JP3654563B2

JP3654563B2 - Multipolar molded connector

Info

Publication number: JP3654563B2
Application number: JP05242799A
Authority: JP
Inventors: 勝彦小野田
Original assignee: Yazaki Corp
Current assignee: Yazaki Corp
Priority date: 1999-03-01
Filing date: 1999-03-01
Publication date: 2005-06-02
Anticipated expiration: 2019-03-01
Also published as: DE10009653A1; JP2000251999A; DE10009653C2

Description

【０００１】
【発明の属する技術分野】
本発明は、端子部を含む複数のバスバーを端子ホルダの表裏に千鳥状に係止させ、端子ホルダの外側を樹脂材で覆う際のバスバーの位置ずれを防止すると共に、構造のコンパクト化を図った多極成形コネクタに関するものである。
【０００２】
【従来の技術】
図１０は従来の成形コネクタの一例（特開平８−２５０１９３号参照）を示すものである。
この成形コネクタ９０は、端子９１をインサート成形した合成樹脂製のコア９２と、コア９２の凹部に充填され、端子９１の周囲に密着する柔軟性のシール剤９３と、コア９２の外側を覆う合成樹脂製のコネクタハウジング９４とで構成されている。コア９２とシール剤９３とコネクタハウジング９４とはそれぞれ絶縁性を有している。
【０００３】
端子９１は二段に対向して配置され、コネクタハウジング９４の両側のコネクタ嵌合部９５，９６内に端子９１の両先端部が突出して位置している。例えば一方のコネクタ嵌合部９６に機器等のコネクタ部（図示せず）が接続され、他方のコネクタ嵌合部９５にワイヤハーネス側のコネクタ（図示せず）が嵌合される。端子９１はシール剤９３を貫通しているから、一方のコネクタ嵌合部９６から他方のコネクタ嵌合部９５への水等の浸入が防止される。
【０００４】
この成形コネクタ９０の製造方法は、先ずコア９２と一体に複数本の端子９１をインサート成形して一次成形体９７を得る。コア９２によって端子間の絶縁を行うと共に、端子相互の位置決めを行う。次いで、一次成形体９７のコア９２の凹部にシール剤９３を充填する。そして、一次成形体９７を金型（図示せず）にセットし、一次成形体９７の上から樹脂材を注入してコネクタハウジング９４を形成し、成形コネクタ９０を得る。
【０００５】
一次成形を行うのは、端子９１が樹脂圧力に押されて位置ずれを起こし、相互に短絡するのを防止するためでもあり、また防水構造をとっているから、端子９１を露出させたままにすることができないためでもある。
【０００６】
【発明が解決しようとする課題】
しかしながら、上記従来の成形コネクタ及びその製造方法にあっては、近年のワイヤハーネスの回路数の増大や機器内の回路数の増大等に伴って、端子９１を多極化した場合に、成形コネクタ９０が大型化するという問題があった。成形コネクタ９０の大型化は例えば自動車等のコネクタ配置スペースの縮小化に反するものであり、多極成形コネクタのコンパクト化が必要であった。また、端子９１を多極化させる場合に、一次成形時において端子９１の位置決めや固定を上手く行わないと、端子９１が相互に接触して短絡したりする危険があり、特に端子９１のピッチを狭くしないと成形コネクタ９０が大型化してしまうために、端子９１の位置決めと固定を正確に行わなければならないが、その作業はなかなか困難なものであり、一次成形に多くの工数とコストを必要としていた。特に、端子９１の多極化と成形コネクタ９０のコンパクト化を達成するためには、一次成形において端子９１を一段にではなく少なくとも二段あるいは四段というように多段に配置する必要があり、一次成形において端子９１を正確に多段に位置決めして成形固定させる技術の開発が望まれていた。
【０００７】
本発明は上記した点に鑑み、端子を多極化した多極成形コネクタにおけるコンパクト化（小型化）と製造工数の低減と低コスト化とを達成することができ、しかも端子の位置決めと固定を正確に行うことができ、且つ端子を容易に多段化することができる多極成形コネクタを提供することを目的とする。
【０００８】
【課題を解決するための手段】
上記目的を達成するために、本発明は、絶縁性の板状の端子ホルダの表裏に、各バスバーに対する複数のガイド溝が千鳥状に配設され、各ガイド溝の周縁に、各バスバーに対する係止爪が設けられ、表裏の各ガイド溝に表裏の各バスバーが千鳥状に配置固定され、該端子ホルダの一端から各バスバーの端子部が水平に突出して位置し、該端子ホルダの他端から各バスバーの導出部が並列に立ち上げられ、各導出部に水平な接触部が続き、表側の各バスバーの導出部よりも裏側の各バスバーの導出部が長く形成され、該裏側の各バスバーの導出部と接触部とが該表側の各バスバーの導出部の間と接触部の間とに並列に進入し、その状態で該端子ホルダが樹脂材で覆われて、表裏の各バスバーの各接触部が該樹脂材から同一面で並列に露出したことを特徴とする多極成形コネクタを採用する（請求項１）。前記端子ホルダが複数層に配置されたことも有効である（請求項２）。また、前記樹脂材が、前記端子ホルダに一次成形されたコアと、該コアに二次成形されたコネクタハウジングとで構成されることも有効である（請求項３）。
【０００９】
【発明の実施の形態】
以下に本発明の実施の形態の具体例を図面を用いて詳細に説明する。
図１は本発明の多極成形コネクタの製造方法における連鎖端子と端子ホルダの組付工程を示すものである。
【００１０】
連鎖端子１，２は端子ホルダ３の表裏に挿着される。各連鎖端子１，２は、複数本のバスバー４，５を並列に配置し、各バスバー４，５の一端及び他端を板状の連鎖部６〜９で連結して成るものであり、バスバー４，５の先端側にピン状の端子部１０，１１、バスバー４，５の基端側に細板状の接触部１２，１３を有している。
