Connector and method of manufacturing a connector

Abstract

The present disclosure relates to a connector and a manufacturing method of a connector. The connector includes a terminal fitting and a housing that holds the terminal fitting. The housing includes a first resin molded body in which at least a portion of the terminal fitting is embedded, the first resin molded body being made of a first material, and a second resin molded body in which at least a portion of the first resin molded body is embedded, the second resin molded body being made of a second material. The first material has a coefficient of linear thermal expansion that is smaller than the second material.

Description

Technical Field

[0001] This disclosure relates to a connector in which terminal fittings are held in a housing and a method of manufacturing the connector. Background Technology

[0002] In the prior art, for example, JP2014-017197A discloses a connector configured to embed a terminal fitting into a resin housing. This type of connector is manufactured by molding the terminal fitting into the housing.

[0003] When using the connector as described above, during the energization of the terminal fitting, the temperature of the terminal fitting and the surrounding shell increases due to Joule heating caused by the energization. Conversely, when the terminal fitting is not energized, this temperature increase does not occur. In other words, by repeatedly switching between energization and de-energization of the terminal fitting, the temperature of the terminal fitting and the shell fluctuates repeatedly. Here, generally, the metal material constituting the terminal fitting and the resin material constituting the shell have different coefficients of thermal expansion (e.g., linear coefficients of thermal expansion), and therefore, the expansion and contraction rates associated with temperature fluctuations are also different. For example, in the normal environment of connector use, the linear coefficient of thermal expansion of copper is approximately 17.7 × 10⁻⁶ / ℃, while that of polypropylene is approximately 110.0 × 10⁻⁶ / ℃. Due to this difference in linear coefficients of thermal expansion, when the aforementioned temperature fluctuations occur repeatedly, damage such as cracks may occur within the shell, starting from the shell portion adjacent to an acute angle such as a corner of the terminal fitting.

[0004] On the other hand, to prevent such damage to the shell (i.e., to improve so-called thermal shock resistance), it is possible to construct the shell using a resin material that has a smaller difference in linear thermal expansion coefficient compared to the metal material constituting the terminal fittings. However, resin materials with such thermal properties are generally expensive, thus raising concerns about increasing the manufacturing cost of the connector. Summary of the Invention

[0005] This disclosure provides a connector that improves thermal shock resistance while reducing increased manufacturing costs, as well as a method for manufacturing the connector.

[0006] A connector includes: a terminal mating member; and a housing that retains the terminal mating member. The housing includes: a first resin molded body in which at least a portion of the terminal mating member is embedded, the first resin molded body being made of a first material; and a second resin molded body in which at least a portion of the first resin molded body is embedded, the second resin molded body being made of a second material. The first material has a coefficient of linear thermal expansion smaller than that of the second material.

[0007] A method of manufacturing a connector, wherein a terminal fitting is held by a shell, the method comprising: molding a first resin molded body made of a first material, wherein at least a portion of the terminal fitting is embedded in the first resin molded body such that the first resin molded body has the shape of a portion of the shell; and molding a second resin molded body made of a second material, wherein at least a portion of the first resin molded body is embedded in the second resin molded body such that the second resin molded body has the shape of another portion of the shell. The first material has a coefficient of linear thermal expansion smaller than that of the second material.

[0008] This disclosure has been briefly described above. The details of this disclosure will be further clarified by referring to the accompanying drawings and reading the following description of the modes for implementing this disclosure (hereinafter referred to as "Embodiments"). Attached Figure Description

[0009] Figure 1 This is a perspective view showing a connector and a mating connector according to an embodiment of the present disclosure.

[0010] Figure 2 It is along Figure 1 The AA line is cut as follows Figure 1 The connector shown is a cross-sectional view.

[0011] Figure 3 This is a perspective view showing the housing that holds the terminals.

[0012] Figure 4 This is a perspective view of the terminals.

[0013] Figure 5 This is a perspective view showing a first resin molded body integrally formed with a terminal by using a terminal as an insert member in a single molding process.

[0014] Figure 6 It is along Figure 5 A cross-sectional view taken from the BB line.

