WO2013022117A1

WO2013022117A1 - Connector and manufacturing method of connector

Info

Publication number: WO2013022117A1
Application number: PCT/JP2012/070718
Authority: WO
Inventors: Hajime Kato; Masayuki Kataoka; Hiroki Komatsu; Takeshi Innan
Original assignee: Yazaki Corporation
Priority date: 2011-08-11
Filing date: 2012-08-08
Publication date: 2013-02-14
Also published as: JP2013041677A; CN203721948U

Abstract

To provide simplification of a connector and improvement in quality of the connector by preventing deformation of a primary molded part to ensure waterproofness. A connector 10 is fixed so as to cover an exposed portion of a conductor 21 of a wire harness 20 including the conductor 21 and a coating part 22. The connector 10 includes a terminal 30, a primary molded part 40 and a secondary molded part 50. The terminal 30 includes a terminal part 31 and a connection part 32. The primary molded part 40 includes a body 41 and a top part 42. The body 41 is molded by injection molding so as to cover the conductor 21, the terminal part 31 and the connection part 32. The secondary molded part 50 is molded by an injection molding method so as to cover substantially the whole primary molded part 40 and a part of the terminal part 31.

Description

DESCRIPTION

CONNECTOR AND MANUFACTURING METHOD OF CONNECTOR Technical Field

The present invention relates to a connector which is mounted in a vehicle such as an automobile and is fixed integrally to a wire harness, and a manufacturing method of the connector. Background Art

A connector which is mounted in a vehicle etc. and is fixed integrally to a wire harness, and a manufacturing method of the connector are known. One example of this kind of connector is shown in Fig. 4 (see Patent Reference 1).

Fig. 4 is a sectional view showing a conventional connector. A connector 100 is formed in a distal end of a wire harness 200, and includes a terminal 300 connected to a conductor 210 of the wire harness 200, a primary molded part 400 with which the conductor 210 and a coating part 220 are covered, and a secondary molded part 500 with which the primary molded part 400 and the coating part 220 are covered. Also, the connector 100 includes a first sealing member A arranged in the portion of bonding between the primary molded part 400 and the coating part 220, this bonding portion sealed with the first sealing member A, and a second sealing member B arranged in the portion of bonding between the secondary molded part 500 and the coating part 220, this bonding portion sealed with the second sealing member B. The fact that the primary molded part 400 and the secondary molded part 500 are molded by a processing method for pressurizing and injecting an insulating resin into a metallic mold and filling the metallic mold with the resin, the so-called injection molding is disclosed.

The adjacent portion of the terminal 300 and the coating part 220 is integrally covered with the primary molded part 400 to improve insulation resistance, waterproofness and dust resistance of this adjacent portion. Further, the exposed portion of the conductor 210 and the portion of connecting between the terminal 300 and the conductor 210 are covered with the primary molded part 400. By covering all the exposed portion of the conductor 210 with the primary molded part 400, insulation resistance of the exposed portion of the conductor 210 is ensured similarly. Also, the primary molded part 400 and the wire harness 200 are integrally covered with the secondary molded part 500, so that the primary molded part 400 is inhibited from being displaced relatively to the wire harness 200. Further, the fact that durability of a waterproof structure is achieved by preventing water through a gap between the coating part 220 and the primary molded part 400 or the secondary molded part 500 from entering the inside of the connector 100 by the first sealing member A and the second sealing member B made of a liquid seal material having viscosity, for example, silicone is disclosed.

Citation List

Patent Literature

[PTL 1] Japanese Patent Publication No. JP-A-2008-269858 Summary of Invention Technical Problem

The connector 100 described in PTL 1 requires the first sealing member A and the second sealing member B in order to ensure waterproofness of the connector 100. Assembly of the first sealing member A is required after the primary molded part 400 is molded, and also assembly of the second sealing member B is required after the secondary molded part 500 is molded. Therefore, a working process increases and also the number of components increases, and there were disadvantages of having a complicated structure and increasing cost.

Hence, the present applicant has eliminated the first sealing member A and the second sealing member B of the structure of the connector 100 described in PTL 1 , and has devised a structure and a method capable of ensuring waterproofness by the primary molded part 400 and the secondary molded part 500. A connector 100S as a prior invention and a manufacturing method of the connector 00S will be described based on Figs. 3A and 3B.

Fig. 3A is a sectional view of the connector, and Fig. 3B is a sectional view including a metallic mold at the time of molding.