【００１１】
端子部１０，１１の先端は一方の連鎖部６，８に直交し、端子部１０，１１の基端は太幅部１４，１５に続き、太幅部１４，１５は垂直方向の細幅な立上げ部（導出部）１６，１７に続き、立上げ部１６，１７は水平方向の前記接触部１２，１３に続き、接触部１２，１３は垂直方向に屈曲した短い折り返し部１８，１９に続き、折り返し部１８，１９は水平方向の基端部２０，２１に続き、基端部２０，２１は他方の連鎖部７，９に直交している。
【００１２】
本例の連鎖端子１，２の各バスバー４，５は各六本であり、太幅部１４，１５は中間の一本が真直に延び、他の五本は真直な太幅部１４₁，１５₁を中心として対称に水平方向にクランク状に屈曲して、各太幅部１４，１５の間に隙間２２，２３が設けられている。それにより、バスバー４，５の後半部である立上げ部１６，１７や接触部１２，１３や基端部２０，２１が十分な隙間２４，２５を存して位置し、上側（第一）の連鎖端子１の隙間２４に下側（第二）の連鎖端子２が進入可能となっている。下側の連鎖端子２の立上げ部１７や折り返し部１９は上側の連鎖端子１の立上げ部１６や折り返し部１８よりも長く設定されている。その他の部分は上下の連鎖端子１，２において同じ寸法である。なお、これと類似した形状の連鎖端子は特開平１０−１８９２０４号に示されている。
【００１３】
各連鎖端子１，２は端子ホルダ３の表裏に上下から圧入係止される。端子ホルダ３は絶縁性の合成樹脂で形成され、表裏両面にバスバー４，５の太幅部１４，１５を係合させる複数本のガイド溝２６，２７を有している。ガイド溝２６，２７は各太幅部１４，１５の形状に対応して左右の隔壁２８，２９の間に形成されている。隔壁２８，２９の要所に、太幅部１４，１５を係止させる可撓性の係止爪３０が突出形成されている（図１では表面側の係止爪３０のみを図示している）。
【００１４】
端子ホルダ３の表裏両面においてガイド溝２６，２７は千鳥状に配列されている。すなわち表面のガイド溝２６の下側に裏面の隔壁２９が位置し、表裏のガイド溝２６，２７が太幅部１４，１５の幅寸法分、横方向にずれて形成されている。このガイド溝２６，２７の千鳥状配列は端子ホルダ３の表裏全面において適用されている。
【００１５】
図２に図１のＡ−Ａ断面を示す如く、係止爪３０，３１は、バスバー４，５（図５）をガイド溝２６，２７に案内させるガイド傾斜面３２と、バスバー４，５を係止させる水平な係止面３３とを有している。各一対の係止爪３０，３１は左右に対向して位置し、バスバー４，５を確実に係止するようになっている。係止爪３０，３１は垂直方向（板厚方向）の貫通孔３４，３５の一端ないしは他端に形成されている。これは端子ホルダ３を樹脂成形するに際し、図示しない成形用の上型と下型との間で係止爪３０，３１を形成するためであり、貫通孔３４，３５は係止爪３０，３１を形成するための金型の抜き孔である。Ａ−Ａ断面の後方に位置する係止爪３１₁も図示しない後方の貫通孔の端部に形成されている。図１に対応した表面側の各係止爪を符号３０₁〜３０₉で示す。
【００１６】
端子ホルダ３の両面でガイド溝２６，２７を千鳥状に配置したことで、貫通孔３４，３５の位置の自由度が拡大し、上下の各バスバー４，５（図５）に対する係止爪３０，３１を確実に形成することができ、上下の各バスバー４，５を端子ホルダ３に強固に固定可能である。しかも、端子ホルダ３は前後に短くて済み、コンパクトに仕上がっている。
【００１７】
すなわち、図３(a) の如く上下のバスバー４，５を千鳥状ではなく上下同じ垂直線上に配置する場合は、図３(b) の如くガイド溝２６の長手方向前後に貫通孔３４，３５を二つ並べて形成し、各貫通孔３４，３５に臨む係止爪３０（３１は図示せず）で各バスバー４，５（図３(a) ）を係止させるために、端子ホルダ３′が前後に肥大化してしまうという問題を生じる。それを避けるために係止爪３０，３１の数を少なくすれば、バスバー４，５の係止力が低下して、後述する一次成形時の樹脂材の圧力でバスバー４，５が位置ずれを起こす危険を生じる。上下のバスバー４，５を千鳥状に配列することで、これらの問題が解消し、構造のコンパクト化とバスバー４，５の確実な位置決め及び固定が可能となる。なお、バスバー４，５を上下二段ではなく一段に配列した場合は構造が横方向に肥大化してしまうことは言うまでもない。
【００１８】
図１において、バスバー４，５の太幅部１４，１５はクランク状に屈曲しているから、太幅部１４，１５の横向き部１４ｂ，１５ｂに対する係止爪３０₃（図１，図２）がクランク状のガイド溝２６，２７の横向き部２６ｂ（２７ａは図示せず）に形成されている。また、横向き部２６ｂの前後で太幅部１４の真直部１４ａ，１４ｃを係止するために、クランク状のガイド溝２６の前後の真直部２６ａ，２６ｃにそれぞれ係止爪３０が配設されている。これによって太幅部１４が前後二箇所の係止爪３０で強固に係止される。
【００１９】
端子ホルダ３の後端には、バスバー４，５の太幅部１４，１５と立上げ部（導出部）１６，１７との境部を支持ないしは挟持して位置決めするガイド突部３６〜３８が等ピッチで並列に形成されている。ガイド突部３６は突起状のもので、上側のバスバー４を支持し、ガイド突部３７，３８は突条であり、下側のバスバー５を支持する。ガイド突部３７，３８はガイド溝３９，４０を構成する。
【００２０】
図４の如く、端子ホルダ３の両面に上下から連鎖端子１，２が組み付けられる。各バスバー４，５は端子ホルダ３のガイド溝２６，２７に係合し、各係止爪３０，３１（図５）で係止される。ガイド溝２６，２７へのバスバー４，５の圧入は、図示しないプレス機等を用いて行われる。連鎖端子１，２の状態で一時に複数本のバスバー４，５が組み付けられるから作業性及び生産性が良好である。
【００２１】
上下の端子部１０，１１は端子ホルダ３の板厚分の垂直距離を存して千鳥状に、すなわち一ピッチずつ横方向に位相ずれして配置される。上下の連鎖端子１，２の各立上げ部１６，１７は各ガイド突部３６〜３９の間を通って並列に位置決めされ、それにより各接触部１２，１３は同一平面上で横並びに近接して正確に位置し、各基端部２０，２１は上下にやや離間して千鳥状に位置している。図４の状態すなわち端子ホルダ３と上下の連鎖端子１，２とで第一の端子ホルダ組立体４１が構成される。
