JP5916197B2 - Waterproof connector and manufacturing method thereof - Google Patents

Description

  The present invention relates to a waterproof connector and a method of manufacturing the same, and more particularly, a waterproof connector having a further improved waterproof performance of a so-called molded connector produced by insert molding a metal connector part constituting the connector into an electrically insulating resin. And a manufacturing method thereof.

  In recent years, electronic and information devices such as personal computers, mobile phones, and information terminals are rapidly spreading. These electronic / information devices incorporate various types of electrical connectors for connection to external devices, many of which are USB standards. In order to prevent the so-called EMI (Electro Magnetic Interference Electromagnetic Interference) interference, such a connector usually prevents noise from entering from the outside to the inside to prevent an electronic circuit in the electronic device from being damaged. The insulation housing with the contacts attached is covered with a shield case to shield electromagnetically.

  For example, as shown in Patent Document 1 below, this type of connector is generally made of a highly conductive contact, a housing made of an electrically insulating resin to which the contact is attached, and a metal covering the outside of the housing. The shield case is configured such that after the predetermined number of contacts are mounted on the housing, the housing is covered with the shield case.

  Patent Document 2 below describes a connector having such a connector made of a waterproof structure. As shown in FIGS. 19 and 20, the waterproof connector 10 includes a plurality of contact terminals 13, a housing 11 in which these contact terminals are integrally fixed by injection molding, and a shell attached to the front of the housing. 12 and a seal member 14 mounted rearward. The housing 11 is provided with a seal member connection groove 111 for mounting the seal member 14 therein. The seal member 14 extends along the outer periphery of the seal member 14 so that the through hole 140 corresponding to the seal member connection groove 111 of the housing 11 and the upper case 100A and the lower case 100B of the device housing are inserted into the seal member 14. And an airtight groove 141 formed. The front protrusion 142 and the rear protrusion 142A of the seal member 14 are partitioned by an airtight groove 141. Due to the connection between the recesses 140A and 140B formed inside the through hole 140 of the seal member 14, the seal member connection groove 111 formed in the housing 11 is formed outside the seal member connection groove 111 as shown in FIG. The seal member 14 that is mounted is engaged with the through hole 140 in an airtight manner. The shell 12 has a pair of fixing holes 121 in the upper part of the shell 12 in order to fix a hook of a mating connector (not shown). Water may enter the inside of the printed circuit board mounted on the main body through the gaps between the fixing hole 121, the housing 11, and the upper case 100A and the lower case 100B of the device housing, and may cause serious damage. However, in this connector 10, since the assembly of the seal member 14, the upper case 100 </ b> A and the lower case 100 </ b> B of the device housing has an airtight structure, water entering the connector 10 passes through the fixing hole 121 of the shell 12. Furthermore, it can prevent entering into the main body.

  The connector 10 is used by being mounted on a mobile phone housing. The connector mounted on the mobile phone is also provided with a terminal protective cover at the opening of the device housing on which the connector is mounted in order to improve waterproof performance. It is done to provide. (For example, refer to Patent Document 3 below).

  In addition, since the connector 10 is integrally molded and fixed to the housing 11 in which a plurality of contact terminals 13 are injection-molded, water can be prevented from penetrating through the contact terminals 13. . Such a connector is manufactured by a method in which a contact is set in a mold having a predetermined shape, and then the mold is closed and an electrically insulating resin is injected therein, and the resin and the contact are integrally molded. Yes. Such a manufacturing method is a method by insert molding, and the connector manufactured by this method is also called a molded connector. The manufacturing method and connector of such a molded connector are described in Patent Documents 4 and 5 below, for example.

JP 2002-298984 A (paragraphs [0020] to [0024], FIG. 1) JP 2009-176734 A (paragraphs [0038] to [0044], FIG. 3, FIG. 4, FIG. 6) JP 2005-228756 A (paragraphs [0033], [0034], FIG. 2) JP 2001-351745 (paragraph [0032], FIG. 2) Japanese Patent Laid-Open No. 06-254902 (paragraphs [0008] to [0013], FIG. 1)

  Mobile electronic devices, particularly mobile phones, are used in harsh environments, and depending on the usage situation, there are many opportunities to be used in environments that are not desirable for this device. This mobile phone can be used in places where there is a lot of moisture, dust, or rain, and it can be immersed in spilled water and dropped into water. In addition, they are often used in unexpected environments, and these are all used in harsh environments for equipment. For this reason, when the portable electronic device is placed in such an environment, there is a risk that water may enter the device through the connector.

  From this point of view, when the connector of the above-mentioned patent document is observed, the connector of the above-mentioned patent document 1 can prevent intrusion of external noise. Moreover, it is said that the connector of the said patent documents 2-5 can prevent the penetration | invasion of the water into an apparatus again. However, among these connectors, so-called molded connectors are manufactured by insert molding, so the metal connector parts and the housing, that is, the resin, are integrally formed, so that it seems that water can be prevented from entering. Metal connector parts, for example, metal and resin appear to be in close contact between the contact and the housing, but they are not actually in close contact, resulting in a micron-order fine gap between them. As a result, water may enter through this fine gap. The cause of such a fine gap is considered to be caused by a composite factor such as a degree of adhesion between the metal connector part and the resin at the time of insert molding, or a difference in both materials and expansion coefficient. Therefore, even if it is a molded connector by insert molding, this connector has the subject which cannot prevent water invasion.