The connector 100S of the prior invention is arranged in the vicinity to which a conductor 21 OS of a wire harness 200S is exposed, and includes a primary molded part 400S with which the top of a coating part 220S of the wire harness 200S is covered, and a secondary molded part 500S with which substantially the whole primary molded part 400S, an exposed portion of the conductor 21 OS and a part of a terminal 300S electrically connected to the conductor 21 OS are covered. The secondary molded part 500S is molded after the primary molded part 400S is molded on the coating part 220S. In that case, the primary molded part 400S is supported and fixed by a metallic mold 600S. A resin material for molding the secondary molded part 500S is injected from a gate 620S into a space part 61 OS formed by the metallic mold 600S, the terminal 300S and the primary molded part 400S to form the secondary molded part 500S.

In such a prior invention, a gap D may first occur between the metallic mold 600S and the coating part 220S of the wire harness 200S. This is because a part of the primary molded part 400S cannot be pressed by the metallic mold 600S due to variations in dimensions of the coating part 220S of the wire harness 200S. Also, the primary molded part 400S may be deformed by applying an injection pressure to an end face of the primary molded part 400S at the time of injection molding of the secondary molded part 500S. This is because the pressure applied to the end face of the primary molded part 400S is transmitted to the inside of the primary molded part 400S, with the result that a part of the primary molded part 400S is deformed and protrudes from the metallic mold 600S (see arrows Y1→Y2→Y3 of Fig. 3B).

Therefore, in the connector 100S of the prior invention, it was found that a waterproof function may be damaged by deforming a shape of the primary molded part 400S by a holding pressure, an injection pressure and a resin temperature at the time of injection in the case of molding the secondary molded part 500S. Also, when a shape of the secondary molded part 500S is complicated, there is a possibility that deformation of the primary molded part 400S cannot be inhibited on only molding conditions, and it was simultaneously found to have problem points of, for example, causing trouble such as a sink in the secondary molded part 500S. As described above, the connector of the prior invention and the manufacturing method of the connector had a problem that waterproofness of the connector cannot be ensured since the primary molded part is deformed at the time of molding of the secondary molded part.

The invention has been implemented in view of the circumstances described above, and an object of the invention is to provide simplification of a connector and improvement in quality of the connector by preventing deformation of a primary molded part to ensure waterproofness.

Solution to Problem

In order to achieve the object described above, a connector according to the invention and a manufacturing method of the connector are characterized by the following (1) and (2).

(1) A connector fixed integrally to a distal end of a wire harness, comprising a terminal, a primary molded part, and a secondary molded part, wherein the terminal comprises a terminal part, and a connection part electrically connected to a conductor of the wire harness,

the primary molded part has a body, and a top part which extends from the body and is thinner than said body, and the body is formed so as to cover a part of the terminal part of the terminal, the connection part, and a part of the conductor exposed from a coating part of the wire harness, and the top part is formed so as to cover the coating part of the wire harness, and

the secondary molded part is formed so as to cover the body, a part of the top part, and a part of the terminal part of the terminal.

(2) A manufacturing method of a connector fixed integrally to a distal end of a wire harness,

wherein a connection part of the terminal is electrically connected to a conductor of the wire harness,

a primary molded part is injection-molded so as to cover a part of a terminal part of the terminal, the connection part, and a part of the conductor exposed from a coating part of the wire harness with a body, and cover the coating part of the wire harness with a top part thinner than the body, respectively, and

a secondary molded part is injection-molded so as to cover the body of the primary molded part, a part of the top part of the primary molded part, and a part of the terminal part of the terminal.

According to the connector with the configuration of the above (1), a positional relation among the terminal, the conductor and the coating part becomes stable by the body, and an injection pressure generated at the time of molding of the secondary molded part is inhibited from acting on the top part of the primary molded part, and displacement of the top part of the primary molded part can be prevented. Therefore, the top part of the primary molded part makes close contact with the coating part and water can be prevented from entering a gap between the top part and the coating part, and the connector with good waterproofness can be provided.

According to the manufacturing method of the connector with the configuration of the above (2), the secondary molded part is molded so as to cover substantially the whole primary molded part after the primary molded part is adhesively fixed to the terminal, the conductor and the coating part, so that deformation or movement of the top part of the primary molded part due to the injection pressure at the time of molding of the secondary molded part is prevented, and a force of adhesion between the wire harness and the primary molded part after molding is increased, and the connector with good waterproofness can be manufactured.

Advantageous Effects of Invention

According to the invention, at the time of molding of the secondary molded part, deformation of the top part of the primary molded part can surely be inhibited by the body of the primary molded part and further, the primary molded part becomes pressed and bonded by the secondary molded part, and a force of adhesion between the wire harness and the primary molded part is enhanced, and the connector with good waterproofness and the manufacturing method of the connector can be provided.

The invention has been described above briefly. Further, the details of the invention will become more apparent by reading through a mode for carrying out the invention described below with reference to the accompanying drawings.

Brief Description of Drawings

Figs. 1A and 1 B show a connector of a first embodiment according to the invention, and Fig. 1A is a sectional view, and Fig. 1 B is a sectional view including a metallic mold.