【００２２】
図５（図４のＢ−Ｂ断面図）の如く、端子ホルダ３の表裏両面の各ガイド溝２６，２７に上下の連鎖端子１，２（図１）の各バスバー４，５の太幅部１４，１５が挿入ないしは圧入されて千鳥状に位置する。各太幅部１４，１５は各一対の係止爪３０，３１で抜け出しなく係止される。
【００２３】
図４の端子ホルダ組立体４１を樹脂材で一次成形してコア（一次成形体）を作り、コアにコネクタハウジングを二次成形して、二段の端子部１０，１１を有する多極成形コネクタを構成させることも可能であるが、本例においては、図７の如く、第二の端子ホルダ組立体４２を形成し、第一の端子ホルダ組立体４１と合わせて四段の端子部１０，１１，４３，４４を有する多極成形コネクタ４５（図９）を製造する。
【００２４】
図６において端子ホルダ４６は図１の第一の端子ホルダ３よりも二倍程度に横長に形成され、且つ前後に若干長く形成されて、中央部に上下の連鎖端子４７，４８の各端子部４３，４４に対するガイド溝４９，５０の真直部４９ａ（５０ａは図示せず）を並列に有している。上下のガイド溝４９，５０は第一の端子ホルダ３と同様に千鳥状に配列されている。
【００２５】
上下（第三及び第四）の連鎖端子４７，４８は、第一，第二の連鎖端子１，２と同一形状及び同一ピッチの端子部４３，４４を有し、各端子部４３，４４はクランク状の太幅部５１，５２に続いている。太幅部５１，５２の前後の真直部５１ａ，５１ｃ，５２ａ，５２ｃは第一，第二の連鎖端子１，２の前後の真直部１４ａ，１４ｃと同程度の長さに形成され、前後の真直部５１ａ，５１ｃ，５２ａ，５２ｃの間の横向き部（端子ホルダ４６の長手方向に延びる部分）５１ｂ，５２ｂは第一，第二の連鎖端子１，２の横向き部１４ｂ，１５ｂよりも十分に長く形成され、上下の連鎖端子４７，４８の立上げ部（導出部）５３，５４が三本づつ左右に大きく離間し、左右の立上げ部５３，５４の間に空間５５，５６が構成され、その空間５５，５６内に第一，第二の連鎖端子１，２の立上げ部１６，１７が位置するようになっている。
【００２６】
また、上下の連鎖端子４７，４８の立上げ部５３，５４は第一，第二の連鎖端子１，２の立上げ部１６，１７よりも長く、且つ下向きの折り返し５７，５８は長く形成されている。第二の端子ホルダ組立体４２（図７）の上方に第一の端子ホルダ組立体４１を配置するようになっている。その際に、各バスバー４，５５，６１，６２の接触部１２，１３，５９，６０は同一平面に位置する。第三の連鎖端子４７の立上げ部５３や折り返し部５７よりも第四の連鎖端子４８の立上げ部５４や折り返し部５８が長く設定されていることは第一，第二の連鎖端子１，２と同様である。その他の構成は第一，第二の連鎖端子１，２とほぼ同様であるので説明を省略する。
【００２７】
第二の端子ホルダ４６は第三，第四の連鎖端子４７，４８に対応した形状のガイド溝４９，５０を両面に有し、各ガイド溝４９，５０に臨む係止爪６３（表側の係止爪６３のみを図示する）を有している。上下の各ガイド溝４９，５０は千鳥状に、すなわち表側のガイド溝４９の下側に裏側の隔壁６５が位置し、裏側のガイド溝５０の上側に表側の隔壁６４が位置して、両ガイド溝４９，５０が一ピッチないしそれ以下のピッチで横方向に位相ずれした状態に配列されている。
【００２８】
第三の連鎖端子４７の端子部４３が第一の連鎖端子３（図４）の端子部１０と上下に対向し、第四の連鎖端子４８の端子部４４が第二の連鎖端子２（図４）の端子部１１と上下に対向するように、各ガイド溝４９，５０が配置されている。ガイド溝４９，５０の長い横向き部４９ｂには二対の係止突起６３₁，６３₂が溝長手方向に配置され、バスバー６１の係止力を高めている。第二の端子ホルダ４６の他の構成は第一の端子ホルダ３とほぼ同様であるので、同一符号を示して詳細な説明を省略する。３４，３５は係止爪６３を形成するための貫通孔、３６〜３８がガイド突部、４０はガイド溝、４９ｃは後半の真直部である。
【００２９】
図７の如く、端子ホルダ４６の上下両面に各連鎖端子４７，４８が組み付けられる。バスバー６１，６２はガイド溝４９，５０に挿入ないしは圧入され、係止爪６３で抜け出しなく係止される。上側の連鎖端子４７の立上げ部５３の間に下側の連鎖端子４８の立上げ部５４が進入して並列に位置し、両連鎖端子４７，４８の接触部５９，６０が同一平面に位置する。両側の各六本の立上げ部５３，５４及び接触部５９，６０の間に空間６６が構成される。端子ホルダ４６の後端部には、第一の端子ホルダ組立体４１（図４）のバスバー４，５の立上げ部１６，１７を挿通させる切欠部６７が形成されている。
【００３０】
図４の第一の端子ホルダ組立体４１を図７の第二の端子ホルダ組立体４２の上側に配置することで、上記空間６６に第一の端子ホルダ組立体４１のバスバー４，５の立上げ部１６，１７と接触部１２，１３が並列に位置し、第四の連鎖端子４８の基端側の連鎖部６８の下側に第一の連鎖端子１（図４）の連鎖部７が位置し、第三の連鎖端子４７の先端側の連鎖部６９の上側に第二の連鎖端子２の連鎖部８が位置する。
【００３１】
この状態で図８の如く樹脂材による一次成形（予備成形）が行われ、このインサート成形により上下の端子ホルダ３（図４），４６（図７）が合成樹脂製のコア７１で覆われて、一次成形体７２が構成される。成形後に連鎖部６〜９（図４），６８，６９，７３，７４（図７）がバスバー４，５，６１，６２の両端から切断除去される。成形前に上記連鎖部を切断することも可能である。
【００３２】
端子部１０，１１，４３，４４はコア７１から前方に突出し、接触部１２，１３，５９，６０はコア７１と一体のコネクタ部７５（コア７１の一部）の上面に並列に露出して位置する。端子部１０，１１，４３，４４は四段に構成され、端子の多極化が達成される。上から第一段と第二段の端子部１０，１１が千鳥状に位置し、第二段と第三段の端子部１１，４３が上下に対向して位置し、第三段と第四段の端子部４３，４４が千鳥状に位置する。コネクタ部７５は端子部１０よりも高く突出して位置する。コア７１には、二次成形（本成形）時の樹脂材との固着性を向上させるための溝７６が形成されている。
