Connector device

Abstract

A connector device includes a connector housing including a plurality of terminal accommodating chambers, a plurality of terminals accommodated in the plurality of terminal accommodating chambers, and a plurality of electric wires configured to be soldered to each of the plurality of terminals. A laser irradiation through-hole is formed on each side wall forming the terminal accommodating chamber, the laser irradiation through-hole is configured to allow the plurality of terminals and the plurality of electric wires to be soldered to each other inside the terminal accommodating chamber, and the laser irradiation through-hole is configured to allow laser light emitted from a laser soldering machine provided outside the connector housing to enter one of the plurality of terminal accommodating chambers.

Description

Technical Field

[0001] The subject of this disclosure relates to a connector device. Background Technology

[0002] Typical wiring harnesses installed in vehicles and other applications consist of numerous bundled and integrated wires, often with complex shapes. Connectors for connecting intended devices are typically attached to the ends of the wires. During the manufacture of the wiring harness, the sheath at the end of each wire, which is covered with an insulator such as resin, is stripped to expose the core wire, and metal terminals are attached to the end of the wire. The terminals are typically clamp terminals, and the exposed distal ends of the wire core and the covered portions of the core wire are clamped to the terminals by fastening. The metal terminals clamped to the wires are then inserted and secured into a predetermined cavity formed within the connector housing, which serves as the connector body.

[0003] Prior art discloses a technique for performing pressure welding within a connector housing. Specifically, a terminal insert includes a U-shaped surround surrounding a core wire within the housing. The core wire and the surround are pressure welded using a pressure welding tool. Due to the surround of the terminal insert, heat generated during the welding process is less likely to be transferred to the connector housing. Therefore, welding can be performed within the connector housing to join the core wire to the terminal insert without damaging the connector housing due to combustion. The surrounding portion further prevents the core wire from loosening through its securing function. Examples of specific methods for pressure welding include resistance welding and ultrasonic welding (see, for example, JPH8-37044A).

[0004] However, when performing pressure welding as in the prior art, the relatively large electrodes of the welding machine need to be inserted near the terminal fitting and the core wire of the wire to be welded, thus necessitating a large opening in the connector housing. Furthermore, it is not easy to position tools such as electrodes at the intended welding positions, reducing the possibility of automated operation.

[0005] When accommodating a large number of wires in a connector, multiple terminals and wires need to be arranged side-by-side along the width and height directions of the connector. However, the techniques used in the prior art are not available when assembling such connectors. Alternatively, multiple connectors need to be prepared, with the terminals and wires arranged in a line in each connector, and the multiple connectors need to be stacked and integrated vertically after the terminals and wires are soldered. Therefore, the manufacturing process will be complex, and the advantages of soldering terminals and wires in the connector housing will be affected. Summary of the Invention

[0006] An illustrative aspect of the subject matter of this disclosure is a connector device that facilitates soldering and avoids complex assembly when terminals are disposed in a connector housing.

[0007] According to an illustrative aspect of the subject matter of this disclosure, a connector device includes: a connector housing comprising a plurality of terminal receiving chambers; a plurality of terminals received in the plurality of terminal receiving chambers; and a plurality of wires configured to be soldered to each of the plurality of terminals. Laser-irradiated vias are formed on sidewalls, each sidewall forming one of the terminal receiving chambers, the laser-irradiated vias being configured to allow the plurality of terminals and the plurality of wires to be soldered to each other inside the terminal receiving chambers, and the laser-irradiated vias being configured to allow laser light emitted from a laser welding machine disposed outside the connector housing to enter one of the plurality of terminal receiving chambers.

