JPH0869851A - Electric harness and its preparation - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an electric harness that is easy to structure and assemble and is suitable in automobile air bags, and to provide a manufacturing method. SOLUTION: An electrical component 32 and crimp terminals 86, 88, and 90 are inserted and held in a housing 4. Leeds 34a and 34b of the electrical component 32 are crimped to, and a conductor 18 of a cable 16 is connected to each of these terminals. A cover 8 in united with the housing 4 and an over- mold portion 12 is molded, thereby sealing and integrating a strain relief for the cable 16 therewith.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention particularly relates to an electric harness having a connector for eliminating the influence of noise and the like and a method for manufacturing the electric harness.

[0002]

BACKGROUND OF THE INVENTION Automotive airbags are inflated by an initiator having a squib that is electrically triggered by a current generated by a control system. This control system is connected to the initiator by a wire harness, and this wire harness is generally provided with an electrical connector that allows the initiator and the control system to be easily interconnected after they are individually assembled. Is. According to a typical design, the initiator is attached to the air bag assembly from which tabs or pin-shaped male terminals extend to contact the receptacle (female) terminals of the electrical connector. This allows the use of a simple plug-in assembly.

It is known to incorporate an electrical suppression device in the circuit to suppress (suppress) the signal to the initiator in order to prevent false activation of the initiator by spurious signals. This prevents false signals, which are generally not as large as the trigger signal, from erroneously triggering the initiator, preventing erroneous activation of the air bag device and allowing the trigger signal to perform a predetermined function.

British Patent Application No. 2,267,188A discloses an electrical connector for connecting the conductors of a flat cable of a wire harness to the terminals of an initiator. In this connector, the connector terminals are soldered to the respective cable strips and then extend in the orthogonal direction. One end of an electrical component, for example a choke coil, is connected to a conductive strip and the other end is connected to an extension of its conductor which is electrically isolated from it by an opening. This extension is then interconnected to one of the interconnect terminals, thereby incorporating the suppression device within the conductive path. Electrical components such as this suppression device may be soldered to the conductive strips as well as the connector terminals. All of which are incorporated into a two-piece connector housing that snaps together and includes interengageable spikes / cavities that extend through the cable insulation to secure the flat conductor cable to the connector pin contacts. I'm out.

Another connector useful for the above applications is assigned European Patent Application No. 0600 to the present applicant.
411-A1. In this connector, the insulation includes a plurality of electrical terminals whose housing has wire terminations that are connected to the conductors of the insulated wire. These terminations are formed at right angles to the fittings that make electrical contact with the contacts of the initiator. Lead receiving slots are provided between the termination and mating portions to engage the leads of the restraining device without soldering. All of these are housed in an insulating housing with a latch cover with retention arms to keep the restraining device in place.

[0006]

Since a large number of air bag assemblies are incorporated into vehicles, further modification of the manufacturability of these connectors is necessary. In particular, when incorporating the airbag into the steering wheel of an automobile, the conductor must be wound in a helical shape so that it can follow the rotation of the steering wheel, so the strain relief between the connector housing and the conductor must be ensured. Need to Further, it is preferable to ensure that the connector housing is maintained in the closed position after holding the components in the assembly to ensure device integrity.

Therefore, the present invention has been made in view of the above problems of the conventional electric harness for an air bag assembly, and provides an electric harness having a simple and easy structure and assembly, and a method for manufacturing the electric harness. With the goal.

[0008]

In order to achieve the above-mentioned object, an electric harness of the present invention includes a housing for holding an electric component and a plurality of terminals, and a plurality of terminals inserted from a cable insertion end of the housing. A cable connected to a selected terminal of the housing and a cover incorporated into the housing. This electric harness is characterized by having an overmolded part (boot) overmolded on the outer periphery of the cable insertion end of the housing and the cover that are combined.

Further, according to the method of manufacturing an electric harness of the present invention, the electric component is arranged in the housing, and the pressure contact terminal is inserted and held in the housing for pressure connection with one lead of the electric component. Inserting another pressure contact terminal into the housing for pressure contact connection with another lead of the electric component, engaging a cover with the housing to enclose a plurality of terminals and electric components, and overmolding the cover and the housing. Overmolding the part (boot).

According to the present invention, since these components or elements are assembled and manufactured by moving them in the common axis direction, they are extremely suitable for automatic assembly using a robot and can be manufactured at low cost.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION Preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that terms such as “upper” and “lower” are used here for convenience of description of the present invention and are used in relation to the illustrated embodiment.
In other words, it should be understood that the present invention can be readily implemented or applied in other orientations.