[0015] Figure 7 This is a perspective view of a second resin molded body integrally formed with a first resin molded body, which is used as an insert member through secondary molding. Detailed Implementation

[0016] In the following description, connector 1 according to an embodiment of this disclosure will be described with reference to the accompanying drawings. Figure 1 As shown, connector 1 can be fitted onto mating connector 2. Connector 1 and mating connector 2 are typical connectors used for power circuits such as inverters or motors installed in vehicles such as hybrid vehicles or electric vehicles.

[0017] like Figure 1 As shown, connector 1 is connected to the ends of a pair of wires 3, which serve as power lines, while mating connector 2 is connected to the ends of a pair of wires 4, which also serve as power lines. By fitting connector 1 and mating connector 2 together, wires 3 and 4 are electrically connected to each other.

[0018] For ease of description, the following is as follows: Figures 1 to 2 As shown, the "front-back direction," "up-down direction," and "width direction" are defined. These directions are orthogonal to each other. The front-back direction coincides with the mating direction of connector 1 and mating connector 2. The feed side and retraction side of the mating of connector 1 and mating connector 2 are respectively set as the front side and the rear side.

[0019] like Figure 2 As shown, connector 1 includes terminals 10, a housing 20 that holds the terminals 10, an upper shield 50 that covers the upper part of the housing 20, and a lower shield 60 that covers the lower part of the housing 20. Each component constituting connector 1 will be described sequentially below.

[0020] First, terminal 10 will be described. Terminal 10 is formed by stamping, bending, etc., of a metal sheet. Figure 4 As shown, the terminal 10 includes a connecting portion (male terminal portion) 11 extending in the front-rear direction and a hanging portion 12 extending downward from the rear end of the connecting portion 11, and has a generally L-shaped shape when viewed in the width direction.

[0021] The connecting portion 11 has a cylindrical contact portion 13 extending in the front-rear direction, except for the rear end (the boundary with the suspension portion 12). The suspension portion 12 has a flat plate shape with its thickness direction facing the front-rear direction, and a screw through hole 14 extending in the front-rear direction is formed at the lower end of the suspension portion 12. The terminal 10 is made of copper or aluminum. The linear coefficient of thermal expansion of copper is approximately 16.6 × 10⁻⁶ / ℃, while that of aluminum is approximately 23.0 × 10⁻⁶ / ℃. For example, the value of the linear coefficient of thermal expansion can be measured according to the test method for the linear coefficient of thermal expansion defined in Japanese Industrial Standard (JIS) K7197.

[0022] Next, shell 20 will be described. For example... Figure 2 As shown, the shell 20 includes a first resin molded body 30 as a one-time molding body and a second resin molded body 40 as a two-time molding body. The linear coefficient of thermal expansion of the material constituting the first resin molded body 30 is smaller than that of the material constituting the second resin molded body 40. Its functions and effects will be described later.

[0023] First, the first resin molded body 30 will be described. For example... Figure 5 and Figure 6As shown, the first resin molded body 30 is a one-piece molded body integrally formed with the terminal 10 by using the terminal 10 as an insert member in a one-time molding process (insertion molding). The first resin molded body 30 is made of a composition containing polyethylene terephthalate resin and glass fiber. The composition constituting the first resin molded body 30 may also contain an elastomer. The linear coefficient of thermal expansion of the material constituting the first resin molded body 30 is greater than the linear coefficient of thermal expansion of the metal material constituting the terminal 10, and less than the linear coefficient of thermal expansion of the material constituting the second resin molded body 40 (details will be described later).

[0024] like Figure 5 and Figure 6 As shown, the first resin molding body 30 integrally includes a shaft-shaped portion 31 filled in the hollow portion of the cylindrical contact portion 13 of the terminal 10, a front end portion 32 connected to the front end of the shaft-shaped portion 31 and covering the front opening of the contact portion 13, a rear end portion 33 connected to the rear end of the shaft-shaped portion 31 and covering the rear opening of the contact portion 13, and an extension portion 34 connected to the rear side of the rear end portion 33 and covering the portion near the boundary between the connecting portion 11 and the suspension portion 12. Most of the outer peripheral surface of the contact portion 13 of the terminal 10, except for the rear end portion, and most of the outer peripheral surface of the suspension portion 12 of the terminal 10, except for the upper end portion, are exposed to the outside and not covered by the first resin molding body 30. As described above, a portion of the terminal 10 is embedded in the first resin molding body 30.