Figs. 2A and 2B show other embodiments of the connector according to

Figs. 1A and 1 B, and Fig. 2A is a sectional view of a second embodiment, and Fig. 2B is a sectional view of a third embodiment. Figs. 3A and 3B show a connector according to a prior invention, and Fig. 3A is a sectional view, and Fig. 3B is a sectional view including a metallic mold.

Fig. 4 is a sectional view of a conventional connector.

Description of Embodiments

Preferred embodiments according to the invention will hereinafter be described based on the drawings. [First embodiment]

A connector 10 which is a first embodiment of the invention will be described based on Figs. 1A and 1 B.

Figs. 1A and 1 B show the connector of the first embodiment according to the invention, and Fig. 1A is a sectional view, and Fig. 1 B is a sectional view including a metallic mold. The connector 10 is arranged in the distal end of a wire harness 20. The wire harness 20 includes a conductor 21 and a coating part 22, and the connector 10 is fixed so as to cover an exposed portion (the distal end of the wire harness 20) of the conductor 21. On the other hand, the connector 10 includes a terminal 30, a primary molded part 40 and a secondary molded part 50.

The terminal 30 includes a terminal part 31 extending in substantially a linear shape, and a connection part 32 extending from the terminal part 31. The connection part 32 of the terminal 30 is electrically connected to the top of the conductor 21.

The primary molded part 40 is made of thermosetting resin elastomer, and includes a body 41 with a large diameter shape and substantially a rectangular cross section, and a tubular top part 42 which extends from the body 41 and is thinner than the body 41. The body 41 is annularly formed by injection molding so as to cover each of the whole peripheries of the exposed portion of the conductor 21 , a part of the terminal part 31 of the terminal 30 and the connection part 32. Also, the top part 42 extends from the distal end of the coating part 22 toward the back (a direction opposite to the terminal 30) along the coating part 22, and is annularly formed by injection molding so as to cover the whole periphery of the coating part 22.

The body 41 is formed so as to enhance insulation resistance and greatly project in an outward direction of the connection part 32. The top part 42 is formed thinner than the body 41 along the coating part 22 in order to prevent water from entering a gap between the coating part 22 and the top part 42. The primary molded part 40 ensures insulation properties of the terminal 30 and the wire harness 20, and determines a relative positional relation between the terminal 30 and the wire harness 20.

The secondary molded part 50 is made of a deformation-resistant insulating resin such as a polyester resin or a polyamide resin, and is annularly molded by injection molding so as to cover a part of the terminal part 31 of the terminal 30 and substantially the whole primary molded part 40 excluding a part of the top part 42 of the primary molded part 40. That is, the secondary molded part 50 is formed so as to press the whole primary molded part 40 in order to increase adhesion of the primary molded part 40. Further, a step in a height direction is formed by a difference between the body 41 and the top part 42 in an outside diameter. As a result, an injection pressure at the time of molding of the secondary molded part 50 is made resistant to acting on the top part 42, so that deformation in the top part 42 can be inhibited. Also, the secondary molded part 50 has a function as a housing of the connector 10.

The connector 10 is formed in the following procedure (see Fig. 1B). Step 1 : The conductor 21 is electrically connected to the terminal 30, and the primary molded part 40 is annularly molded by injection molding so as to cover the connection part 32 of the terminal 30, the exposed portion of the conductor 21 and a part of the coating part 22. In that case, a part of the terminal part 31 , the connection part 32 and the conductor 21 are covered with the body 41 of the primary molded part 40, and the body 41 is formed thicker than the top part 42, and the coating part 22 is covered with the top part 42, and the top part 42 is formed in a tubular shape thinner than the body 41 along the coating part 22.

Step 2: The coating part 22, the terminal 30 and the primary molded part 40 are pinched by a metallic mold (a cavity core) 60. In that case, a space part 61 is formed inside the metallic mold 60 by the metallic mold 60, the terminal 30 and the primary molded part 40.

Step 3: A secondary molding resin material is injected into the space part 61 through a gate 62 for resin injection of the metallic mold 60, and the secondary molded part 50 is molded.

At the time of injection molding, an injection pressure is applied to the primary molded part 40, but a force by which the injection pressure acts on the top part 42 is reduced by the body 41 and deformation of the top part 42 can be prevented. Therefore, a state of adhesion of the primary molded part 40 to the coating part 22 is held, and water can be prevented from entering a gap between the primary molded part 40 and the coating part 22. Also, the secondary molded part 50 is molded so as to surround the primary molded part 40 and its contact area increases and the primary molded part 40 made of elastomer is elastically pressed and bonded, with the result that the primary molded part 40 can be brought into close contact with the wire harness 20.