First, a description will be given with reference to FIG. The electrical harness 1 according to the invention comprises an electrical connector 2. The electrical connector will be simply referred to as a connector hereinafter. The connector 2 comprises a housing 4 having a mating projection 6 which is received by a mating device. A cover 8 is arranged on the housing 4. Strain relief 10 from inside cover 8
Extends to the rear of the housing 4. The strain relief 10 includes a cover 8 and a boot 12 overmolded around the rear end of the housing 4. A flexible flat cable (FFC) 1 of an electric harness 1 that is integrally molded from the boot 12 and has a strain relief tail portion 14 extending therein and a conductor 18 inside.
6 is enclosed and prevents the electrical connections within the connector 2 from being affected by external forces applied to this cable 16.

The fitting protrusion 6 has a substantially cylindrical shape and has a notch 20.
a and 20b are formed on the front and rear surfaces. A pair of circular openings 24, 26 open into the bottom surface 22 of the mating protrusion 26, through which the terminals of a mating electrical device (not shown) are received and provide electrical interconnection therebetween. Mating protrusion 6
Can be of any shape depending on the device to be fitted.

Next, the housing 4 will be described with reference to FIG. The housing 4 has a front portion 28 including a device receiving area 30 and an electrical component 32 such as a capacitor, resistor or high frequency choke provided therein to prevent spurious electromagnetic radiation from being transmitted to the device. The electrical component 32 is
In this case, a pair of conductive members 34a, 3 which are electric leads.
4b is included. The component receiving area 30 of the front portion 28 includes a plurality of upstanding component positioning and holding members 36a-g,
It ensures that the part 32 is properly placed and held securely in the housing 4. The leads 34a and 34b extend to the first support structure 38 and the third support structure 40, respectively.

The first and third support structures 38 and 40 have the same shape and dimensions, and are identified by suffixing a and b,
The following is a summary. Each support structure 38, 40
Includes front support portions 42a, b and rear support portions 44a, b. Longitudinal receiving slot (channel)
46a and 46b are front supporting portions 42a and 42b and rear supporting portions 44.
The lead 34 of the electric component 32 extends through a and b.
Accepts a and 34b. The front supports 42a, b are separated slots 48a extending across the channels 46a, b.
It is separated from the rear support parts 44a, b by b. Receiving channels 46a, b and separation slots 48a, b open above and have tapered surfaces around them to assist in automated assembly of the components described below.

Behind the first support structure 38, the central post 5
A first strap support structure is provided that includes lateral legs 50 located in opposite directions from 2 and forms a first strap channel 56 between a central post 52 and a bottom support 54. The first holding channel 57 extending rearward of the strap channel 56 and orthogonal to the strap channel 56 has the lateral legs 5.
0 and the opposing slot of the central post 52. A second lateral leg 58 is formed on both sides of the central post 52 and at a distance from the central post 52. The second lateral leg 58 has the same structure and function as the lateral leg 50 described above. A second bottom support 60 is disposed between the central post 52 and the second lateral leg 58, thereby forming a second strap channel 62. A second strap channel 56 which is behind the first strap channel 56 and extends orthogonally thereto.
A retention channel 63 is formed by the opposing slot of the lateral leg 58 and the central post 52. The first and second holding channels will be described below.

A first terminal receiving post 64 is formed in front of the second strap channel forming the structures 52, 58, 60 and extends in communication with the circular opening 26 through the base of the front portion 28. The second terminal receiving post 6 is provided behind the third support structure 40 and adjacent to the first terminal receiving post 64.
6 is provided in communication with the circular opening 24. This first
And the second posts 64, 66 allow electrical interconnection from within the front portion 28 of the housing 4 to the terminals of a mating device (not shown).

First and second strap channels 56,
Behind 62 is a bulkhead 68. Guide grooves 70a, 70b extend into the front portion 28 across the bulkhead 68. A channel 72 is provided on the outer circumference of the bulkhead 68.
Is formed by a flange 74 spaced from a rear surface 76 of the housing 4. The channel 72 may be partitioned by a longitudinally extending rib between the rear surface 76 and the flange 74, as described below with reference to the cover 8. Further, a frame 78 extends rearward from the bulkhead 68. The frame 78 is formed by parallel and spaced lateral rails 80a, b, one side of which is connected to the bulkhead 68 and the other side is connected by a tie bar (connecting rod-like body) 82,
An opening 84 is formed between them. A tubular boss 83 stands up from the tie bar 82 to position the cover 8 during assembly as described later. A boss receiving structure 85 is disposed adjacent to the first support structure 38 on the front portion 28 of the housing 4 to position the cover 8.