  These connectors also have the following problems. For example, the connector of Patent Document 2 includes a plurality of contact terminals, a housing in which these contact terminals are integrally fixed by injection molding, a shell mounted on the front of the housing, and a seal member mounted on the rear. Since the assembly of the seal part, the upper case and the lower case of the device casing has an airtight structure, water entering the connector can be further prevented from entering the main body through the fixing hole of the shell. ing. However, this waterproof structure has the above-mentioned problems, and the housing must be fitted with a shell at the front and a seal member at the rear with these members separated by a predetermined distance. The length becomes longer, which increases the mounting space on the device casing. In addition, the number of parts increases, and the mounting to the circuit wiring board must be screwed to the housing, so that the mounting work is cumbersome and labor-intensive. On the other hand, this type of shell is also provided. It is not possible to adopt a normal method for mounting the connector, for example, a method in which a mounting piece is provided on the shell and the mounting piece is fixed to the circuit wiring board by soldering.

  In addition, since the connector of Patent Document 3 is designed to hermetically seal the opening of the device housing provided with the connector with a terminal protective cover, the connector mounting hole can be sealed with the terminal protective cover when the connector is not used. Intrusion of water or the like can be prevented, but a special structure terminal protection cover is required, and the design of the equipment housing must be changed so that the protection cover can be attached. For this reason, there is a possibility that the terminal protection cover may come off and be lost from the device casing, and the cost of the device as a whole will be increased. Note that such a waterproof cover is now exchanged for a fee once every two years in order to maintain waterproofness. Therefore, even in the molded connector of each of the above patent documents, there is a gap between components, and there is a possibility that water droplets or dust may enter the inside from this gap, and in particular, it is not possible to prevent water immersion due to capillary action. That is, in the connector incorporated in the portable electronic device, a part of the connector, in particular, the tip portion of the metal shell is exposed from the device casing, and there is a risk of intrusion from the exposed portion by capillary action.

Therefore, the present invention was made to solve such problems of the prior art, and an object of the present invention is a mold in which a metal connector part constituting a connector is produced by insert molding in an electrically insulating resin. Waterproof connector with further improved waterproof performance of the connector and its manufacturing method, specifically, a fine gap formed between a metal connector part of an insert-molded molded connector and a connector housing made of an electrically insulating resin is waterproof-sealed. Another object of the present invention is to provide a waterproof connector having a further improved waterproof performance and a method for manufacturing the waterproof connector.
Another object of the present invention is to reliably prevent entry of water, dust and the like with a simple structure, and in particular, to reliably prevent entry of water and the like by capillarity from a gap between components constituting the connector. It is providing the prevention connector and its manufacturing method.
Another object of the present invention is to provide a waterproof connector having the above-mentioned object, further reducing the number of parts, and reducing the size, for example, the height, and the manufacturing method thereof.

In order to solve the above problems, in the waterproof connector of the first aspect of the present invention, a metal connector parts constituting the connector is disposed within an electrically insulating resin, and a connector housing said electrically insulating resin-proof In the water connector,
The metal connector part has a contact electrically connected to a contact of the mating connector at one end, an opening at least at one end, and a hollow hole communicating with the opening at least at one end, and the mating connector is located near the inside of the opening. A metal shell made of a metal tubular body having a butt-joining portion that is a plug-in portion to be inserted and has a pair of opposed short sides butted against each other with a gap between them;
The clearance between the connector housing and prior SL contacts and the metal shell together are waterproof seal by a waterproof sealing material, the gap of the butt joint of the metal shell is waterproof seal by the waterproof sealant It is characterized by.

The waterproof connector according to the second aspect is the waterproof connector according to the first aspect, wherein the metal shell is provided with a mounting fixing piece and a ground terminal to be mounted on a circuit wiring board or the like on the outer periphery. And the connector housing are waterproofly sealed with the waterproof sealant .

Moreover, in the waterproof connector manufacturing method according to the third aspect of the present invention for manufacturing the waterproof connector according to either the first or second aspect, the following steps (a) and (b) are included. To
(A) One end of the connector is electrically contacted with the contact of the mating connector, and at least one end has an opening and a hollow hole communicating with the opening inside, and the mating connector is inserted in the vicinity of the opening. A metal shell made of a metal tubular body having a butt-joined portion in which a pair of opposing short sides are abutted with a gap provided therebetween, and the contact is formed inside the mold from the inner wall of the metal shell. A step of producing a molded connector using the electrically insulating resin as a connector housing by injecting the electrically insulating resin into the mold after being supported and fixed separately .
(B) Filling the gap between the contact of the molded connector and the metal shell and the connector housing with the waterproof sealant for waterproof sealing, and waterproofing the gap at the butt joint of the metal shell A process of filling the sealant and waterproofing it .

Further, in the waterproof connector manufacturing method according to the fourth aspect, in the waterproof connector manufacturing method according to the third aspect, the step (b) includes immersing the molded connector in a container in which a liquid waterproof sealant is stored. The container is placed in another sealed container, the inside of the sealed container is depressurized, and the waterproof sealant is filled with the waterproof sealant in a gap between the metal connector part and the electrically insulating resin, and waterproof sealed. And

In the waterproof connector manufacturing method according to the fifth aspect, in the waterproof connector manufacturing method according to the third aspect, the step (a) includes the following steps (c) to (e). And
(C) A contact and metal shell integrated forming step in which a highly conductive metal plate of a predetermined size is punched and bent and connected to a carrier with a connecting piece, and the contact and the metal shell are integrally formed;
(D) A mold is disposed around the contact and the metal shell integrally molded in the step (c), an electrically insulating synthetic resin is injected into the metal shell, and the contact is molded to form a resin. A housing molding step of molding the housing comprising the body,
(E) A carrier cutting step of cutting the contact, the metal shell, and the connecting piece from the carrier after molding the housing in the step (d).

In the waterproof connector manufacturing method according to the sixth aspect, in the waterproof connector manufacturing method according to the fifth aspect, the step (d) includes the step of forming the contact and metal shell integrally formed in the step (c). The housing is made of a resin molded body that is surrounded by a mold, injects the electrically insulating resin into the metal shell, covers the outer periphery, and is integrally molded.