[0008] Other aspects and advantages of the subject matter of this disclosure will be set forth in the following description, drawings and claims. Attached Figure Description

[0009] Figure 1 This is a perspective view showing the appearance of the connector housing of a female connector device according to an embodiment of the subject matter of this disclosure;

[0010] Figure 2 It shows along Figure 1 Longitudinal cross-sectional view of the section intercepted by line AA;

[0011] Figure 3 This is a perspective view showing an example of the area ECU, which is the connection counterpart of the connector assembly;

[0012] Figure 4 A and Figure 4 B is a longitudinal cross-sectional view showing different states during the manufacturing process of the connector assembly; and

[0013] Figure 5 A and Figure 5 B is a longitudinal cross-sectional view showing different states during the manufacturing process of the connector assembly. Detailed Implementation

[0014] Specific embodiments of the subject matter of this disclosure will now be described with reference to the accompanying drawings.

[0015] Figure 1 This is a perspective view showing the appearance of the connector housing 11 of a female connector device (connector 10A) according to an embodiment of the subject matter of this disclosure. This embodiment only describes an example of a female connector, and a male connector can also be implemented in a similar manner.

[0016] like Figure 1 As shown, the connector housing 11 forms a connector device that connects a portion of a wiring harness (i.e., the ends of a large number of wires forming the wiring harness) mounted on a vehicle or the like to a mating device.

[0017] Figure 1The connector housing 11 shown is L-shaped. That is, the direction of the connector housing 11 is bent at 90 degrees at the middle part of the connector housing 11, so that the direction of the front end 11a of the connector is different from the direction of the rear end on the opposite side. With this shape, the wires of the wiring harness arranged in the vehicle can be prevented from protruding excessively from the device.

[0018] For example, the connector front end 11a of the connector housing 11 is positioned facing the connector connection portion 10a and moved in the connector insertion and removal direction Az, thereby being fitted into such a position. Figure 3 The connector connection portion 10a of the connector 10B shown.

[0019] exist Figure 1 In the example shown, the five terminal openings 11b arranged along the connector width direction Aw are arranged in three rows along the connector height direction Ay in the connector front end 11a. That is, the connector housing 11 has 15 terminal openings 11b. The male terminal of the connector connection portion 10a is inserted into each terminal opening 11b.

[0020] Figure 2 It shows along Figure 1 A longitudinal cross-sectional view of the section intercepted by line AA. (See diagram below.) Figure 2 As shown, multiple cavities (terminal receiving chambers) 12, which communicate with each terminal opening 11b, are arranged in parallel inside the connector housing 11.

[0021] Each cavity 12 has a rectangular cross-sectional shape and can accommodate a metal terminal 13. The connector housing 11 has 15 wire insertion openings 14 that communicate with each of the 15 cavities 12. Each wire insertion opening 14 has space for a wire connection portion 13b for accommodating the metal terminal 13 and a sheathed wire 30, which will be described later.

[0022] In this embodiment, a predetermined number of metal terminals 13 are pre-placed in each of the 15 cavities 12, and the lower cover 15, the middle cover 16, and the upper cover 17 are respectively installed as follows: Figure 2 The connector housing 11 shown. These components are assembled as a single unit.

[0023] The assembly process is as follows. First, the metal terminal 13 is installed in the lowermost cavity 12 of the connector housing 11, and then the lower cover 15 is installed. Next, the metal terminal 13 is installed in the middle cavity 12 and the middle cover 16 is installed. Finally, the metal terminal 13 is installed in the uppermost cavity 12 and the upper cover 17 is installed.

[0024] Each metal terminal 13 includes a terminal engagement portion 13a and a wire connection portion 13b. The terminal engagement portion 13a has a groove for receiving a pin-shaped male terminal and can engage with the male terminal. The terminal engagement portion 13a also includes a protrusion formed by an elastic member such as a spring, thereby enabling a stable electrical connection.

[0025] like Figure 2 As shown, the wire connection portion 13b of the metal terminal 13 is a flat plate coupled to the terminal mating portion 13a, and is formed in an L-shape in which the middle portion of the wire connection portion 13b is bent at 90 degrees. Therefore, the wire connection portion 13b includes a portion extending along the connector insertion and removal direction Az and another portion extending along the connector height direction Ay.