Above the components described above in FIG. 2 is a first interconnect member 86, a second interconnect member 88 and a third interconnect member 90. The first interconnect member 86 is configured to connect to an electrical lead (hereinafter simply referred to as lead) 34a and extends to one of the electrical component 32 and the conductor 18 of the cable 16 in the receiving channel 46a. The second interconnection member 88 is a terminal of the mating device and the other conductor 1 of the cable 16.
It is configured to be connected to one of the eight. The third interconnect member 90 has another lead 34b extending from the electrical component 32.
And is connected to one of the terminals of the other device. When the combination of these interconnection members 86, 88, 90 is connected to the electrical component 32 and the conductor 18 of the cable 16, it provides an electrical interconnection between the cable 16 and a mating device (not shown) within the device. A suppression device 32 is added in the circuit to prevent the entry of spurious signals into it.

Simultaneously with the second and third interconnect members 88, 90, the first interconnect member 86 is manufactured from a conductive metal material by conventional stamping and bending processes. First
The interconnection member 86 includes an electrical component connection end 92a, a conductor connection end 94a and a strap 96a therebetween. The electrical component connecting end 92a has a tab 100a bent downward.
And finger-shaped portions (fingers) 102a and 102b divided by the conductor connection (pressure contact) slot 104.

The insertion slot 10 is provided at the lower end of the press contact slot 104.
Have six. The insertion opening 106 is tapered inward. When the insulating layers of the connection devices 34a, 34b of the electric component 32 are formed of enameled wires such as general insulated wires or magnet wires, the pressure welding slot 1
Opposing cut surfaces 108a and 108b are formed in the lower part of 04, and the insulating layer is cut during the pressure contact connection to completely expose the conductor.

In this embodiment, the connecting portion 92a has the same structure as a terminal commercially available under the trademark of MAG-MATE from the amplifier company of the home country. A notch 110 is continuously formed in the press contact slot 104 to form fingers 102a and 102a.
Gives elasticity to b. A hole 112a is formed behind the downward facing tab 100a and is used for automatic assembly of the device 2, and the pilot of the insertion tool fits into the hole 112a and makes a correct positioning. The strap portion 96a extends behind the hole 112a. Front strap part 11
4a extends continuously from the electrical component connecting end 92a to the rear strap portion 116a offset by the intermediate step 118a located below. Opposite barbs 119a are provided along this step 118a to bite laterally into the retention channel 57 when the interconnection member 86 is inserted into the housing 4. The rear part 116a reaches the standing conductor connecting end 94a.

The conductor connection end 94a of the illustrated embodiment is preferably formed for interconnection with a flexible flat cable (FFC) 16. Here, a plurality of standing ears 120
Is provided and the outer surface forms a cutting edge and is particularly sharply formed to penetrate the insulating layer on the same surface of the conductor 18 of the FFC 16. Then, this tip portion is crimped (caulked) and comes into contact with the periphery of the conductor 18 to establish an electrical connection. In the illustrated embodiment, the conductor connecting portion 94a is open upward, and the embossing 123 is formed for good connection.

The second interconnect member 88 has a terminal connecting end 126.
a, which is interconnected to the conductor connecting end 94b via the central strap portion 96b. Conductor connection end 94b and central strap portion 96b are similar in construction to those described above for first interconnect member 86, and therefore description will not be repeated here. The terminal connecting end 126a arranged at the front side is composed of a pair of facing cantilever arms 128a and 128b facing downward.
These arms are of conventional construction and have a base 130.
Extends forward from and is substantially parallel to the front. This is done before connecting surface 130 before diffusing to form terminal receiving area 132.
Mutually converge toward a and b. Here, the terminals of the device are inserted to make electrical contact. Terminal connection portion 126a
Is configured to fit within port 64 so that the terminals are interconnected with it.