In the waterproof connector manufacturing method according to the seventh aspect, in the waterproof connector manufacturing method according to the third aspect, the metal shell is provided with a mounting fixing piece to be mounted on a circuit wiring board or the like and an earth terminal on the outer periphery. These locations are also molded with the electrically insulating resin.

In the waterproof connector manufacturing method according to the eighth aspect, in the waterproof connector manufacturing method according to the fifth or seventh aspect, the connecting piece is the ground terminal.

In the waterproof connector manufacturing method according to the ninth aspect, in the waterproof connector manufacturing method according to the third aspect, a cleaning step is added after the step (b), and the metal connector is added in the cleaning step. It is characterized by removing the waterproof sealant adhering to the external electrical connection part of the part.

In the waterproof connector manufacturing method according to the tenth aspect, in the waterproof connector manufacturing method according to the third aspect, the waterproof sealant is in a liquid state before being filled into the gap of the molded connector. characterized in that it is intended to solid into after.

According to the waterproof connector of the first aspect of the present invention, even a molded connector in which a metal connector part constituting the connector is insert-molded in an electrically insulating resin, a connector comprising the metal connector part and the electrically insulating resin. The waterproof performance can be further improved because the water-tight sealant is filled in the minute gap between the housing and waterproof.

Further, according to the waterproof connector of the first aspect of the present invention, the butt of the joint portion of the metal shell is filled and filled with the waterproof sealant, so that the penetration of water by the capillary phenomenon is transmitted through the butt portion. Can be prevented.

In addition, according to the waterproof connector of the second aspect of the present invention, water can be prevented from entering from the mounting fixing piece and the ground terminal, and mechanically applied to the circuit wiring board or the like using the mounting fixing piece and the ground terminal. And can be electrically connected and connected. Further, the size can be reduced, for example, the height can be reduced.

Further, according to the method for manufacturing a waterproof connector of the third aspect of the present invention, a waterproof sealant is filled with a waterproof sealant in a minute gap between a metal connector part and an electrically insulating resin produced by insert molding, so that waterproof performance is achieved. However, it is possible to manufacture a waterproof connector that is remarkably improved as compared with a molded connector that is simply molded. The manufactured waterproof connector can particularly prevent water from entering due to capillary action. In addition, since the waterproof sealant is filled in the gap between the contact and the metal shell and the connector housing for waterproof sealing, a waterproof connector with significantly improved waterproof performance can be manufactured. In particular, water intrusion due to capillary action can be prevented. Further, since the housing also covers the outer periphery of the metal shell, the metal shell can be protected and a waterproof member or the like can be easily attached to the housing covering the outer periphery. In addition, since the waterproof sealant is filled and buried in the butt of the joint portion of the metal shell, a waterproof connector that can prevent water intrusion through the butt portion, that is, capillary action can be manufactured.

Moreover, according to the waterproof connector manufacturing method of the fourth aspect of the present invention, the waterproof sealant can be easily filled in the gap between the metal connector part and the electrically insulating resin by the decompression process.

Further, according to the waterproof connector manufacturing method of the fifth and sixth aspects of the present invention, the contact, the metal shell and the carrier are integrally formed of the same plate material connected by the connecting piece, and these are electrically insulating synthetic resin. Thus, the molding is completed once, the housing molded body can be easily created, and the waterproof connector can be manufactured efficiently and easily.

Further, according to the waterproof connector manufacturing method of the seventh and eighth aspects of the present invention, water can be prevented from entering from the mounting fixing piece and the ground terminal, and the circuit wiring can be made using the mounting fixing piece and the ground terminal. A waterproof connector that can be mechanically and electrically connected and connected to a substrate or the like can be manufactured. Further, the size can be reduced, for example, the height can be reduced.

Further, according to the waterproof connector manufacturing method of the ninth aspect of the present invention, solder connection or the like is ensured by removing the waterproof sealant adhering to the external electrical connection portion.

Further, according to the waterproof connector manufacturing method of the tenth aspect of the present invention, a waterproof sealant that is liquid before being filled into the gaps of the molded connector and that is volatilized and solidified after being filled is used. Therefore, the waterproof sealant can be easily filled in the minute gaps of the molded connector by the decompression process.

1 shows a waterproof connector according to Embodiment 1 of the present invention, FIG. 1A is a front perspective view seen from the front, and FIG. 1B is a rear perspective view seen from the rear. 2 is a detailed view of the waterproof connector of FIG. 1, FIG. 2A is a front view, FIG. 2B is a top view, FIG. 2C is a bottom view, FIG. 2D is a left side view, and FIG. 3A is a sectional view taken along line III-III in FIG. 2A, FIG. 3B is an enlarged sectional view of a part of FIG. 3A, and FIG. 3C is an enlarged sectional view of the IIIC portion of FIG. 4 is a process block diagram of a method for manufacturing the waterproof connector of FIG. FIG. 5 is a partial process block diagram of FIG. FIG. 6 shows a contact, FIG. 6A is a perspective view of a contact group in which a plurality of contacts are arranged and arranged, and FIG. 6B is a side view of one contact of FIG. 6A. 7 shows a metal shell, FIG. 7A is a front perspective view, and FIG. 7B is a rear perspective view. 8 is a detailed view of the metal shell of FIG. 7, FIG. 8A is a front view, FIG. 8B is a top view, FIG. 8C is a bottom view, FIG. 8D is one side view, and FIG. 9 is an enlarged cross-sectional view taken along line IX-IX in FIG. 8A. FIG. 10 shows a part of the manufacturing process, FIG. 10A shows a molded body obtained by integrally molding the contact and the metal shell, FIG. 10A is a front perspective view, and FIG. 10B is a rear perspective view. 11 is a detailed view of FIG. 10, FIG. 11A is a front view, FIG. 11B is a top view, FIG. 11C is a bottom view, FIG. 11D is one side view, and FIG. 12 is an enlarged cross-sectional view taken along line XII-XII in FIG. 11A. FIG. 13 is an enlarged cross-sectional view corresponding to FIG. 12 in a state where a mold is disposed on the contact / metal shell molded body of FIG. 14 shows an exterior waterproof seal member, FIG. 14A is a perspective view, and FIG. 14B is a cross-sectional view taken along line XV-XV in FIG. 15A. 15 shows a state before the exterior waterproof seal member is attached to the housing, FIG. 15A is a front perspective view, and FIG. 15B is a rear perspective view. 16 shows the molded connector before dipping the waterproof sealant, FIG. 16A is a sectional view, FIG. 16B is an enlarged sectional view of a part of FIG. 16A, and FIG. 16C is an enlarged sectional view of the XVIC portion of FIG. FIG. 17 is a schematic view of a test apparatus. 18 shows a waterproof connector according to Embodiment 2 of the present invention, FIG. 18A is a front view, FIG. 18B is a top view, FIG. 18C is a bottom view, FIG. 18D is one side view, and FIG. 18E is the other side view. 18F is a rear view, and FIG. 18G is a sectional view taken along line XVIII-XVIII in FIG. 18A. FIG. 19 is a perspective view of a conventional connector. FIG. 20 is a cross-sectional view taken along the vertical direction with the connector of FIG. 19 mounted on the device casing.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, the embodiment shown below exemplifies a waterproof connector and a manufacturing method thereof for embodying the technical idea of the present invention, and is not intended to specify the present invention. Other embodiments within the scope of the claims are equally applicable.