[Second embodiment]

Fig. 2A is a sectional view showing a second embodiment. A body 41 of a primary molded part 40 is formed in substantially a circular cross section. At the time of injection molding of a secondary molded part 50, an injection pressure is equally dispersed and deformation of the primary molded part can be minimized.

[Third embodiment]

Fig. 2B is a sectional view showing a third embodiment. An end face opposite to a top part 42 in a primary molded part 40 and an end face positioned in the side of a terminal part 31 in a secondary molded part 50 are formed as even flat surfaces while covering a part of the terminal part 31 of a terminal 30 with the end faces. A connector 10 configured thus can be miniaturized as compared with the connectors 10 of the first and second embodiments.

As described above, the connector 10 according to the embodiments of the invention includes the terminal 30, the primary molded part 40 and the secondary molded part 50, and is fixed in the vicinity of the distal end of the wire harness 20. The primary molded part 40 includes the elongated top part 42 formed along the coating part 22 of the wire harness 20, and the body 41 which is thicker than the top part 42 and is formed so as to cover a part of the terminal part 31 of the terminal 30, the connection part 32 and the conductor 21. Also, the body 41 is covered with the secondary molded part 50 which is formed so as to cover a part of each of the top part 42 and the terminal 30.

According to this configuration, a relative positional relation among the terminal 30, the conductor 21 and the coating part 22 becomes stable by the body 41 and also, an injection pressure generated at the time of molding of the secondary molded part 50 is inhibited from acting on the top part 42 and thereby, displacement of the top part 42 of the primary molded part 40 can be prevented. Therefore, the top part 42 of the primary molded part 40 makes close contact with the coating part 22 and water can be prevented from entering a gap between the top part 42 and the coating part 22, and the connector 10 with good waterproof ness can be provided.

Also, the connector 10 according to the embodiments of the invention includes the body 41 which greatly projects in an outward direction of the connection part 32 and has substantially a rectangular or circular cross section. Therefore, vertical and horizontal movement of the primary molded part 40 at the time of molding of the secondary molded part 50 can be inhibited.

Also, in a manufacturing method of the connector 10 according to the embodiments of the invention, the connection part 32 of the terminal 30 is first electrically connected to the conductor 21 of the wire harness 20. Next, the primary molded part 40 is injection-molded so as to cover a part of the terminal part 31 of the terminal 30, the connection part 32 and the conductor 21 with the large-diameter body 41 , and cover the coating part 22 of the wire harness 20 with the elongated top part 42, respectively. Then, it is characterized in that the secondary molded part 50 is injection-molded so as to cover a part of the terminal part 31 of the terminal 30 and substantially the whole primary molded part 40 excluding a part of the top part 42 of the primary molded part 40.

According to this manufacturing method, the secondary molded part 50 is molded so as to cover substantially the whole primary molded part 40 after the primary molded part 40 is adhesively fixed to the terminal 30, the conductor 21 and the coating part 22, so that deformation or movement of the primary molded part 40 due to the injection pressure at the time of molding of the secondary molded part 50 is prevented, and a force of adhesion between the wire harness 20 and the primary molded part 40 after molding is increased, and the connector 10 with good waterproofness can be manufactured.

In addition, the invention is not limited to the embodiments described above, and modifications, improvements, etc. can be made properly. Moreover, as long as the invention can be achieved, the number of components, materials, shapes, dimensions, numerical values, modes, arrangement places, etc. of each component in the embodiments described above are arbitrary and are not limited.

The body 41 of the primary molded part 40 is described as the rectangular or circular shape in the embodiments, but deformation of the top part 42 is prevented by forming an outside diameter of the body 41 larger than that of the top part 42. Therefore, the shape is not limited to the rectangular or circular shape, and various modifications can be made.

In the embodiments of the invention, one terminal 30 and one wire harness 20 are described in detail, but plural terminals or wire harnesses (for example, arrangement in a parallel state) may be used.

The present application is based on Japanese patent application No.

2011-176084 filed on August 11 , 2011 , and the contents of the patent application are incorporated herein by reference.

Industrial Applicability

The present invention is useful for simplification of a connector and improvement in quality of the connector by preventing deformation of a top part of a primary molded part to ensure waterproofness.

Reference Signs List

10 CONNECTOR

20 WIRE HARNESS

21 CONDUCTOR

22 COATING PART

30 TERMINAL

31 TERMINAL PART

32 CONNECTION PART

40 PRIMARY MOLDED PART

41 BODY

42 TOP PART

50 SECONDARY MOLDED PART

60 METALLIC MOLD

Claims

1. A connector fixed integrally to a distal end of a wire harness, comprising a terminal, a primary molded part, and a secondary molded part,

wherein the terminal comprises a terminal part, and a connection part electrically connected to a conductor of the wire harness,

2. A manufacturing method of a connector fixed integrally to a distal end of a wire harness,