The third electrical interconnect member 90 comprises a forward-positioned electrical component contact end 92b having a similar construction as described above with respect to the component contact end 92a of the first interconnect member 86.
The hole 112b is formed for the same purpose as described above. The strap portion 96c interconnects the electrical component contact end 92b with an electrical terminal contact end of similar construction as the electrical terminal contact end 126a of the second interconnect member 88. The third interconnection member 90 has a strap portion 96c. This is a U-shaped member that extends between the electrical component contact end 92b and the terminal contact end 126b. The electrical terminal contact end 126b is configured to fit within the port 66 and contacts a terminal inserted through the circular opening 24.

Each interconnect member 86, 88, 90 is depressed downward as indicated by arrows A1, A2, A3, respectively, to move the housing 4
Is inserted into. Prior to the insertion of the first interconnect member 86, the leads 34a of the electrical component 32 are connected to the receiving channel 46.
It extends into a and straddles the separation slot 48a and is supported on both sides thereof. Then push down on the interconnecting member 86, tab 1
00 is aligned with and pressed into the separation slot 48a. During pressing of the interconnection member 86, the lead 46
a enters the slot 104, and cuts and removes the insulating layer at the cut surfaces 108a and 108b to make electrical connection. Consistent with the contact of the device 32, the intermediate step 118a is received within the first retention channel 57, the barb 119a bites into the first side wall 50 and interferes with the central post 52 to allow the interconnection member 86 to be assembled and Prevents separation during subsequent use. The front strap portion 114a is the first strap channel 5
6 and extends rearwardly therefrom and the rear part 116a of the strap 96a is arranged in the guide groove 70a. As a result, the conductor connecting end 94a is located in the opening 84 of the frame 78.

The second interconnect member 88 is inserted in the direction of arrow A2 so that the terminal contact end 126a is aligned with the port 64 and received therein. Intermediate step 118
b is received in the second retaining channel 63 and retains the interconnect member 88 in the manner described above. Front strap part 1
14b is located in the second strap channel 62,
The rear portion 116b of the strap portion 96b is held and supported.
Are received in the guide groove 70b. The conductor connecting end 94b of the interconnecting member 88 is the conductor connecting end 9 of the first interconnecting member 86.
It is arranged in the opening 84 of the frame 78 similarly to 4a.

The third interconnection member 90 is inserted into the housing 4 in the direction of arrow A3. Tab 1 of component contact end 92b
00b straddles lead 34b received in channel 46b in a manner similar to that described above for first interconnect member 86. Further, the terminal connection end 126b is aligned with and received by the port 66, and the strap portion 96c which contacts the electric terminal of the counterpart device penetrating the circular opening 24 is superposed on the support member 134.

As is apparent from FIG. 2, the housing 4 in which the parts are received has a sufficiently tapered surface to assist in the insertion of the parts. These tapered surfaces facilitate insertion of mating parts. The component contact portions 92a and 92b of the first interconnection member 86 and the third interconnection member 90 are inserted in the insertion directions A1 and A3.
Since it is opened to the connection lead 34 of the electrical component 32
Solder interconnections with a, b are made when the interconnection members 86, 90 are inserted into the housing 4.

According to the assembly described above, a partially assembled electrical connector 2 is shown in FIG. The cover 8 includes a front retaining arm 136 having a barb 138 that engages a ledge 140 of the housing 4. There is a latch strap 142 that is arranged rearward and along the side of the cover 8, and each latch strap 142 extends downward from the latch strap 142.
Has an opening 144 therein to receive a latch 146 located on a component 148 of the connector housing 4 configured to receive the strap 142. The latch 146 has a cam surface 150 and allows the strap 142 to expand and
42 passes over the latch 146 so that the latch 146 opens 1
44 to be accepted.

Behind the strap 142 is an upper bulkhead 150, which corresponds to the lower bulkhead 68. The upper bulkhead 150 has a rear surface 15 of the cover 8.
4 includes a flange 152 spaced rearwardly from which a channel 156 is formed. The channel 156 is partitioned by a plurality of ribs 158 into the cavity, the purpose of which will be described later. Aft from bulkhead 150, there is a closure frame 160 similar to that described above for frame 78. But for this, the plate 16
2 is added. A holding arm 164 having a barb 166 is arranged below the closed frame 160 and is housed in an opening along the arm 78 of the housing 4. A boss receiving opening 167 is formed at the rear end of the closed frame 160 so that the boss 83 is received during the assembly operation and is accurately aligned by the reaction force when the cover 8 is latched to the housing 4. A boss (not shown) is included as part of the cover 8 and corresponds to the boss receiving structure 85 of the front portion 28 of the housing 4.