[Embodiment 1]
With reference to FIGS. 1-3, the waterproof connector which concerns on embodiment of this invention is demonstrated. 1 shows a waterproof connector according to Embodiment 1 of the present invention, FIG. 1A is a front perspective view seen from the front, FIG. 1B is a rear perspective view seen from the rear, and FIG. 2 is a detailed view of the waterproof connector of FIG. 2A is a front view, FIG. 2B is a top view, FIG. 2C is a bottom view, FIG. 2D is a left side view, FIG. 2E is a right side view, and FIG. 3A is a cross-sectional view taken along line III-III in FIG. Fig. 3A is an enlarged sectional view of a part of Fig. 3A, and Fig. 3C is an enlarged sectional view of a IIIC portion of Fig. 3A.

  A waterproof connector (hereinafter referred to as “connector”) 1 according to Embodiment 1 of the present invention includes a plurality of contacts 2 made of a highly conductive metal material, and a metal tube in which these contacts are arranged and electromagnetically sealed. It has a metal shell 3 made of a body, and an electrically insulating housing 4 that supports and fixes these contacts at a predetermined interval. The housing 4 is disposed inside the metal shell 3 in a state where a plurality of contacts 2 are separated from the inner wall of the metal shell and are electrically insulated. It is formed of a molded body that covers the periphery and is integrally molded. That is, the housing 4 is manufactured by a molding process in the connector manufacturing process.

This connector is a molded connector made of a molded body. Next, the molded connector 1M is waterproofed, and as shown in FIG. 3, the fine G1 and G2 between the contact 2 and the metal shell 3 and the housing 4, the gap G3 between the housing and the seal member, and the metal shell The gap between the joints 3a ' is filled with a waterproof sealant to provide a waterproof seal. The manufacturing method can be performed by a simple waterproofing process as will be described later. In addition, the connector 1 manufactured by the manufacturing method has contacts, a metal shell, and an electrically insulating resin (housing) integrally molded, and in addition, a fine gap formed between them is filled with a waterproof sealant. Therefore, the waterproof performance is significantly improved. That is, even in the case of a molded connector molded by insert molding, a waterproof sealant is filled in a minute gap generated between a connector metal part (contact, shell) and a resin, so that the waterproof performance is remarkably improved.

  Hereinafter, a method for manufacturing the connector 1 will be described with reference to FIGS. 4 is a process block diagram of the method of manufacturing the waterproof connector of FIG. 1, and FIG. 5 is a partial process block diagram of FIG.

Connector parts production process I
First, the contact will be described with reference to FIG. 6A is a perspective view of a contact group in which a plurality of contacts are arranged and arranged, and FIG. 6B is a side view of one contact in FIG. 6A.

As shown in FIG. 6A, the contact 2 includes a plurality of, for example, five contacts 2 ₁ to ₂₅ , and these contacts have the same structure. One contacts _{2 1} will be described. The contact 2 _1, as shown in FIG. 6B, the contact portion 2a of mating connector contact (not shown) is brought into contact with one end, the connecting portion 2c and contacts electrically connected to the wiring such as the circuit wiring board to the other end It consists of an elongated piece having an intermediate part 2b which is connected to the part 2a and the connecting part 2c and is fixed to the housing 4 by molding, and is formed by punching out a good conductive metal plate having a predetermined area and thickness. ing. The contact portion 2a has a predetermined length in the length direction in order to make good contact with the contact of the counterpart connector. The tip 2a ′ is curved upward so that the sliding contact of the contact of the counterpart connector is smooth. In the state shown in FIG. 6A, the intermediate part 2 b is located at the upper side and the connection part 2 c at the lower side. Therefore, the intermediate part 2 b is bent at approximately 90 ° between them and fixed to the housing 4 by molding. It has become. The connection part 2c is a connection piece extending substantially horizontally from the intermediate part 2b to connect to a conductor on the circuit wiring board. Further, it is preferable to provide a narrow groove or a recessed hole in the intermediate portion 2b. Thereby, the creeping distance of an intermediate part becomes long and can improve a waterproof effect. The narrow groove and the recessed hole are formed by laser processing or the like. In addition, although the contact was comprised by the elongate piece, it is not limited to this, Arbitrary contacts may be sufficient, for example, a round bar shape may be sufficient. In addition, these contacts 2 ₁ to ₂₅ are connected at the carrier portion and are manufactured integrally with the metal shell.