[0026] Because the connector housing 11 is formed in an L-shape, the multiple cavities 12 arranged side by side in the connector housing 11 along the connector height direction Ay are offset from each other. That is, the length of the cavity 12 along the connector insertion and removal direction Az is the smallest in the lower cavity 12, larger than the minimum length in the middle cavity 12, and the largest in the upper cavity 12.

[0027] Regarding the length of the connector height direction Ay of the multiple wire insertion openings 14 arranged along the connector insertion and removal direction Az. Figure 2 The left wire has the shortest insertion length into opening 14, the middle wire has a longer insertion length into opening 14 than the shortest length, and the right wire has the longest insertion length into opening 14.

[0028] The wire connection portion 13b of the plurality of metal terminals 13 also has an offset corresponding to the relative offset between the plurality of cavities 12 and the wire insertion opening 14. That is, the length of the wire connection portion 13b in the connector insertion and removal direction Az is the smallest among the lower metal terminals 13 in the connector height direction Ay, larger among the middle metal terminals 13, and the largest among the upper metal terminals 13. Due to the offset, the positions of the rear ends of the plurality of metal terminals 13 are shifted relative to each other in the wire insertion opening 14 along the connector height direction Ay. Therefore, the positions of the rear ends of the plurality of metal terminals 13 are shifted so that they do not overlap each other.

[0029] like Figure 2 As shown, the solder portions Px1, Px2, and Px3 of the plurality of metal terminals 13, which are displaced from each other, are displaced from each other along the connector height direction Ay so that they do not overlap, which is similar to the position of the rear end of the metal terminals 13. Therefore, when the metal terminals 13 are installed in each space of the cavity 12 and the wire insertion opening 14 of the connector housing 11, the plurality of solder portions Px1, Px2, and Px3 can be soldered from the outside of the connector housing 11.

[0030] The connector housing 11 also has machining holes at the positions facing the welding portions Px1, Px2, and Px3, so as to receive laser beams for welding from the outside.

[0031] Specifically, a machining hole (through hole) 15a is formed in the lower cover 15 at a position facing the welding part Px1. Two machining holes 16a and 16b are formed in the middle cover 16 at positions facing the welding parts Px1 and Px2 respectively. Three machining holes 17a, 17b, and 17c are formed in the upper cover 17 at positions facing the welding parts Px1, Px2, and Px3 respectively.

[0032] Figure 3 This is a perspective view showing an example of the area ECU20, which is the connection counterpart of the connector device.

[0033] The area ECU 20 is a control unit that manages a predetermined area on the vehicle and controls other ECUs and various on-board devices included within that managed area. The area ECU 20 is connected to other ECUs and various on-board devices via wiring harnesses. For example, Figure 1 The connector 10A shown is located at the distal end of the wire forming the wire harness.

[0034] Figure 3 The illustrated region ECU20 includes a male connector 10B that can be fitted into a female connector 10A. When the connector 10A of the wiring harness is positioned facing the connector connection portion 10a of the connector 10B and pushed along the connector insertion and removal direction Az, the connector 10A can be fitted into the connector connection portion 10a. Therefore, the circuitry of the terminals of the connector 10A is connected to each circuitry of the terminals of the connector 10B.

[0035] Here, since the connector housing 11 of connector 10A is formed as follows Figure 1 and Figure 2 The L-shape shown indicates that the wires of the harness connected to connector 10A are routed out of connector 10A along the connector height direction Ay. Therefore, the wiring path of the harness can be prevented from protruding excessively from the position of connector 10B along the connector insertion and removal direction Az.

[0036] The following will describe the use of, for example Figure 1 and Figure 2 The manufacturing process of the connector housing 11 shown as an assembly that forms part of a wire harness when manufacturing a connector device.

[0037] Figure 4 A, Figure 4 B Figure 5 A, and Figure 5 B is a longitudinal cross-sectional view showing different stages in the manufacturing process of the connector assembly. Figure 4 In the state shown in A, such as in Figure 2 In the state shown, the metal terminals 13 are pre-installed in each cavity 12 of the connector housing 11, and the lower cover 15, the middle cover 16, and the upper cover 17 are installed.