[0025] The front end portion 32 has a tapered shape that protrudes forward. Therefore, the front end portion 32 serves as a resin cap that provides finger-touch prevention for the terminal 10 and picks up the mating terminal (not shown) in the mating connector 2 connected to the terminal 10 (function of improving insertion and removal resistance). The rear end portion 33 is an annular flange portion that protrudes radially outward from the contact portion 13 of the terminal 10.

[0026] Next, the second resin molded body 40 will be described. For example... Figure 7 As shown, the second resin molded body 40 is a secondary molded body integrally formed with the first resin molded body 30 by using the first resin molded body 30 integrally formed with the terminal 10 as an insertion member through secondary molding (insertion molding).

[0027] Similar to the first resin molded body 30, the second resin molded body 40 is also made of a composition containing polyethylene terephthalate resin and glass fiber. By utilizing the fact that the linear coefficient of thermal expansion of glass fiber is less than that of polyethylene terephthalate resin, the content of glass fiber in the composition constituting the first resin molded body 30 is greater than the content of glass fiber in the composition constituting the second resin molded body 40, resulting in a lower linear coefficient of thermal expansion of the material constituting the first resin molded body 30 than that of the material constituting the second resin molded body 40. In this embodiment, the content of glass fiber in the composition constituting the first resin molded body 30 is 30% by weight, while the content of glass fiber in the composition constituting the second resin molded body 40 is 15% by weight. Generally, glass fiber is more expensive than polyethylene terephthalate resin.

[0028] like Figure 2 , Figure 3 ,as well as Figure 7 As shown, the second resin molded body 40 includes a terminal holding portion 41 extending in the front-rear direction and an wire lead-out portion 42 extending downward from the rear end of the terminal holding portion 41, and has a generally L-shaped shape when viewed in the width direction.

[0029] In the terminal holding portion 41, a pair of first resin molded bodies 30, integrally formed with the terminal 10, are integrally formed in a side-by-side arrangement in the width direction. For example... Figure 2 and Figure 7 As shown, the rear end portion 33 and the extension portion 34 of the first resin molded body 30 are embedded in the terminal holding portion 41, while the contact portion 13 of the terminal 10 is not embedded in the terminal holding portion 41 (exposed forward). Therefore, in the first resin molded body 30, the axial portion 31 and the front end portion 32 located inside and at the distal end of the contact portion 13 are also not embedded in the terminal holding portion 41. Thus, a portion of the first resin molded body 30 is embedded in the terminal holding portion 41 of the second resin molded body 40.

[0030] In the terminal holding portion 41, a pair of terminal receiving recesses 43 are formed to correspond to the contact portions 13 of a pair of terminals 10 arranged in the width direction. Within the interior space of each terminal receiving recess 43, the contact portion 13 of the corresponding terminal 10 is coaxially positioned and exposed forward. The terminal holding portion 41 is provided with an annular groove 44 in the shape of an elongated hole extending in the width direction, thereby surrounding the pair of terminal receiving recesses 43. Figure 2 As shown, the annular seal 71 is disposed in the annular groove 44.

[0031] like Figure 2 and Figure 7As shown, a through-hole 45 extending vertically is formed in the wire lead-out portion 42. A suspension portion 12 for a pair of terminals 10 is positioned directly above the upper opening of the through-hole 45. An opening 46 is formed in the rear end surface of the upper end portion of the wire lead-out portion 42 (the boundary between the terminal holding portion 41 and the wire lead-out portion 42). By forming the opening 46, a pair of screw through-holes 14 formed in the suspension portion 12 of the pair of terminals 10 are exposed rearwardly (see...). Figure 2 and Figure 7 ).

[0032] like Figure 2 As shown, a pair of wires 3, each having an annular seal 72 mounted on its outer periphery, are inserted into a wire through-hole 45 from below. The seal 72 seals between the pair of wires 3 and the wire through-hole 45. The ends of the wires 3 inserted into the wire through-hole 45 are respectively connected to the suspension portions 12 of the corresponding terminals 10 via connecting terminals 5 made of metal.