  The metal shell will be described with reference to FIGS. 7 shows the appearance of the metal shell, FIG. 7A is a front perspective view, FIG. 7B is a rear perspective view, FIG. 8 is a detailed view of the metal shell of FIG. 7, FIG. 8A is a front view, and FIG. 8C is a bottom view, FIG. 8D is one side view, FIG. 8E is the other side view, and FIG. 9 is an enlarged cross-sectional view taken along line IX-IX in FIG. 8A.

As shown in FIGS. 7 to 9, the metal shell 3 has a flat angle having front and rear openings 3 _F and 3 _R having substantially rectangular shapes at both ends and a cavity hole (space) 3 _S communicating with these openings inside. A thin metal plate material such as a stainless steel plate or the same metal plate as the contact 2 is punched into a predetermined shape, and the punched piece is formed into a predetermined shape by bending or bending. That is, this metal shell 3 has a flat rectangular tubular body having openings 3 _F and 3 _{R in the} front and rear, and a space 3 _S inside, and surrounded by upper and lower plate portions 3 a and 3 b and left and right plate portions 3 c and 3 d. It has become.

  The metal shell 3 made of this tubular body is joined by the upper plate portion 3a. This joint portion 3a ′ is a place where a pair of opposed short sides of a punched piece (band-like metal piece) having a predetermined size as a material of the metal shell is abutted, and this place is joined by laser welding or the like. In order to facilitate joining by welding or the like, it is preferable to form a temporary fastening means, for example, a means comprising a locking projection and a locking groove into which the locking projection is fitted, and join the joining portion. Since laser welding of the joint 3a 'takes time, it is possible to save troublesome work by holding it with temporary fixing means, insert molding and covering the outer wall surface of the metal shell with the housing resin material. become. According to this method, a gap is formed on the abutting surface of the joint, and the gap is filled with a waterproof sealant described later and waterproof-sealed.

Upper plate portion 3a is formed from a pair of inner walls on both sides of the front opening 3 _F side of the surface hole 3a ₁ recess which is recessed toward the outside. These recessed hole 3a _1, when the mating connector is inserted into the front opening 3 _F, the locking portion of the connector is engaged, and which fulfill the retaining function of the connector. On the left and right plate portions 3c and 3d, substrate fixing legs 3c ₁ and 3d ₁ are formed by cutting both plate portions. These board fixing legs 3c ₁ and 3d ₁ serve as fixing parts of the circuit wiring board. By these cutting and raising, through holes 3c ₁ ′ and 3d ₁ ′ are formed at the cut and raised portions, but these through holes are closed by molding. The lower plate portion 3b, a rear opening 3 _R side, a pair of ground terminals 3r ₂ is formed that extends to a pair of board fixing feet 3r ₁ and rearwardly bent downward from the edge. These substrate fixing legs 3r ₁ and ground terminal 3r ₂ is disposed substrate fixing legs 3r ₁ between both ground terminals 3r _2. The board fixing leg 3r ₁ serves as a fixing part of the circuit wiring board. Ground terminal 3r ₂ is a connecting portion to be connected to conductors on the circuit board.

Further, the metal shell 3 is provided on the inner wall surfaces of the upper and lower plate portions 3a, 3b and the left and right plate portions 3c, 3d, and is provided with a narrow groove and a recessed hole on the inner wall surface to which the intermediate portion 2b of the contact 2 is fixed. Is preferred. Thereby, creepage distance becomes long and can improve a waterproof effect. The metal shell is a flat rectangular tubular body, but is not limited to this shape, and may be an arbitrary shape, for example, a circular tubular body. Further, it may be closed with a lid without opening the rear opening 3 _R. Further, not only the electromagnetic shielding member but also the outer shell made of a metal tube may be used.

Mold connector fabrication process II by insert molding
The molded connector _1M will be described with reference to FIGS. 10 shows a part of the manufacturing process, FIG. 10A shows a molded body in which contacts and a metal shell are integrally formed, FIG. 10A is a front perspective view, FIG. 10B is a rear perspective view, and FIG. 11A is a front view, FIG. 11B is a top view, FIG. 11C is a bottom view, FIG. 11D is one side view, FIG. 11E is the other side view, and FIG. 12 is XII-XII in FIG. FIG. 13 is an enlarged cross-sectional view corresponding to FIG. 12 showing a state in which a mold is disposed on the contact / metal shell molded body of FIG.

The mold connector _1M is manufactured by the following steps (a) to (c). The housing 4 is manufactured in this process.

(A) Contact and metal shell integrated formation process First, the contact 2 and the metal shell 3 are formed in a predetermined area of a long metal plate that is continuously supplied. Since the contact 2 and the metal shell 3 are formed of the same material, a long, highly conductive metal plate having a predetermined thickness and width is used as the long metal plate. In the long metal plate, an area for forming the contact 2 and the metal shell 3 for one connector is defined in the length direction. As shown in FIGS. 10 to 13, this section includes a carrier portion 5A connected to a long metal plate, a contact creation area 2A extending from the carrier portion relatively long forward, and the tip of the contact creation area 2A. In this area, the contact 2 and the metal shell 3 are formed, respectively. That is, in the contact creation area 2A, the carrier portion 5A is positioned and fixed, and the five contacts 2 ₁ to 2 ₅ , the two ground terminals 3r ₂ and the board fixing leg 3r ₁ are formed by punching and bending. To do. At this time, the upper plate portion 3a of the metal shell 3 is placed in two, and each contact is bent. Similarly, the metal shell creation area 3A has openings 3 _F and 3 _{R in the} front and rear and a space 3 _S in the front and rear by punching and bending, and is surrounded by the upper and lower plate portions 3 a and 3 b and the left and right plate portions 3 c and 3 d. A flat, rectangular tube is formed. Reference numeral 3a ′ denotes a joint. The five contacts 2 _{1 to} 2 ₅ are arranged such that the respective contact portions 2 a are spaced apart from the inner wall surface of the metal shell, that is, the inner wall surface of the tubular body, by a predetermined distance from the contact portion 2 c and the metal shell 3 of each contact. ground terminal 3r ₂ was extended is linked to the carrier portion 5A. Since the and the metallic shell 3 and the carrier portion 5 is connected with the ground terminal 3r _2, it can be treated as an integral part of the molding of the contact / metal shell. That is, even if the five contacts 2 ₁ to ₂₅ are not separated from the inner wall surface of the metal shell by a predetermined distance and connected to the metal shell, they are connected by the ground terminal, so that they can be handled as an integral part. In addition, although the metal shell 3 and the carrier part 5 were connected with the earth terminal, other connecting pieces may be used.