【００３３】
図９の如く、一次成形体７２に雌型のコネクタハウジング７７とフランジ部７８とが樹脂材で二次成形され、二次成形体である多極成形コネクタ４５が完成する。端子部１０，１１，４３，４４（図８）はコネクタハウジング７７で覆われてコネクタ嵌合室７８内に位置し、後側のコネクタ部７５はフランジ部７８から突出して位置する。フランジ部７８の両側には、取付孔７９を構成するブッシュ８０が一体成形される。フランジ部７８は例えば機器に直付けされ、それと同時にコネクタ部７５が機器側の雌コネクタ（図示せず）に嵌合接続される。端子部１０，１１，４３，４４（図８）を含む雌型のコネクタ部８１には例えばワイヤハーネス（図示せず）の雄型のコネクタが嵌合接続される。
【００３４】
なお、図７の第二の端子ホルダ組立体４２の下に第三の端子ホルダ組立体（図示せず）を配置し、端子部を六段としてさらに多極化させることも可能である。その場合、第三の端子ホルダ組立体の端子部は第二の端子ホルダ組立体４６の端子部４４の下側に位置し、第三の端子ホルダは第二の端子ホルダ４６よりも長く形成され、第二の端子ホルダ組立体４２のバスバー６２の立上げ部５３の外側に第三の端子ホルダのバスバーの立上げ部が位置する。
【００３５】
【発明の効果】
以上の如く、請求項１記載の発明によれば、端子ホルダにバスバーを固定することで、樹脂成形時の樹脂圧によるバスバーの位置ずれが防止され、端子部の狭ピッチ化が可能となり、多極成形コネクタのコンパクト化が実現される。また、バスバーを千鳥状に配置することで、狭ピッチであるにかかわらず上下左右の各バスバーの間隔を大きくとることができ、絶縁性が向上する。また、ガイド溝にバスバーが係合して正確に位置決めされ、狭ピッチでの端子の位置精度が向上する。また、係止爪でバスバーが係止されて確実に固定されるから、端子の位置ずれが確実に防止されると共に、バスバーの固定作業が容易化し、作業性が向上し、製造コストが低減される。また、係止爪を形成するための貫通孔（型抜き孔）を端子ホルダに開ける際に、表裏のバスバーを千鳥に配置したから、貫通孔の位置の自由度が増し、各貫通孔をバスバー長手方向ではなく幅方向に設けることができ、それによりバスバー長手方向の端子ホルダのコンパクト化が可能となり、多極成形コネクタのコンパクト化が達成される。また、表裏のバスバーの接触部を並列に位置させることで、樹脂成形時に接触部を露出させて、接触部を狭ピッチで形成することができる。また、請求項２記載の発明によれば、端子ホルダの二倍の数の端子の段数で多極コネクタを簡単に構成することができる。また、請求項３記載の発明によれば、端子ホルダをコアで固定することで、バスバーが一層強固に固定され、二次成形時の強い圧力でのバスバーの位置ずれが確実に防止される。
【図面の簡単な説明】
【図１】本発明に係る多極成形コネクタの製造方法の一工程を示す分解斜視図である。
【図２】端子ホルダを示す図１のＡ−Ａ断面図である。
【図３】 (a) は端子ホルダの係止爪と貫通孔の関係を説明する断面図、(b) は同じく斜視図である。
【図４】第一の端子ホルダ組立体を示す斜視図である。
【図５】端子ホルダにバスバーを千鳥状に配置した状態を示す図４のＢ−Ｂ断面図である。
【図６】第二の端子ホルダに連鎖端子を組み付ける状態を示す分解斜視図である。
【図７】第二の端子ホルダ組立体を示す斜視図である。
【図８】一次成形体を示す斜視図である。
【図９】二次成形体である多極成形コネクタを示す斜視図である。
【図１０】従来例を示す縦断面図である。
【符号の説明】
３，４６端子ホルダ
４，５，６１，６２バスバー
１０，１１，４３，４４端子部
１２，１３，５９，６０接触部
１６，１７，５３，５４立上げ部（導出部）
２６，２７，４９，５０ガイド溝
３０，３１，６３係止爪
４５多極成形コネクタ
７１コア
７７コネクタハウジング[0001]
BACKGROUND OF THE INVENTION
The present invention locks a plurality of bus bars including terminal portions in a zigzag manner on the front and back of the terminal holder, prevents the bus bar from being displaced when the outside of the terminal holder is covered with a resin material, and achieves a compact structure. The present invention relates to a multipolar molded connector .
[0002]
[Prior art]
FIG. 10 shows an example of a conventional molded connector (see JP-A-8-250193).
The molded connector 90 includes a synthetic resin core 92 in which a terminal 91 is insert-molded, a flexible sealing agent 93 that is filled in a concave portion of the core 92 and closely contacts the periphery of the terminal 91, and a synthetic covering the outside of the core 92. The connector housing 94 is made of resin. The core 92, the sealing agent 93, and the connector housing 94 are insulative.