[0033] More specifically, the wire 3 is a covered wire in which the outer periphery of the conductor core 3a is covered by an outer sheath 3b, and the conductor core 3a is exposed from the outer sheath 3b at the end of the wire 3. The exposed conductor core 3a of the wire 3 is clamped and fixed to the lower end of the connecting terminal 5 by using a caulking piece 5a provided at the lower end of the connecting terminal 5 extending in the vertical direction. A screw through hole 5b is provided at the upper end of the connecting terminal 5. With the screw through hole 5b of the connecting terminal 5 and the screw through hole 14 of the terminal 10 aligned, the upper end of the connecting terminal 5 and the hanging part 12 of the terminal 10 are clamped and fixed by using screws 77 and nuts 78 sequentially inserted into the screw through hole 5b and screw through hole 14.

[0034] Therefore, the end of each wire 3 is connected to the suspension portion 12 of the corresponding terminal 10 via the connecting terminal 5. After the connection between a pair of wires 3 and a pair of terminals 10 is completed in this way, the opening 46 is closed by a cover 74 on which a seal 73 is installed. The seal 73 seals between the inner wall of the opening 46 and the cover 74.

[0035] Next, the upper shielding cover 50 will be described. For example... Figure 1 As shown, the upper shield 50, made of metal, has a shape that can cover the upper part of the shell 20 from above, sides, and rear. The upper shield 50 is mounted to the shell 20 (second resin molded body 40) from the rear, thereby covering the upper part of the shell 20 from above, sides, and rear.

[0036] The upper shield 50 has a pair of flange portions 52 with bolt holes 51 respectively formed therein. The pair of bolt holes 51 are used when connector 1 and mating connector 2 are engaged with each other. In addition, the upper shield 50 has a retaining plate 54 with a hole 53 formed therein. Connector 1 is fixed to the device by screwing a bolt (not shown) inserted into the hole 53 of the retaining plate 54 of the upper shield 50 into the bolt hole of a device such as an inverter or motor.

[0037] Next, the lower shielding cover 60 will be described. For example... Figure 1 As shown, the lower shield 60, made of metal, has a shape that can cover the lower part of the housing 20 (more specifically, the wire lead-out portion 42). The lower shield 60 is mounted on the housing 20 (second resin molded body 40) from the bottom to cover the lower part of the housing 20.

[0038] The upper shield 50 and the lower shield 60 are mounted on the housing 20 by screws 76 (see...). Figure 1 and 2 They are fastened and electrically connected to each other. One pair of wires 3 is covered by a shielding ring 75 (see...). Figure 1 and Figure 2 The conductive braid (not shown) of the bundled wires is secured and electrically connected to the lower shield 60. The components constituting connector 1 have been described above.

[0039] The connector 1 having the above-described structure is fitted into a mating connector 2 connected to a pair of wires 4 (see...). Figure 1 In the engaged state of connector 1 and mating connector 2, a pair of terminal receiving portions (not shown) of mating connector 2 are respectively inserted into and engaged with a pair of terminal receiving recesses 43 of connector 1 (see...). Figure 1 Therefore, a pair of mating terminals (female terminals, not shown) housed in a pair of terminal housings are connected to the contact portion (male terminal) 13 of a pair of terminals 10.

[0040] Furthermore, the cover (not shown) of the mating connector 2 is fitted into the annular groove 44 of the connector 1. Therefore, the cover and the seal 71 (see...) Figure 2 The tight contact seals the mating portion between connector 1 and mating connector 2.

[0041] Additionally, insert into the upper shield 80 of the mating connector 2 (see...) Figure 1 A pair of bolts (not shown) formed in the holes 81 in the pair of flange portions 82 of the upper shield 50 of the connector 1 are screwed into the bolt holes 51 formed in the pair of flange portions 52 of the upper shield 50 of the connector 1. Therefore, the upper shield 50 of the connector 1 and the upper shield 80 of the mating connector 2 are fastened and electrically connected by a pair of bolts, and a good shielding effect can be obtained.