[0038] In such Figure 4 In the state shown in A, a plurality of covered wires 30 forming a wire harness are connected to each metal terminal 13 in the connector housing 11. Figure 4 Only three covered wires 30-1, 30-2, and 30-3, arranged along the connector insertion and removal direction Az, are shown as covered wires 30. When the covered wires 30 are connected to all 15 metal terminals 13 mounted in the connector housing 11, the 15 covered wires 30 are arranged sequentially facing the wire insertion opening 14 and connected sequentially to each metal terminal 13.

[0039] like Figure 4 As shown in Figure A, the insulating sheath 30b is pre-stripped from the distal end of the covered wire 30 to expose the core wire 30a.

[0040] First, such as Figure 4 As shown in Figure A, multiple covered wires 30-1, 30-2, and 30-3 are arranged near the wire insertion opening 14. Next, as... Figure 4 As shown in Figure B, the covered wire 30-1, which is at the minimum distance from the rear end of the wire connection portion 13b and faces the wire insertion opening 14, is first inserted into the wire insertion opening 14. Then, the covered wire 30-1 is positioned such that the entire core wire 30a at the distal end of the covered wire 30-1 overlaps with the wire connection portion 13b of the metal terminal 13.

[0041] In this state, such as Figure 4 As shown in Figure B, the core wire 30a of the covered wire 30-1 is located at the soldering part Px1. Since the machining holes 15a, 16a, and 17a are formed at the position facing the soldering part Px1, the right-side space outside the connector housing 11 is connected to the space where the core wire 30a of the covered wire 30-1 is located through the machining holes 15a, 16a, and 17a.

[0042] Therefore, a laser welder (not shown) located outside the connector housing 11 is used to irradiate a laser beam LB for welding from the right-hand space toward the laser irradiation direction AL. Then, as... Figure 5 As shown in Figure A, the laser beam LB passes sequentially through the openings of the processing holes 17a, 16a, and 15a, and reaches the position of the core wire 30a of the covered wire 30-1. The core wire 30a, heated and melted by the laser beam LB, is welded to the wire connection portion 13b of the metal terminal 13 at the welding portion Px1.

[0043] When using a galvanizing scanner or similar equipment, the position of the laser beam LB can be easily adjusted to coincide with the positions of multiple welding parts Px1, Px2, Px3, etc.

[0044] exist Figure 4 In the example shown in A, the laser beam LB is emitted from the outside. Alternatively, the laser beam LB can be guided to the vicinity of each of the weld portions Px1, Px2, and Px3 via optical fibers or the like. In this case, the optical fibers are positioned to pass through the openings of the machining holes 17a, 16a, 15a, etc.

[0045] After the welding of the covered wire 30-1 is completed, the covered wire 30-2 is then processed. Specifically, the covered wire 30-2 is selected and positioned facing the central wire insertion opening 14, with a midpoint distance from the rear end of the wire insertion opening 14 to the wire connection portion 13b. The covered wire 30-2 is then inserted into the wire insertion opening 14. The covered wire 30-2 is positioned such that the entire core wire 30a at its distal end overlaps with the wire connection portion 13b of the metal terminal 13.

[0046] In this state, such as Figure 5 As shown in Figure B, the core wire 30a of the covered wire 30-2 is located at the soldering part Px2. Since the machining holes 16b and 17b are formed at the position facing the soldering part Px2, the right side space outside the connector housing 11 is connected to the space where the core wire 30a of the covered wire 30-2 is located through the machining holes 16b and 17b.

[0047] Therefore, the laser beam LB used for welding is aligned with the machining hole 17b and irradiates from the right-side space outside the connector housing 11 toward the laser irradiation direction AL. Then, as... Figure 5 As shown in Figure B, the laser beam LB passes sequentially through the openings of the processing holes 17b and 16b and reaches the position of the core wire 30a of the covered wire 30-2. The core wire 30a, heated and melted by the laser beam LB, is welded to the wire connection portion 13b of the metal terminal 13 at the welding portion Px2.