[0003]
The terminals 91 are arranged so as to face each other in two stages, and both end portions of the terminals 91 protrude from the connector fitting portions 95 and 96 on both sides of the connector housing 94. For example, a connector portion (not shown) such as a device is connected to one connector fitting portion 96, and a connector (not shown) on the wire harness side is fitted to the other connector fitting portion 95. Since the terminal 91 penetrates the sealing agent 93, the entry of water or the like from one connector fitting portion 96 to the other connector fitting portion 95 is prevented.
[0004]
In this method of manufacturing the molded connector 90, first, a plurality of terminals 91 are insert-molded integrally with the core 92 to obtain a primary molded body 97. Insulation between the terminals is performed by the core 92, and positioning between the terminals is performed. Next, a sealing agent 93 is filled in the concave portion of the core 92 of the primary molded body 97. Then, the primary molded body 97 is set in a mold (not shown), a resin material is injected from above the primary molded body 97 to form a connector housing 94, and a molded connector 90 is obtained.
[0005]
The primary molding is performed in order to prevent the terminal 91 from being displaced by the resin pressure and causing a short circuit between the terminals 91. Also, since the waterproof structure is adopted, the terminal 91 is left exposed. It is also because you cannot do it.
[0006]
[Problems to be solved by the invention]
However, in the above-described conventional molded connector and the manufacturing method thereof, when the number of terminals 91 is increased due to the recent increase in the number of circuits in the wire harness or the increase in the number of circuits in the device, the molded connector 90 is There was a problem of increasing the size. Increasing the size of the molded connector 90 is contrary to the reduction in the connector arrangement space of, for example, automobiles, and it is necessary to make the multipolar molded connector compact. Further, when the terminals 91 are multipolarized, if the terminals 91 are not positioned and fixed well at the time of primary molding, there is a risk that the terminals 91 contact each other and short-circuit, and the pitch of the terminals 91 is not particularly narrowed. In order to increase the size of the molded connector 90, it is necessary to accurately position and fix the terminals 91. However, the operation is quite difficult, and a lot of man-hours and costs are required for the primary molding. In particular, in order to achieve the multipolarization of the terminals 91 and the compactness of the molded connector 90, it is necessary to arrange the terminals 91 in multiple stages such as at least two or four stages instead of one stage in the primary molding. It has been desired to develop a technique for accurately positioning and fixing the terminals 91 in multiple stages.
[0007]
In view of the above points, the present invention can achieve compactness (miniaturization), reduction in manufacturing man-hours and cost reduction in a multipolar molded connector with multipolarized terminals, and accurately positioning and fixing terminals. It is an object of the present invention to provide a multipolar molded connector which can be performed and can easily be multistaged.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, according to the present invention, a plurality of guide grooves for each bus bar are arranged in a staggered manner on the front and back of an insulating plate-like terminal holder, and the engagement with respect to each bus bar is arranged on the periphery of each guide groove. claw is provided, the front and back of the bus bars on the front and back in the guide groove is arranged fixed in a staggered manner, and positioned terminal portions projecting horizontally in the bus bars from one end of the terminal holder, the other end of the terminal holder The lead-out parts of each bus bar are started up in parallel, the horizontal contact parts are continued to each lead-out part, the lead-out part of each bus bar on the back side is formed longer than the lead-out part of each bus bar on the front side, and each bus bar on the back side is formed. The lead-out portion and the contact portion enter in parallel between the lead-out portion and the contact portion of each bus bar on the front side, and in this state, the terminal holder is covered with a resin material, and each contact of each bus bar on the front and back sides The parts are exposed in parallel on the same surface from the resin material. The adopting multi-pole molded connector, wherein (claim 1). It is also effective to the terminal holder is arranged in a plurality of layers (Claim 2). It is also effective that the resin material is constituted by a core primary-molded on the terminal holder and a connector housing secondary-molded on the core (Claim 3).
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Specific examples of embodiments of the present invention will be described below in detail with reference to the drawings.
FIG. 1 shows an assembling step of a chain terminal and a terminal holder in the method for producing a multipolar molded connector of the present invention.
[0010]
The chain terminals 1 and 2 are inserted into the front and back of the terminal holder 3. Each chain terminal 1, 2 is formed by arranging a plurality of bus bars 4, 5 in parallel and connecting one end and the other end of each bus bar 4, 5 with plate-like chain portions 6-9. Pin-shaped terminal portions 10 and 11 are provided on the distal end sides of 4, 5 and thin plate-like contact portions 12 and 13 are provided on the proximal end sides of the bus bars 4 and 5, respectively.
[0011]
The distal ends of the terminal portions 10 and 11 are orthogonal to one of the chain portions 6 and 8, the base ends of the terminal portions 10 and 11 are continued from the wide width portions 14 and 15, and the wide width portions 14 and 15 are narrow in the vertical direction. Following the rising portions (leading portions) 16 and 17, the rising portions 16 and 17 are connected to the contact portions 12 and 13 in the horizontal direction, and the contact portions 12 and 13 are connected to the short folded portions 18 and 19 bent in the vertical direction. The folded portions 18 and 19 continue to the horizontal base end portions 20 and 21, and the base end portions 20 and 21 are orthogonal to the other chain portions 7 and 9.
[0012]
The bus bars 4 and 5 of the chain terminals 1 and 2 in this example are each six, and the thick portions 14 and 15 are straight in the middle, and the other five are straight and wide portions 14 ₁ , symmetrically around the 15 ₁ is bent horizontally into a crank shape, a gap 22, 23 is provided between the KakuFutoshihaba portions 14 and 15. Accordingly, the rising portions 16 and 17, the contact portions 12 and 13, and the base end portions 20 and 21, which are the rear half portions of the bus bars 4 and 5, are located with sufficient gaps 24 and 25, and the upper side (first). The lower (second) chain terminal 2 can enter the gap 24 of the chain terminal 1. The rising portion 17 and the folding portion 19 of the lower chain terminal 2 are set longer than the rising portion 16 and the folding portion 18 of the upper chain terminal 1. Other portions have the same dimensions in the upper and lower chain terminals 1 and 2. A chain terminal having a similar shape is disclosed in Japanese Patent Laid-Open No. 10-189204.