[0042] <Functions and Effects>

[0043] As described above, when connector 1 is actually used with connector 1 and mating connector 2 engaged, the temperature of terminal 10 and the surrounding housing 20 rises due to Joule heating caused by the energization of terminal 10. On the other hand, this temperature rise does not occur when terminal 10 is not energized. In other words, by repeatedly switching the energization and de-energization of terminal 10, the temperature of terminal 10 and housing 20 fluctuates repeatedly. Here, since the metal material constituting terminal 10 and the resin material constituting housing 20 have different linear coefficients of thermal expansion, their expansion and contraction rates related to temperature fluctuations are also different. Due to this difference in linear coefficients of thermal expansion, when the aforementioned temperature fluctuations are repeated, damage such as cracks may occur in housing 20, starting from a portion of housing 20 adjacent to an acute angle such as a corner of terminal 10. It is desirable to prevent this damage to housing 20 (i.e., improve its thermal shock resistance).

[0044] In this regard, in the connector 1 according to this embodiment, the shell 20 includes a first resin molded body 30 in which a portion of the terminal 10 is embedded, and a second resin molded body 40 in which a portion of the first resin molded body 30 is embedded. The linear coefficient of thermal expansion of the material constituting the first resin molded body 30 is smaller than the linear coefficient of thermal expansion of the material constituting the second resin molded body 40. Therefore, compared to the case where the entire shell 20 is formed of the second resin molded body 40, the thermal deformation rate of the portion directly in contact with the terminal 10 (i.e., the first resin molded body 30) can be reduced. Therefore, damage to the shell 20 near the terminal 10 due to heat generated during use of the connector 1 can be prevented. Furthermore, in connector 1, the first resin molded body 30 and the second resin molded body 40 are made of a composition containing the same substances (polyethylene terephthalate resin and glass fiber). The glass fiber content in the composition constituting the first resin molded body 30 is greater than that in the composition constituting the second resin molded body 40, resulting in a lower linear coefficient of thermal expansion (CCE) of the material constituting the first resin molded body 30 compared to the material constituting the second resin molded body 40. Generally, glass fiber is more expensive than polyethylene terephthalate resin. Therefore, compared to the case where the entire shell 20 is formed from the first resin molded body 30, the amount of the more expensive material with a smaller CCE (glass fiber in this embodiment) can be reduced, thereby reducing the increase in manufacturing cost of connector 1. Therefore, connector 1 according to this embodiment can improve thermal shock resistance while reducing the increase in manufacturing cost.

[0045] Furthermore, when the resin composition constituting the first resin molded body 30 also contains an elastomer, the elastomer is included in the resin composition, which increases the fracture strain value of the first resin molded body 30 and enables the resin composition to withstand greater stress. Therefore, the thermal shock resistance of the connector 1 can be further improved.

[0046] <Other Embodiments>

[0047] This disclosure is not limited to the above embodiments, and various variations can be adopted within the scope of this disclosure. For example, this disclosure is not limited to the above embodiments, and can be appropriately modified and improved. Furthermore, as long as this disclosure can be implemented, the material, shape, size, quantity, arrangement, etc. of the elements in the above embodiments are optional and not limited.

[0048] In the above embodiments, the first resin molded body 30 and the second resin molded body 40 are made of a composition containing the same combination of substances (polyethylene terephthalate resin and glass fiber), and the glass fiber content in the composition constituting the first resin molded body 30 is greater than the glass fiber content in the composition constituting the second resin molded body 40, such that the linear coefficient of thermal expansion of the material constituting the first resin molded body 30 is less than the linear coefficient of thermal expansion of the material constituting the second resin molded body 40. On the other hand, the first resin molded body 30 and the second resin molded body 40 can be made of a composition containing different combinations of substances, such that the linear coefficient of thermal expansion of the material constituting the first resin molded body 30 is less than the linear coefficient of thermal expansion of the material constituting the second resin molded body 40.

