bending portion accommodating portion 44 Resin introduction hole 45 Resin introduction passage 60 Electric wire holding piece 70 Synthetic resin material (insert molding resin) 81 Support portion (of busbar) 82 Center joint portion (of busbar) 83 Connecting portion (of busbar)

────────────────────────────────────────────────── ─── Continued on the front page (72) Inventor Masataka Suzuki 206-1 Nunobikihara, Haibara-cho, Haibara-gun, Shizuoka Prefecture Inside Yazaki Parts Co., Ltd. (72) Hiroyuki Ashiya 206-1 Nunobikihara, Haibara-cho, Haibara-gun, Shizuoka (56) References JP-A-5-54920 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) H01R 12/08 H01R 35/04

Claims (11)

(57) [Claims] An electric wire and a flat cable having a conductor exposed portion at their ends are held along a plate surface of a mounting plate, the conductor exposed portions are joined to each other, and at least a part of a mounting plate and the conductor are connected to each other. In a connector for connecting an electric wire and a flat cable, which is insert-molded with a synthetic resin material so as to cover the joint portion of the exposed portion together, a plurality of windows are formed on the mounting plate in accordance with the conductor pitch of the flat cable, Also, a plurality of busbars having both front and rear surfaces exposed at each of the window portions and both ends embedded in the mounting plate are provided, and a conductor exposed portion of the flat cable and a conductor exposed portion of the electric wire are provided on one surface of each busbar. Overlap sequentially, in this state, the bus bar and the two conductor exposed portions are joined,
A connector for connecting an electric wire and a flat cable, wherein the connector is formed by insert molding including the bus bar. 2. The connector for connecting an electric wire and a flat cable according to claim 1, wherein both the flat cable and the electric wire are arranged on one plate surface of the mounting plate with the conductor exposed portions facing in the same direction, and A connector for connecting an electric wire and a flat cable, wherein the connector is held between the mounting plate and a cover detachably fitted to one plate surface of the mounting plate. 3. A connector for connecting an electric wire and a flat cable according to claim 2, wherein:
A flat cable holding surface for holding the flat cable in a straight line is formed, and on a back surface of the cover, a front end side of the electric wire is held parallel to the flat cable, and a base end side of the electric wire is in a direction perpendicular to the flat cable. A connector for connecting an electric wire and a flat cable, wherein an L-shaped electric wire accommodating portion for holding the electric wire is formed. 4. The connector for connecting an electric wire and a flat cable according to claim 3, wherein the L-shaped electric wire accommodating portion includes:
A plurality of wire holding grooves for holding the distal end of the electric wire in parallel with the flat cable at the conductor pitch of the flat cable by fitting the distal end of each electric wire, and bent in an L-shape from the distal end to the proximal end. A connector for connecting an electric wire and a flat cable, comprising a bent portion accommodating portion for accommodating the bent portions of all the electric wires together. 5. The connector for connecting an electric wire and a flat cable according to claim 4, wherein a penetrating resin introduction hole for guiding insert molding resin filled from the outside into the electric wire holding groove is provided on a plate surface of the cover. A connector for connecting an electric wire and a flat cable, wherein the connector is formed. 6. The connector for connecting an electric wire and a flat cable according to claim 4 or 5, wherein the cover is provided with a resin introduction passage for guiding insert molding resin filled from the outside to the bent portion accommodating portion. A connector for connecting an electric wire and a flat cable. 7. A connector for connecting an electric wire to a flat cable according to claim 3, wherein the mounting plate is provided with an electric wire drawing portion for guiding and holding an electric wire extending in a direction perpendicular to the flat cable. A connector for connecting an electric wire and a flat cable, wherein an electric wire pressing piece for holding the electric wire between the electric wire extracting portion and the electric wire extracting portion is detachably fitted to the electric wire extracting portion. 8. A connector for connecting an electric wire to a flat cable according to claim 1, wherein said mounting plate is provided with a locking claw for hooking an ear at a tip of said flat cable. A connector for connecting an electric wire and a flat cable. 9. A connector for connecting an electric wire and a flat cable according to any one of claims 1 to 8, wherein a recess for filling an insert molding resin is provided around a portion of the mounting plate provided with a bus bar. A connector for connecting an electric wire and a flat cable, wherein a connector is formed. 10. The connector for connecting an electric wire and a flat cable according to claim 1, wherein the bus bar has both ends supporting portions embedded in the mounting plate, and a window portion of the mounting plate. And a central joint having a joint surface for joining the exposed portions of the flat cable and the electric wire, the joint being formed integrally with the flat cable and the conductor via a joint having a small heat transfer area. Characteristic wire and flat cable connector. 11. A method for manufacturing a connector for connecting an electric wire and a flat cable according to claim 1, wherein the electric wire having a conductor exposed portion at a tip after insert-molding the mounting plate having the bus bar. And the flat cable is held along the plate surface of the mounting plate, and the conductor exposed portion of the flat cable and the conductor exposed portion of the electric wire are sequentially stacked on one surface of each bus bar, and in that state, the bus bar and the conductors Manufacturing a connector for connecting electric wires and flat cables, wherein the exposed portions are joined, and then insert molding is performed so as to cover with a synthetic resin material including a bus bar, a joined portion of the exposed conductor portion, and a part of the mounting plate. Method.