[0013]
The chain terminals 1 and 2 are press-fitted and locked to the front and back of the terminal holder 3 from above and below. The terminal holder 3 is formed of an insulating synthetic resin and has a plurality of guide grooves 26 and 27 for engaging the wide portions 14 and 15 of the bus bars 4 and 5 on both front and back surfaces. The guide grooves 26 and 27 are formed between the left and right partition walls 28 and 29 corresponding to the shapes of the wide portions 14 and 15. A flexible locking claw 30 that locks the wide width portions 14 and 15 is formed protrudingly at the important points of the partition walls 28 and 29 (FIG. 1 shows only the locking claw 30 on the surface side. ).
[0014]
The guide grooves 26 and 27 are arranged in a staggered manner on both the front and back surfaces of the terminal holder 3. That is, the partition wall 29 on the back surface is located below the guide groove 26 on the front surface, and the front and back guide grooves 26 and 27 are formed so as to be shifted in the lateral direction by the width of the thick portions 14 and 15. The staggered arrangement of the guide grooves 26 and 27 is applied to the entire front and back surfaces of the terminal holder 3.
[0015]
As shown in the AA cross section of FIG. 1, the locking claws 30, 31 include a guide inclined surface 32 that guides the bus bars 4, 5 (FIG. 5) to the guide grooves 26, 27, and the bus bars 4, 5. And a horizontal locking surface 33 to be locked. Each pair of latching claws 30 and 31 is positioned opposite to the left and right to securely latch the bus bars 4 and 5. The locking claws 30 and 31 are formed at one end or the other end of the through holes 34 and 35 in the vertical direction (plate thickness direction). This is because when the terminal holder 3 is resin-molded, the locking claws 30 and 31 are formed between an upper mold and a lower mold (not shown), and the through holes 34 and 35 are formed in the locking claws 30 and 31. It is the punching hole of the metal mold | die for forming. Engaging claws 31 ₁ located behind the A-A cross section is also formed on the end portion of the rear through-holes (not shown). Reference numerals 30 ₁ to 30 ₉ denote the respective locking claws on the surface side corresponding to FIG.
[0016]
By arranging the guide grooves 26 and 27 in a staggered manner on both sides of the terminal holder 3, the degree of freedom of the positions of the through holes 34 and 35 is expanded, and the locking claws 30 for the upper and lower bus bars 4 and 5 (FIG. 5). 31 can be reliably formed, and the upper and lower bus bars 4, 5 can be firmly fixed to the terminal holder 3. Moreover, the terminal holder 3 is short in the front and rear directions, and is compact.
[0017]
That is, when the upper and lower bus bars 4 and 5 are arranged on the same vertical line instead of the staggered pattern as shown in FIG. 3A, the through holes 34 and 35 are arranged in the longitudinal direction of the guide groove 26 as shown in FIG. In order to lock the bus bars 4 and 5 (FIG. 3 (a)) with the locking claws 30 (31 not shown) facing the through holes 34 and 35, the terminal holder 3 ' This causes the problem of enlargement before and after. If the number of the locking claws 30 and 31 is reduced to avoid this, the locking force of the bus bars 4 and 5 decreases, and the bus bars 4 and 5 are displaced due to the pressure of the resin material at the time of primary molding described later. There is a danger of it happening. By arranging the upper and lower bus bars 4 and 5 in a staggered manner, these problems can be solved, and the structure can be made compact and the bus bars 4 and 5 can be positioned and fixed reliably. Needless to say, when the bus bars 4 and 5 are arranged in a single row instead of two vertically, the structure is enlarged in the lateral direction.
[0018]
In FIG. 1, since the wide portions 14 and 15 of the bus bars 4 and 5 are bent in a crank shape, the locking claws 30 ₃ for the lateral portions 14b and 15b of the wide portions 14 and 15 (FIGS. 1 and 2). Is formed in a lateral portion 26b (27a is not shown) of the crank-shaped guide grooves 26, 27. Further, in order to lock the straight portions 14a and 14c of the wide width portion 14 before and after the laterally facing portion 26b, locking claws 30 are respectively provided on the straight portions 26a and 26c of the crank-shaped guide groove 26. Yes. As a result, the wide width portion 14 is firmly locked by the locking claws 30 at the two front and rear positions.
[0019]
At the rear end of the terminal holder 3, there are guide protrusions 36 to 38 for supporting or holding the boundary portions between the wide portions 14 and 15 of the bus bars 4 and 5 and the rising portions (leading portions) 16 and 17 for positioning. They are formed in parallel at equal pitches. The guide protrusions 36 are protruding and support the upper bus bar 4, and the guide protrusions 37 and 38 are protrusions and support the lower bus bar 5. The guide protrusions 37 and 38 constitute guide grooves 39 and 40.
[0020]
As shown in FIG. 4, the chain terminals 1 and 2 are assembled on both sides of the terminal holder 3 from above and below. The bus bars 4 and 5 engage with the guide grooves 26 and 27 of the terminal holder 3 and are locked by the locking claws 30 and 31 (FIG. 5). The press-fitting of the bus bars 4 and 5 into the guide grooves 26 and 27 is performed using a press machine or the like (not shown). Since a plurality of bus bars 4 and 5 are assembled at a time in the state of the chain terminals 1 and 2, workability and productivity are good.
[0021]
The upper and lower terminal portions 10 and 11 are arranged in a staggered manner with a vertical distance corresponding to the plate thickness of the terminal holder 3, that is, shifted in phase in the lateral direction by one pitch. The upright portions 16 and 17 of the upper and lower chain terminals 1 and 2 are positioned in parallel through the guide protrusions 36 to 39, so that the contact portions 12 and 13 are arranged side by side on the same plane. The base end portions 20 and 21 are located in a staggered manner with a slight separation in the vertical direction. The first terminal holder assembly 41 is configured by the state of FIG. 4, that is, the terminal holder 3 and the upper and lower chain terminals 1 and 2.
[0022]
As shown in FIG. 5 (BB sectional view of FIG. 4), the wide width portions of the bus bars 4, 5 of the upper and lower chain terminals 1, 2 (FIG. 1) are formed in the guide grooves 26, 27 on the front and back surfaces of the terminal holder 3. 14 and 15 are inserted or press-fitted and located in a staggered manner. Each of the wide portions 14 and 15 is locked by the pair of locking claws 30 and 31 without coming out.