[0049] In the above embodiments, the glass fiber content in the composition constituting the first resin molding body 30 is 30% by weight, while the glass fiber content in the composition constituting the second resin molding body 40 is 15% by weight. However, when the relationship between the linear coefficients of thermal expansion is achieved through the glass fiber content, the glass fiber content in the composition constituting the first resin molding body 30 can be greater than the glass fiber content in the composition constituting the second resin molding body 40, and the content of the two types of glass fibers need not be limited to the specific values ​​described above.

[0050] Here, the features of the embodiments of connector 1 and the manufacturing method of connector 1 according to the present disclosure described above will be briefly summarized and listed in the following first to fifth aspects.

[0051] According to a first aspect of this disclosure, a connector (1) includes: a terminal fitting (10); and a housing (20) that holds the terminal fitting (10). The housing (20) includes: a first resin molded body (30) in which at least a portion of the terminal fitting (10) is embedded, the first resin molded body (30) being made of a first material; and a second resin molded body (40) in which at least a portion of the first resin molded body (30) is embedded, the second resin molded body (40) being made of a second material. The first material has a coefficient of linear thermal expansion smaller than that of the second material.

[0052] According to the connector with the first aspect of the structure, the linear coefficient of thermal expansion of the material of the first resin molded body in which the terminal fitting is embedded is smaller than the linear coefficient of thermal expansion of the material of the second resin molded body in which the first resin molded body is embedded. Therefore, compared to the case where the entire shell is formed of the second resin molded body, the thermal deformation rate of the portion in direct contact with the terminal fitting (i.e., the first resin molded body) can be reduced. Therefore, damage to the shell around the terminal fitting due to temperature fluctuations when the terminal fitting is energized or de-energized can be prevented. Furthermore, compared to the case where the entire shell is formed of the first resin molded body, the amount of more expensive material with a relatively small linear coefficient of thermal expansion can be reduced, thereby reducing the increase in the manufacturing cost of the connector. Therefore, the connector with this structure can improve thermal shock resistance while reducing the increase in manufacturing cost.

[0053] According to a second illustrative aspect of this disclosure, the connector (1) is capable of connecting to a mating connector (2) including mating terminals. The terminal fitting (10) includes a contact portion (13) formed in the form of a hollow tube having a first open end and a second open end, the contact portion (13) being configured to contact the mating terminals when the connector (1) is connected to the mating connector (2). The first resin molded body (30) includes: a shaft-like portion (31) disposed inside the hollow tube of the contact portion (13), the shaft-like portion (31) having a first end and a second end, the second end being closer to the second open end of the contact portion (13) than the first end; a first end portion (32) connected to the first end of the shaft-like portion (31) and covering the first open end of the contact portion (13); and a second end portion (33) connected to the second end of the shaft-like portion (31) and covering the second open end of the contact portion (13).

[0054] According to the connector with the second aspect of its construction, a first resin molded body is integrally formed and disposed within the hollow of the tubular contact portion of the terminal fitting and within both of the pair of openings in the contact portion. Therefore, the first resin molded body is disposed around the contact portion, where, when the terminal fitting is energized, particularly large temperature fluctuations may occur around this contact portion due to the contact resistance with the mating terminals, in addition to the resistance of the terminal fitting itself. Therefore, the connector's thermal shock resistance can be further improved.

[0055] According to a third aspect of this disclosure, the first material comprises a first component and the second material comprises a second component, each of the first and second components containing polyethylene terephthalate resin and glass fiber. The first component has a greater glass fiber content than the second component.

[0056] According to the connector having a third aspect of its construction, the first resin molded body and the second resin molded body are formed using a resin composition containing polyethylene terephthalate resin and glass fiber. Furthermore, the glass fiber content in the resin composition of the first resin molded body is greater than the glass fiber content in the resin composition of the second resin molded body. This difference in the composition allows the aforementioned relationship between the coefficients of linear thermal expansion to be achieved.

[0057] According to a fourth aspect of this disclosure, the first component further comprises an elastomer.

[0058] According to the connector with the fourth aspect of its construction, the resin composition constituting the first resin molded body further contains an elastomer. When the elastomer is included in the resin composition, the fracture strain value of the first resin molded body increases, and the resin composition can withstand greater stress. Therefore, the thermal shock resistance of the connector can be further improved.