(B) Housing molding step The contact 2 and the metal shell 3 integrated in the step (a) are positioned and fixed by the carrier portion 5 to form a predetermined space between the contact 2 and the metal shell 3 and the mold. As described above, a plurality of molds are arranged on the outer periphery of the metal shell 3. That is, as shown in FIG. 13, the front mold M _F is in front of the metal shell 3, the upper mold M _T is in the upper direction, the lower mold M _B is in the lower direction, the left and right molds (not shown), and the rear is in the rear by placing the molds _{M R,} to form a space Sa, Sb, Sc, Sc ₁ and Sr between the contact 2 and the metal shell 3. Upper mold M _T, the lower mold M _B and the left and right mold, the grooves 7 depressions in the vicinity of the front opening 3 _F metal shell 3 is provided. Because the contact 2 and the metal shell 3 integrated there is a space around the carrier portion 5, the front mold M _F, the upper mold M _T, the lower mold M _B and the left and right molds and posterior molds M _R Easy to place. In particular, the contact creation area 2A between the carrier portion 5A and the metal shell creation area 3A, since are the wide, easily disposed even backwards mold M _R.

Next, an electrically insulating synthetic resin material is injected into these spaces Sa, Sb, Sc, Sc ₁ and Sr, and the contact 2 and the metal shell 3 are molded. Incidentally, the synthetic resin material, the front mold M _F, the upper and lower side molds M _T, M _B, the left and right mold, the injection holes and air vent holes provided in one of the mold posterior mold M _R, the injection hole Inject from. Thereby, the contact 2 and the metal shell 3 are inserted into the electrically insulating synthetic resin material to form a molded body integrally molded. This molded body becomes the housing 4. The housing 4 is in the internal space _{3 S} metallic shell 3, the contact stationary housing part 4e for supporting and fixing the contacts ₂ 1 to 2 ₅ five, 4e _1, the rear housing portion 4r which covers the rear opening 3R, outer periphery That is, the molded body is composed of the outer housing parts 4a to 4d (see FIGS. 1 and 2) covering the upper and lower plate parts 3a and 3b and the left and right plate parts 3c and 3d. The upper and lower plate portions 3a, 3b and lateral plate portions 3c, the locking projection 4a ₁ on the outer peripheral wall surface of the 3d is formed (see FIG. 3A). The locking projection 4a _1, exterior waterproof seal member 8 is engaged.

(C) after molding in the carrier portion cutting step the step (b), the front mold M _F, the upper and lower side molds M _T, M _B, remove the rear mold M _R and the left and right dies, each contact 2 _The carrier part 5 connected to ₁ to ₂₅ and the ground terminal 3r ₂ is cut off. This decoupling, ground terminal 3r ₂ is cut slightly longer than the contacts ₂ 1 to 2 _5. Through these steps (a) to (c), one connector is manufactured, and then the carrier portion 5A is moved to successively manufacture the next connector.

After the housing 4 is formed, an exterior waterproof seal member 8 is attached to the outer periphery to waterproof between a housing (not shown) such as a mobile phone. As shown in FIG. 14, the exterior waterproof seal member 8 is composed of an annular seal packing sized to be attached to the outer periphery of the housing 4, and has an opening 8 a sized to fit into the outer periphery of the housing 4. It is comprised with the elastic member.
The outer periphery 8b is inflated into a shape that fits into a mounting groove (not shown) of the device housing, for example, a semicircular shape. Furthermore, recessed grooves ₈₁ are formed on the inner wall surface of the opening 8a. As shown in FIG. 15, the exterior waterproof seal member 8 is attached to the locking protrusion 4 a ₁ on the outer periphery of the housing 4. By this attachment, it can be waterproofed with the equipment casing.

Through the above process, can be fabricated mold connector 1 _M. The molded connector _1M has the same outer shape as the connector 1 shown in FIGS. However, the mold connector 1 _M, even by insert molding, etc. between the contact and the metal shell and the housing 4, is empty fine gap G _1, G _2, G ₃ as shown in FIG. 16. Therefore, this fine gap is waterproof-sealed in the following process. 16 shows the molded connector before dipping the waterproof sealant, FIG. 16A is a sectional view, FIG. 16B is an enlarged sectional view of a part of FIG. 16A, and FIG. 16C is an enlarged sectional view of the XVIC portion of FIG. is there. The cross-sectional view of FIG. 16A corresponds to that cut along III-III of FIG. 2A.

Waterproof sealant soaking process III
As shown in FIG. 5, put mold connector 1 _M in vessel Box ₁ of a predetermined shape which stores a waterproof sealant Li _1, immersed in the waterproofing sealant (see Figure 3A). The waterproof sealant Li _1, to use Sankei Chemical Co., Ltd. under the trade name of "WPS-100". The waterproof sealant is in a liquid form and has a property of solidifying and sealing after being filled in the molded connector.