[0048] After the above processing, the same processing can also be performed on the covered wire 30-3. That is, the covered wire 30-3 is inserted into the wire insertion opening 14 and positioned such that the entire core wire 30a at the distal end of the covered wire 30-3 overlaps with the wire connection portion 13b of the metal terminal 13.

[0049] In this state, the core wire 30a of the covered wire 30-3 is present at the solder joint Px3. Since the machining hole 17c is formed at the position facing the solder joint Px3, the right side space outside the connector housing 11 is connected to the space where the core wire 30a of the covered wire 30-3 is located through the machining hole 17c.

[0050] Therefore, the laser beam LB is aligned with the machining hole 17c and irradiates from the right side space outside the connector housing 11 towards the laser irradiation direction AL. Then, the laser beam LB passes through the opening of the machining hole 17c and reaches the position of the core wire 30a of the covered wire 30-3. The core wire 30a, heated and melted by the laser beam LB, is welded to the wire connection portion 13b of the metal terminal 13 at the welding portion Px3.

[0051] As described above, by processing the connector in a predetermined order, laser welding can be performed on each of the plurality of weld portions Px1, Px2, and Px3 that are offset from each other inside the connector housing 11. In particular, even if the plurality of metal terminals 13 arranged along the connector width direction Aw and the plurality of metal terminals 13 arranged in multiple rows along the connector height direction Ay are both welded to the covered wires 30, this welding can be performed after the metal terminals 13 and the covered wires 30 are arranged in the connector housing 11.

[0052] Therefore, the manufacturing process is more flexible when manufacturing wire harnesses. For example, it is easier to prepare individual components for manufacturing. Figure 1 and Figure 2 The factory, equipment, personnel, etc. of connector 10A in the state shown, and the components used to perform the respective operations. Figure 4 A, Figure 4 B Figure 5 A, and Figure 5 B shows another factory, equipment, personnel, etc. for processing, and the processing time is changed according to the vehicle production plan.

[0053] like Figure 2 As shown, with the metal terminal 13 pre-assembled in the connector housing 11, when performing as follows Figure 4 A, Figure 4 B Figure 5 A, and Figure 5 The processing shown in B can be easily automated, and manufacturing costs can be reduced.

[0054] According to an aspect of the above embodiment, a connector device (connector 10A) includes: a connector housing (11) comprising a plurality of terminal receiving chambers (e.g., cavities 12); a plurality of terminals (e.g., metal terminals 13) received in the plurality of terminal receiving chambers (cavities 12); and a plurality of wires (e.g., covered wires 30) configured to be soldered to each of the plurality of terminals. Laser-irradiated vias (e.g., machined holes 15a, 16a, 16b, 17a, 17b, 17c) are formed on sidewalls (e.g., lower cover 15, middle cover 16, upper cover 17), each of the sidewalls forming the terminal receiving chambers, the laser-irradiated vias being configured to allow the plurality of terminals and the plurality of wires to be soldered to each other inside the terminal receiving chambers, and the laser-irradiated vias being configured to allow a laser (e.g., a laser beam LB) emitted from a laser welding machine disposed outside the connector housing to enter one of the plurality of terminal receiving chambers.

[0055] According to the connector assembly with the above-described structure, the terminals and wire cores can be welded within the terminal housing chamber by laser irradiation. The laser beam used for welding can be narrowed, so welding can be performed by a laser welding machine located outside the connector housing even if the size of the laser irradiation through-hole is small. During welding, no specific tools need to be close to the parts to be welded, thus eliminating the need for large openings in the connector housing. Therefore, welding can be easily performed after all components are assembled into the connector housing.

[0056] The shape of the plurality of terminal receiving chambers can be configured such that the locations of the portions to be welded (welding portions Px1, Px2, Px3) of the plurality of terminals are separated from each other.