[0023]
The terminal holder assembly 41 of FIG. 4 is first molded with a resin material to form a core (primary molded body), a connector housing is secondarily molded to the core, and a multipolar molded connector having two stages of terminal portions 10 and 11 However, in this example, as shown in FIG. 7, a second terminal holder assembly 42 is formed, and together with the first terminal holder assembly 41, four-stage terminal portions 10, A multipolar molded connector 45 (FIG. 9) having 11, 43, 44 is manufactured.
[0024]
In FIG. 6, the terminal holder 46 is formed in a horizontally long shape about twice as long as the first terminal holder 3 in FIG. 1, and is formed slightly longer in the front and rear, and each terminal portion of the upper and lower chain terminals 47 and 48 in the center. Straight portions 49a (50a not shown) of the guide grooves 49, 50 with respect to 43, 44 are provided in parallel. The upper and lower guide grooves 49 and 50 are arranged in a staggered manner as in the first terminal holder 3.
[0025]
The upper and lower (third and fourth) chain terminals 47 and 48 have terminal portions 43 and 44 having the same shape and the same pitch as the first and second chain terminals 1 and 2, respectively. It continues to the crank-shaped wide portions 51 and 52. The straight portions 51a, 51c, 52a, 52c before and after the wide width portions 51, 52 are formed to have the same length as the straight portions 14a, 14c before and after the first and second chain terminals 1, 2, respectively. Side portions 51b, 52b between the straight portions 51a, 51c, 52a, 52c (portions extending in the longitudinal direction of the terminal holder 46) 51b, 52b are more sufficiently than the side portions 14b, 15b of the first and second chain terminals 1, 2. The upper and lower chain terminals 47 and 48 are vertically separated from each other by three rising portions (leading portions) 53 and 54, and spaces 55 and 56 are formed between the right and left rising portions 53 and 54. The rising portions 16 and 17 of the first and second chain terminals 1 and 2 are positioned in the spaces 55 and 56, respectively.
[0026]
Further, the rising portions 53 and 54 of the upper and lower chain terminals 47 and 48 are longer than the rising portions 16 and 17 of the first and second chain terminals 1 and 2, and the downward turns 57 and 58 are formed longer. ing. The first terminal holder assembly 41 is arranged above the second terminal holder assembly 42 (FIG. 7). At that time, the contact portions 12, 13, 59, 60 of the bus bars 4, 55, 61, 62 are located on the same plane. The fact that the rising portion 54 and the folding portion 58 of the fourth chain terminal 48 are set longer than the rising portion 53 and the folding portion 57 of the third chain terminal 47 are the first and second chain terminals 1 and 2. Same as 2. Since other configurations are substantially the same as those of the first and second chain terminals 1 and 2, the description thereof is omitted.
[0027]
The second terminal holder 46 has guide grooves 49 and 50 having shapes corresponding to the third and fourth chain terminals 47 and 48 on both surfaces, and a locking claw 63 (front side engagement) facing each guide groove 49 and 50. Only the pawl 63 is shown). The upper and lower guide grooves 49, 50 are staggered, that is, the rear partition wall 65 is positioned below the front guide groove 49, and the front partition wall 64 is positioned above the rear guide groove 50. The grooves 49 and 50 are arranged in a state where the phase is shifted in the lateral direction at a pitch of one pitch or less.
[0028]
The terminal portion 43 of the third chain terminal 47 is vertically opposed to the terminal portion 10 of the first chain terminal 3 (FIG. 4), and the terminal portion 44 of the fourth chain terminal 48 is the second chain terminal 2 (FIG. The guide grooves 49 and 50 are arranged so as to face the terminal portion 11 of 4) vertically. Two pairs of locking protrusions 63 ₁ and 63 ₂ are arranged in the longitudinal direction of the long groove 49 b of the guide grooves 49 and 50 to increase the locking force of the bus bar 61. Since the other structure of the 2nd terminal holder 46 is substantially the same as the 1st terminal holder 3, the same code | symbol is shown and detailed description is abbreviate | omitted. Reference numerals 34 and 35 denote through holes for forming the locking claws 63, reference numerals 36 to 38 denote guide protrusions, reference numeral 40 denotes a guide groove, and reference numeral 49c denotes a straight portion in the latter half.
[0029]
As shown in FIG. 7, the chain terminals 47 and 48 are assembled on the upper and lower surfaces of the terminal holder 46. The bus bars 61 and 62 are inserted or press-fitted into the guide grooves 49 and 50, and are locked by the locking claws 63 without coming out. The rising portion 54 of the lower chain terminal 48 enters between the rising portions 53 of the upper chain terminal 47 and is positioned in parallel, and the contact portions 59 and 60 of both chain terminals 47 and 48 are positioned in the same plane. To do. A space 66 is formed between the six raised portions 53 and 54 and the contact portions 59 and 60 on both sides. At the rear end portion of the terminal holder 46, a notch 67 is formed through which the rising portions 16 and 17 of the bus bars 4 and 5 of the first terminal holder assembly 41 (FIG. 4) are inserted.
[0030]
The first terminal holder assembly 41 of FIG. 4 is arranged above the second terminal holder assembly 42 of FIG. 7, so that the bus bars 4, 5 of the first terminal holder assembly 41 stand in the space 66. The raised portions 16 and 17 and the contact portions 12 and 13 are positioned in parallel, and the chain portion 7 of the first chain terminal 1 (FIG. 4) is located below the chain portion 68 on the proximal end side of the fourth chain terminal 48. The chain part 8 of the second chain terminal 2 is positioned above the chain part 69 on the tip side of the third chain terminal 47.
[0031]
In this state, primary molding (preliminary molding) is performed with a resin material as shown in FIG. 8, and the upper and lower terminal holders 3 (FIG. 4) and 46 (FIG. 7) are covered with a synthetic resin core 71 by this insert molding. The primary molded body 72 is configured. After molding, the chain portions 6 to 9 (FIG. 4), 68, 69, 73, and 74 (FIG. 7) are cut and removed from both ends of the bus bars 4, 5, 61, and 62. It is also possible to cut the chain part before molding.