In the component assembly shown in FIG. 3, a support member (not shown) used for the purpose of assembly extends upward through the opening 84 of the frame 78 and pushes down the conductor 16 in the direction of arrow B. At this time, the conductor connecting ends 94a and 94b are supported.
This achieves electrical interconnection with the conductor connection ends 94a, 94b. Note that a hole 169 is provided in the cable 16 to provide the boss 83 for positioning the cable, as shown in FIG. The support member is then removed from opening 84 to obtain the component assembly shown in FIG.

Next, description will be made with reference to FIG. Cover 8
Is pushed down in the direction of arrow C, cover 8 and housing 4
Snap-engage with each other to complete the electrical connector 2.
Here, all the assembly work steps are indicated by arrow A, along the common axis.
Since it moves in the B and C directions, it is suitable for automatic assembly.
Once the cover 8 snaps into the housing 4, the connector 2 is placed in a molding machine to overmold the rear boot 12 around the bulkheads 68, 150. The boot 12 extends rearward from the frames 78, 160 to form an integral strain relief tail 14.

The over-molded boot 12 is made of a material such as molten plastic, and the rear frame portion 78,
160 around the bulkheads 68 and 15 respectively.
Boots 12 by flowing into channels 0, 156 of 0
Is securely locked to the housing 4 and the cover 8. When the partition ribs 158 are included, the melt flows into the cavities between the ribs and hardens. Further, by securely locking the boot 12 to the cover 8 and the housing 4, the separation between the boot 12 and the housing 4 is prevented. Furthermore, since the melt is also injected onto the plate 162, it protects the crimp interconnection with the cable 16 formed below and prevents the molding pressure from adversely affecting the crimp connection. Melt is side rail 80
Since it is made to flow into the surroundings of a and b, and the opening 84 is filled from below to be solidified, the crimp connection portion is protected more reliably.

A strain relief tail 14 is formed integrally with the outside of the boot 12 along the conductor cable 16. This strain relief tail 14 is a cable 16
Tie bar (connecting rod) 17 extending along and surrounding one end of the
Contains 0. Also, a plurality of spaced straps 17
2 extends from the tie bar 170 across the cable 16 and around the other end. There is a circular opening 174 along this tie bar 170 and corresponding to each strip 72. The physical engagement of the cable 16 can be enhanced by providing openings along the insulation or by forming irregularities on the surface, and the melt forming the strain relief tail 14 flows in contact therewith. Note that other forms of strain relief can be used.

[0036]

According to the electric connector of the present invention, all the assembling work is performed only in the direction along the common axis, which is suitable for automatic assembly. In addition, the interconnections do not produce solder or the high heat and chemical derivations that accompany them, resulting in easy assembly and highly reliable connections. Furthermore, since the cover is securely held by overmolding the strain relief boot around the cover and the housing, the components included therein are not displaced. Finally, by integrally molding the strain relief tail with the strain relief boot, the external force applied to the insulated cable is directly transmitted to the housing and the cover, which does not prevent the cable from being interconnected with the conductor. It has a remarkable practical effect.

[Brief description of drawings]

1 is a bottom perspective view of an electrical harness having a connector according to the present invention. FIG.

2 is a partially exploded upper perspective view of the electrical connector of FIG. 1. FIG.

FIG. 3 is an upper perspective view of the electric connector of FIG. 1 partially disassembled and further assembled.

4 is a further assembled and partially exploded top perspective view of the electrical connector of FIG. 1. FIG.

5 is an upper rear perspective view of the electrical harness and connector of FIG.

[Explanation of symbols]

 1 Electrical Harness 4 Housing 8 Cover 16 Cable 32 Electrical Parts 34a, 34B Lead 12 Overmolded Part (Boot) 86, 88, 90 Terminal

Claims (2)

[Claims] 1. A housing in which an electric component and a plurality of terminals are held, a cable inserted from a cable insertion end of the housing and connected to a terminal selected from the plurality of terminals, and the housing are united. An electric harness comprising: a cover; and an overmolded portion overmolded on an outer periphery of the cable insertion end of the combined housing and cover. 2. An electric component is arranged in a housing, a pressure contact terminal is inserted and held in the housing to make pressure contact with a lead of the electric component, and a cover is engaged with the housing to connect the terminal. And encapsulating the electric component, inserting another pressure contact terminal into the housing for pressure contact connection with another lead of the electric component, and overmolding a boot on the cover and the housing. A method of manufacturing an electrical harness including.