[0059] According to a fifth aspect of this disclosure, a method of manufacturing a connector (1) wherein a terminal fitting (10) is held by a shell (20), the method comprising: molding a first resin molded body (30) made of a first material, wherein at least a portion of the terminal fitting (10) is embedded in the first resin molded body (30) such that the first resin molded body (30) has the shape of a portion of the shell (20); and molding a second resin molded body (40) made of a second material, wherein at least a portion of the first resin molded body (30) is embedded in the second resin molded body (40) such that the second resin molded body (40) has the shape of another portion of the shell (20). The first material has a coefficient of linear thermal expansion smaller than that of the second material.

[0060] According to the manufacturing method of the connector with the fifth aspect of the structure, after molding a first resin molded body (one-time molding) to embed a terminal fitting therein, molding a second resin molded body (secondary molding) to embed the first resin molded body therein. Furthermore, the linear coefficient of thermal expansion of the material constituting the first resin molded body is smaller than the linear coefficient of thermal expansion of the material constituting the second resin molded body into which the first resin molded body is embedded. Therefore, compared to the case where the entire shell is formed of the second resin molded body, the thermal deformation rate of the portion directly in contact with the terminal fitting (i.e., the first resin molded body) can be reduced. Therefore, damage to the shell around the terminal fitting due to temperature fluctuations when the terminal fitting is energized or de-energized can be prevented. Furthermore, compared to the case where the entire shell is formed of the first resin molded body, the amount of more expensive materials with a relatively small linear coefficient of thermal expansion can be reduced, thereby reducing the increase in connector manufacturing costs. Therefore, the connector manufactured by the manufacturing method of this structure can improve thermal shock resistance while reducing the increase in manufacturing costs.

Claims

1. A connector, comprising: Terminal fittings; as well as The housing holds the terminal fitting. The shell includes: A first resin molded body, wherein at least a portion of the terminal fitting is embedded therein, the first resin molded body being made of a first material, and A second resin molded body, wherein at least a portion of the first resin molded body is embedded therein, and the second resin molded body is made of a second material. Wherein, the first material has a smaller coefficient of linear thermal expansion than the second material; The connector is capable of connecting to a mating connector that includes mating terminals. The terminal fitting includes a contact portion formed in the form of a hollow tube having a first open end and a second open end. The contact portion is configured to contact the mating terminal when the connector is connected to the mating connector. The first resin molded body includes: A shaft-shaped portion is disposed inside the hollow tube of the contact portion, the shaft-shaped portion having a first end and a second end, the second end being closer to the second opening end of the contact portion than the first end; A first end portion, which is connected to the first end of the shaft-like portion and covers the first opening end of the contact portion; and The second end is connected to the second end of the shaft-shaped portion and covers the second opening end of the contact portion.

2. The connector according to claim 1, in, The first material comprises a first component and the second material comprises a second component, each of the first component and the second component containing polyethylene terephthalate resin and glass fiber, and The first component has a higher content of glass fiber than the second component.

3. The connector according to claim 2, in, The first component also contains an elastomer.

4. A method for manufacturing a connector, wherein, The terminal fitting is held by the housing, and the manufacturing method includes: A first resin molded body is molded from a first material, wherein at least a portion of the terminal fitting is embedded in the first resin molded body such that the first resin molded body has the shape of a portion of the shell; and A second resin molded body is molded, the second resin molded body being made of a second material, wherein at least a portion of the first resin molded body is embedded in the second resin molded body, such that the second resin molded body has the shape of the other portion of the shell, and Wherein, the first material has a smaller coefficient of linear thermal expansion than the second material; The connector is capable of connecting to a mating connector that includes mating terminals. The terminal fitting includes a contact portion formed in the form of a hollow tube having a first open end and a second open end. The contact portion is configured to contact the mating terminal when the connector is connected to the mating connector. The first resin molded body includes: A shaft-shaped portion is disposed inside the hollow tube of the contact portion, the shaft-shaped portion having a first end and a second end, the second end being closer to the second opening end of the contact portion than the first end; A first end portion, which is connected to the first end of the shaft-like portion and covers the first opening end of the contact portion; and The second end is connected to the second end of the shaft-shaped portion and covers the second opening end of the contact portion.

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