Vacuum treatment process IV
The container Box 1 in which the molded connector 1M is put and immersed in the waterproof sealant Li1 is transferred to the vacuum processing step and processed by the decompression processing device 9. The decompression processing device 9 includes a sealed container Box 2 having an open / close lid, an exhaust means (vacuum pump) P for evacuating the sealed container, and a supply for returning the evacuated sealed container to normal pressure. It consists of a gas valve V2. The decompression processing device 9 is provided with submerged support means (not shown) for forcibly sinking and supporting in the waterproof sealant so that the mold connector 1M does not float from the container box 1 during decompression. ing. In the processing by the decompression processing device 9, the valve V1 is opened and the exhaust means (vacuum pump) P is operated to exhaust the air in the upper part of the sealed container Box 2 to reduce the internal pressure. Due to the reduced pressure, a pressure for sucking up the waterproof sealant Li1 also works as the atmospheric pressure in the sealed container Box2 decreases. However, because of the sealed container, the waterproof sealant Li1 does not move upward, but negative pressure is applied to the air in the gap of the molded connector 1M. As a result, the air in the gap of the mold connector 1M expands, and the swollen portion becomes a bubble and floats to the liquid surface of the waterproof sealant. When exhaust is further performed and the pressure becomes close to a vacuum, the air in the gap of the mold connector 1M also becomes a pressure close to a vacuum, expands, and is mostly discharged as bubbles. If the exhaust means is stopped in this state, the air supply valve V2 is opened, and the air pressure in the upper part of the sealed container Box 2 is returned to normal pressure, the air pressure in the gap of the mold connector 1M is also restored. The air in the gaps of the mold connector 1M also expands, and the air that has become extremely lean contracts and returns to its original state. However, since most of the air is already in the form of bubbles, the surrounding waterproof sealant Li1 is used instead. The gap is filled in the mold connector 1M. As a result, almost no air remains in the gap of the molded connector 1M, and instead, a waterproof sealant is filled. That is, as shown in FIG. 3, a waterproof seal is provided in the contact 2 and the minute gaps G1 and G2 between the metal shell 3 and the housing 4, the gap G3 between the housing and the seal member, and the gap between the joint portions 3a ′ of the metal shell 3. Filled with a waterproofing seal.

Cleaning process V
Since the connector 1 processed in the previous step IV has a waterproof sealant attached to contact portions and terminal portions such as contacts and ground terminals, the waterproof sealant is applied to these portions with a cleaning device such as an ultrasonic cleaning device. After washing, the manufacturing process is completed and the connector 1 is completed VI. In this cleaning, a connector is placed in a container box _{3 in} which a cleaning solution is stored, and ultrasonic cleaning is performed.

  The waterproof sealant used in the connector manufacturing method of Embodiment 1 requires a cleaning process because the film covering the contacts and the like is hard, but is not limited to this, and the waterproof seal that coats the contacts and the like is not limited thereto. By using a soft film covering the agent, for example, a trade name “SFE-DP02H” manufactured by Seimi Chemical Co., the connector 1 can be completed VI ′ without the cleaning process V of the manufacturing process ( Dotted arrows in FIG. 14). At this time, since the waterproof sealant covering the contact or the like is soft and the cover is peeled off by wiping when contacting with another contact, the connector can be used without any problem. In addition, the waterproof sealant to be used can be selected depending on the usage mode of the connector, and in accordance with the waterproof sealant selected by the selection, the presence or absence of a cleaning process can also be selected. A combined connector can be manufactured.

Waterproof test The waterproof test of the connector manufactured with the said manufacturing method was done with the following method. In addition, this test is based on JISC0920.
Test 1
As shown in FIG. 17, a non-waterproof connector and a waterproof connector are attached to the appliance K, and the appliance is installed at an inclination of 15 degrees on the floor surface. A water drop of 3 mm / min from a position 200 mm above the appliance. Fall. The test was performed at each position of the instrument for 2.5 minutes and at 4 positions for a total of 10 minutes.
As a result, the non-waterproof connector hardly leaked water, while the waterproof connector did not leak.

Test 2
The non-waterproof connector and the waterproof connector were submerged in water at a depth of 1 m for 30 minutes to confirm whether water had entered the connector.
As a result, all the non-waterproof connectors were leaked, while the waterproof connectors were not leaked.

According to this manufacturing method, a metal connector part is disposed and fixed in a mold having a predetermined shape, and an electrically insulating resin constituting the connector housing is injected into the mold to mold the connector. Since the molded connector is waterproofed, a waterproof connector with significantly improved waterproof performance can be manufactured. In other words, as shown in FIG. 3, this connector includes the contact 2 and the minute gaps G1 and G2 between the metal shell 3 and the housing 4, the gap G3 between the housing and the seal member, and the gap between the joint portions 3a ′ of the metal shell. Since it is filled with a waterproof sealant, the waterproof performance is remarkably improved.

  Therefore, the connector 1 is formed by a molded body in which the housing 4 is insert-molded with the contact 2 and the metal shell 3 in an electrically insulating synthetic resin material, and without increasing the number of parts as in the prior art. In addition, the production can be inlined without using a separate line, and the cost can be reduced. Specifically, the housing 4 is formed by molding the outer periphery of the metal shell 3, that is, the outer periphery of the tubular body, so that the metal shell 3 is protected by a resin material and the metal shell 3 is protected. Even if a cut-and-raised piece is formed for mounting on a circuit board or the like, and a through-hole is formed at that location due to the formation of the cut-and-raised piece, they are blocked by a resin material during molding, so Can prevent water and dust from entering. Furthermore, the exterior waterproof seal member 8 and the like can be easily attached to the outer periphery of the molded housing.

  Furthermore, since the housing can be molded by integrating the contact and the metal shell by a single molding, it is possible to efficiently and easily manufacture the connector. Therefore, the connector 1 is formed by a molded body in which the housing 4 is insert-molded with the contact 2 and the metal shell 3 in an electrically insulating synthetic resin material, and without increasing the number of parts as in the prior art. In addition, the production can be inlined without using a separate line, and the cost can be reduced.