[0057] With this design, even if multiple terminals overlap each other along the laser irradiation direction, and the parts of the terminals to be soldered are offset from each other, they will not overlap due to positional offset. Therefore, even if multiple rows of terminals are arranged in the connector in both horizontal and vertical directions, all terminals can be soldered by simply changing the laser irradiation position, and the operation process is easy to avoid becoming complicated.

[0058] The laser irradiation through-hole can be a plurality of laser irradiation through-holes. The plurality of laser irradiation through-holes can be arranged such that the positions of the plurality of laser irradiation through-holes are separated from each other along the insertion direction (connector height direction Ay) of each of the wires inserted into the terminal receiving chamber (e.g., wire insertion opening 14).

[0059] With this configuration, multiple laser-irradiated vias are arranged in a corresponding offset. Therefore, even if multiple rows of terminals are arranged horizontally and vertically in the connector, by simply changing the laser irradiation position, the laser can irradiate from the outside to the soldering portions of all terminals passing through the laser-irradiated vias. Thus, the operation process can be kept simple.

[0060] The laser irradiation through-hole can be multiple laser irradiation through-holes. The positions of the multiple laser irradiation through-holes (15a, 16a, 17a) overlap with each other in the laser irradiation direction. The laser passes through one or more of the laser irradiation through-holes and reaches the portion of the terminal to be welded (welding portion Px1, Px2).

[0061] With this design, when multiple terminals overlap each other along the laser irradiation direction, the laser can irradiate the portions of the terminals to be joined arranged on the depth side of the overlap through multiple laser irradiation through-holes. Therefore, even if multiple rows of terminals are arranged horizontally and vertically in the connector, all terminals can be soldered by simply changing the laser irradiation position rather than changing the connector housing structure, thus avoiding operational complexity.

[0062] The connector assembly may also include another connector housing configured to fit into the connector housing (11). Each of the plurality of terminal receiving chambers (cavities 12, wire insertion openings 14) may have a curved shape relative to the mating direction in which the connector housing and the other connector housing fit into each other, and may be configured to accommodate each of the plurality of terminals, each having a curved shape.

[0063] With this construction, each terminal housing of the connector housing has a curved shape, thus facilitating the routing of the wires in the connector harness connected to the mating device, preventing them from traversing a path that protrudes significantly from the connection surface of the device. Furthermore, the connector housing's shape surrounding the portion to be soldered is flat, simplifying the soldering process.

Claims

1. A connector device, comprising: Connector housing, which includes multiple terminal receiving chambers; Multiple terminals are accommodated in the multiple terminal housing chambers; and a plurality of wires configured to be soldered to each of the plurality of terminals, Laser-irradiated vias are formed on the sidewalls, each sidewall forming a terminal receiving chamber. The laser-irradiated vias are configured to allow the plurality of terminals and the plurality of wires to be soldered to each other within the terminal receiving chambers. The laser irradiation through-hole is configured to allow a laser emitted from a laser welding machine located outside the connector housing to enter one of the plurality of terminal receiving chambers; The shape of the plurality of terminal receiving chambers is configured such that the locations of the portions of the plurality of terminals to be soldered are separated from each other; Wherein, the laser irradiation through-hole is a plurality of laser irradiation through-holes, and The plurality of laser irradiation through holes are arranged such that the positions of the plurality of laser irradiation through holes are separated from each other along the insertion direction of each of the wires inserted into the terminal receiving chamber.

2. The connector device according to claim 1, in, The laser-irradiated through-hole is a plurality of laser-irradiated through-holes. Wherein, the positions of the plurality of laser-irradiated through holes overlap with each other along the laser irradiation direction, and The laser passes through one or more laser irradiation through-holes and reaches the portion of the terminal to be soldered.

3. The connector device according to any one of claims 1-2, further comprising another connector housing configured to fit into the connector housing, in, Each of the plurality of terminal receiving chambers has a curved shape relative to the mating direction in which the connector housing and the other connector housing fit together, and is configured to accommodate each of the plurality of terminals, each having a curved shape.

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