[0032]
The terminal portions 10, 11, 43, 44 protrude forward from the core 71, and the contact portions 12, 13, 59, 60 are exposed in parallel on the upper surface of the connector portion 75 (a part of the core 71) integrated with the core 71. To position. The terminal portions 10, 11, 43, and 44 are configured in four stages, thereby achieving multipolarization of terminals. From the top, the first and second stage terminal portions 10 and 11 are positioned in a staggered manner, the second and third stage terminal portions 11 and 43 are positioned facing each other vertically, and the third and fourth stage terminals The terminal parts 43 and 44 are located in a staggered manner. The connector part 75 is positioned so as to protrude higher than the terminal part 10. The core 71 is formed with a groove 76 for improving the adhesiveness with the resin material during secondary molding (main molding).
[0033]
As shown in FIG. 9, the female connector housing 77 and the flange portion 78 are secondarily molded with a resin material on the primary molded body 72, and the multipolar molded connector 45, which is a secondary molded body, is completed. The terminal portions 10, 11, 43, and 44 (FIG. 8) are covered with the connector housing 77 and positioned in the connector fitting chamber 78, and the rear connector portion 75 is positioned so as to protrude from the flange portion 78. On both sides of the flange portion 78, a bush 80 constituting the attachment hole 79 is integrally formed. For example, the flange portion 78 is directly attached to the device, and at the same time, the connector portion 75 is fitted and connected to a female connector (not shown) on the device side. For example, a male connector of a wire harness (not shown) is fitted and connected to the female connector portion 81 including the terminal portions 10, 11, 43, and 44 (FIG. 8).
[0034]
It is also possible to arrange a third terminal holder assembly (not shown) under the second terminal holder assembly 42 in FIG. 7 and further increase the number of terminals by six stages. In that case, the terminal portion of the third terminal holder assembly is located below the terminal portion 44 of the second terminal holder assembly 46, and the third terminal holder is formed longer than the second terminal holder 46. The rising part of the bus bar of the third terminal holder is located outside the rising part 53 of the bus bar 62 of the second terminal holder assembly 42.
[0035]
【The invention's effect】
As described above, according to the first aspect of the present invention, by fixing the bus bar to the terminal holder, it is possible to prevent the bus bar from being displaced due to the resin pressure during resin molding, and to reduce the pitch of the terminal portion. Miniaturization of the pole molded connector is realized. In addition, by arranging the bus bars in a staggered manner, the space between the upper, lower, left and right bus bars can be increased regardless of the narrow pitch, and the insulation is improved. In addition, the bus bar is engaged with the guide groove to be accurately positioned, and the position accuracy of the terminals at a narrow pitch is improved. In addition, since the bus bar is locked and securely fixed by the locking claws , the terminal displacement is reliably prevented, the bus bar fixing work is facilitated, the workability is improved, and the manufacturing cost is reduced. The In addition, when opening through holes (die-cut holes) for forming locking claws in the terminal holder , the front and back bus bars are arranged in a staggered manner, so the degree of freedom of the positions of the through holes is increased, and each through hole is connected to the bus bar. The terminal holder can be provided in the width direction instead of the longitudinal direction, whereby the terminal holder in the bus bar longitudinal direction can be made compact, and the multipolar molded connector can be made compact. Moreover, by arranging the contact portions of the front and back bus bars in parallel, the contact portions can be exposed at the time of resin molding, and the contact portions can be formed at a narrow pitch. Further, according to the invention described in claim 2 , the multipolar connector can be easily configured with the number of stages of terminals twice as many as the terminal holder. According to the invention described in claim 3 , by fixing the terminal holder with the core, the bus bar is more firmly fixed, and the displacement of the bus bar due to a strong pressure during the secondary molding is surely prevented.
[Brief description of the drawings]
FIG. 1 is an exploded perspective view showing one step of a method for producing a multipolar molded connector according to the present invention.
2 is a cross-sectional view taken along line AA of FIG. 1 showing a terminal holder.
3A is a cross-sectional view for explaining the relationship between a locking claw and a through hole of a terminal holder, and FIG. 3B is a perspective view of the same.
FIG. 4 is a perspective view showing a first terminal holder assembly.
5 is a cross-sectional view taken along the line BB of FIG. 4 showing a state in which bus bars are arranged in a staggered manner on the terminal holder.
FIG. 6 is an exploded perspective view showing a state in which the chain terminal is assembled to the second terminal holder.
FIG. 7 is a perspective view showing a second terminal holder assembly.
FIG. 8 is a perspective view showing a primary molded body.
FIG. 9 is a perspective view showing a multipolar molded connector which is a secondary molded body.
FIG. 10 is a longitudinal sectional view showing a conventional example.
[Explanation of symbols]
3, 46 Terminal holder 4, 5, 61, 62 Bus bar 10, 11, 43, 44 Terminal part 12, 13, 59, 60 Contact part 16, 17, 53, 54 Rising part (leading part)
26, 27, 49, 50 Guide grooves 30, 31, 63 Locking claws 45 Multipolar molded connector 71 Core 77 Connector housing

Claims

A plurality of guide grooves for each bus bar are arranged in a staggered manner on the front and back sides of the insulating plate-like terminal holder, and a locking claw for each bus bar is provided on the periphery of each guide groove. Each bus bar on the front and back is arranged and fixed in a staggered manner, the terminal portion of each bus bar is horizontally projected from one end of the terminal holder, and the lead-out portion of each bus bar is raised in parallel from the other end of the terminal holder, A horizontal contact portion follows each lead-out portion, and the lead-out portion of each bus bar on the back side is formed longer than the lead-out portion of each bus bar on the front side, and the lead-out portion and the contact portion of each bus bar on the back side are each bus bar on the front side. In this state, the terminal holder is covered with the resin material, and the contact portions of the front and back bus bars are exposed in parallel on the same surface from the resin material. multipolar molded connector, characterized in that it has.

The multipolar molded connector according to claim 1, wherein the terminal holder is arranged in a plurality of layers .

3. The multipolar molded connector according to claim 1 , wherein the resin material includes a core primarily molded on the terminal holder and a connector housing secondarily molded on the core . 4.