  In the connector 1, the inside and outside periphery of the integrated contact and metal shell are molded with resin, but this mold may be limited to the inside of the metal shell and the outer periphery mold may be omitted.

[Embodiment 2]
With reference to FIG. 18, the waterproof connector of Embodiment 2 of this invention is demonstrated. 18 shows a waterproof connector according to Embodiment 2 of the present invention, FIG. 18A is a front view, FIG. 18B is a top view, FIG. 18C is a bottom view, FIG. 18D is one side view, and FIG. 18F is a rear view, and FIG. 18G is a cross-sectional view taken along line XVIII-XVIII in FIG. 18A.

  This connector 1A has a plurality of contacts 2 'and a housing 4' in which these contacts are insert-installed and fixed in a mold and integrally formed with an electrically insulating resin, and a fine gap between the contacts and the housing. It is a waterproof seal that is filled with a waterproof sealant. This connector 1 </ b> A is manufactured by manufacturing steps I to V similar to those of the connector 1. Also in this connector, the contact and the housing are closely joined, and the same effect as the connector 1 can be obtained.

1,1A waterproof connector _{1 M} mold connector _{2,2 21 to} 5, 2 'contact 2a contacts 2b intermediate fixing portion 2c connecting portion 3 metal shell _{3 F} front opening _{3 R} rear opening _{3 S-bore} hole (hole) (the space )
3a Upper plate portion 3a 'Joint portion 3a ₁ recess hole 3b lower plate portion 3c, 3d side plate portions 3c ₁ , 3d ₁ board fixing leg (mounting fixing piece)
3r ₁ board fixing leg (mounting fixing piece)
3r ₂ ground terminal (connection piece)
4,4 'housing 4a~4d outer housing portion 4e contact the stationary housing portion 4r rear housing part 5 the carrier portion 8 exterior waterproof seal member 9 vacuum processing apparatus _{M F} front mold _{M T} upper mold _{M B} lower mold _{M R} backwards Mold Li ₁ Waterproof sealant Li ₂ Cleaning solution Box ₁ Container Box ₂ Sealed container P Pressure reducing means (vacuum pump)

Claims (10)

Metal connector parts constituting the connector is disposed within an electrically insulating resin, in waterproof connector with a connector housing said electrically insulating resin,
The metal connector part has a contact electrically connected to a contact of the mating connector at one end, an opening at least at one end, and a hollow hole communicating with the opening at least at one end, and the mating connector is located near the inside of the opening. A metal shell made of a metal tubular body having a butt-joining portion that is a plug-in portion to be inserted and has a pair of opposed short sides butted against each other with a gap between them;
The clearance between the connector housing and prior SL contacts and the metal shell together are waterproof seal by a waterproof sealing material, the gap of the butt joint of the metal shell is waterproof seal by the waterproof sealant Waterproof connector featuring. The metal shell, characterized in that the attachment fixing portion and the ground terminal is mounted on the circuit wiring board to the outer periphery or the like is provided, between these locations the connector housing is waterproof seal by the waterproof sealant The waterproof connector according to claim 1. The method for producing a waterproof connector according to claim 1 or 2, comprising the following steps (a) and (b):
(A) One end of the connector is electrically contacted with the contact of the mating connector, and at least one end has an opening and a hollow hole communicating with the opening inside, and the mating connector is inserted in the vicinity of the opening. A metal shell made of a metal tubular body having a butt-joined portion in which a pair of opposing short sides are abutted with a gap provided therebetween, and the contact is formed inside the mold from the inner wall of the metal shell. A step of producing a molded connector using the electrically insulating resin as a connector housing by injecting the electrically insulating resin into the mold after being supported and fixed separately;
(B) Filling the gap between the contact of the molded connector and the metal shell and the connector housing with the waterproof sealant for waterproof sealing, and waterproofing the gap at the butt joint of the metal shell A process of filling the sealant and waterproofing it.   In the step (b), the mold connector is immersed in a container in which a liquid waterproof sealant is stored, the container is placed in another sealed container, and the inside of the sealed container is depressurized to form the metal connector part. 4. The method for manufacturing a waterproof connector according to claim 3, wherein the waterproof sealant is filled with a gap between the electrically insulating resins for waterproof sealing. The method for manufacturing a waterproof connector according to claim 3, wherein the step (a) includes the following steps (c) to (e):
(C) A contact and metal shell integrated forming step in which a highly conductive metal plate of a predetermined size is punched and bent and connected to a carrier with a connecting piece, and the contact and the metal shell are integrally formed;
(D) A mold is disposed around the contact and the metal shell integrally molded in the step (c), an electrically insulating synthetic resin is injected into the metal shell, and the contact is molded to form a resin. A housing molding step of molding the housing comprising the body,
(E) A carrier cutting step of cutting the contact, the metal shell, and the connecting piece from the carrier after molding the housing in the step (d).   In the step (d), the contact and the metal shell integrally molded in the step (c) are surrounded by a mold, the electric insulating resin is injected into the metal shell, and the outer periphery is covered. The method for manufacturing a waterproof connector according to claim 5, wherein the housing made of a resin molded body integrally molded is molded.   The waterproofing according to claim 3, wherein the metal shell is provided with a mounting fixing piece and a ground terminal to be mounted on a circuit wiring board or the like on the outer periphery, and these portions are also molded with the electrically insulating resin. A method for manufacturing a connector.   The method for manufacturing a waterproof connector according to claim 5, wherein the connecting piece is the ground terminal.   4. The waterproof connector according to claim 3, wherein a cleaning process is added after the step (b) to remove the waterproof sealant adhering to the external electrical connection portion of the metal connector part in the cleaning process. Method.   The method for producing a waterproof connector according to claim 3, wherein the waterproof sealant is in a liquid state before being filled in the gaps of the molded connector and solidifies after being filled.

Images