Covered connector and its manufacturing method

Abstract

A capped connector includes a connector body and a cap formed of a malleable material that is malleable before curing and cures under predetermined conditions. The cap is cured in a state where it removably closes an opening in the connector body located on the side that mates with a mating connector. The capped connector further includes a protective member formed of an insulating material and disposed within the connector body on the opening side, such that the protective member is positioned between the cap and a connector terminal, the protective member being configured to protect the connector terminal from contact with the malleable material.

Description

Technical Field

[0001] The present invention relates to a capped connector, wherein the opening of the capped connector located on the side for mating with a mating connector is closed by a cap, and to a method of manufacturing a capped connector. Background Technology

[0002] Traditionally, vehicles are equipped with various electronic devices, and wiring harnesses are arranged within the vehicle to transmit power and / or control signals to these electronic devices (see, for example, Patent Document 1). Depending on the presence or absence of vehicle systems, the connectors at the ends of the wiring harnesses arranged within the vehicle can be free and not mate with mating connectors. When the connector is free, its opening on the side that mates with the mating connector is sealed with a cover to prevent water or foreign matter from entering the opening.

[0003] Reference List

[0004] Patent documents

[0005] Patent Document 1: JP2013-176205A Summary of the Invention

[0006] Technical issues

[0007] The aforementioned caps must be manufactured for various types of connectors with different sizes and shapes. Most of the caps are made of resin, and manufacturing caps for various types of connectors requires molds corresponding to each type of connector, which is time-consuming and labor-intensive, leading to increased costs.

[0008] In view of the above problems, the object of the present invention is to provide a covered connector and a method for manufacturing a covered connector, which can reduce the time, labor and cost associated with manufacturing.

[0009] Solution to the problem

[0010] To address the aforementioned problems and achieve the objectives, the present invention provides, in a first aspect, a capped connector comprising: a connector body including a cylindrical connector housing in which connector terminals are received; a cap formed of a malleable material having malleability before curing and curing under predetermined conditions, the cap being cured in a state in which the cap removably closes an opening of the connector body located on the side thereof where a mating connector engages; and a protective member formed of an insulating material and disposed within the connector body on one side of the opening, such that the protective member is positioned between the cap and the connector terminals, the protective member being configured to protect the connector terminals from contact with the malleable material.

[0011] Furthermore, in a second aspect, the present invention provides a method for manufacturing a capped connector, comprising: a coating step of coating a plastic material having plasticity before curing and curing under predetermined conditions onto a specific coating plate, such that the plastic material extends wider than an opening including a connector body, wherein the connector body includes a cylindrical connector housing accommodating connector terminals, the plastic material being coated in a state before curing, and the opening being located on the side of the connector body that mates with a mating connector; a pressing step of pressing the plastic material coated on the coating plate before curing toward the opening of the connector body to close the opening of the connector body with a protective member disposed between the plastic material and the connector terminals, wherein the protective member is formed of an insulating material and is configured to protect the connector terminals from contact with the plastic material; and a curing step of curing the plastic material that has closed the opening and removing the coating plate, thereby completing the cured cap with the cap removably closing the opening.

[0012] Beneficial effects of the invention

[0013] The above-described cover connector and its manufacturing method can reduce manufacturing time, labor, and costs. Attached Figure Description

[0014] Figure 1 This is a schematic perspective view showing a capped connector according to one embodiment;

[0015] Figure 2 yes Figure 1 The connector with cover shown is along Figure 1 A schematic cross-sectional view of the section of line V11-V11 in the middle;

[0016] Figure 3 It is shown Figure 1 and Figure 2 The diagram shows a schematic flowchart illustrating the steps involved in manufacturing the covered connector; and

[0017] Figure 4 It is shown Figure 1 and Figure 2 How the capped connector shown passes through Figure 3 A schematic diagram illustrating the manufacturing method shown.

[0018] Reference tag list

[0019] 1 Connector with Cover

[0020] 2. Wiring harness

[0021] 3 Connector clamps

[0022] 11 Connector Body

[0023] 12 lids

[0024] 12a Plastic materials

[0025] 13 Protective components

[0026] 21. Wire

[0027] 111 Connector Housing

[0028] 111a Opening

[0029] 112 Connector Terminal

[0030] 121 Inner face

[0031] 31 Fixture body

[0032] 32 Coated board

[0033] 311 Placement Hole

[0034] 312 Wire Outlet Hole

[0035] 313 Opening exposed hole

[0036] D11 Placement Direction

[0037] D12 Opening / Closing Direction

[0038] S11 Holding Step

[0039] S12 Coating Step

[0040] S13 Pressing Step

[0041] S14 Curing Steps Detailed Implementation

[0042] The following describes an embodiment of a capped connector and a method for manufacturing a capped connector. First, an embodiment of a capped connector will be described.

[0043] Figure 1 This is a schematic perspective view showing a covered connector according to one embodiment, and Figure 2 yes Figure 1 The connector with cover shown is along Figure 1 A schematic cross-sectional view of the section cut from line V11-V11.

[0044] Figure 1 and Figure 2The illustrated capped connector 1 is configured as an end connector for a wiring harness 2 to be installed inside a vehicle, and includes a connector body 11, a cover 12, and a protective component 13. The capped connector 1 is installed in the vehicle with its opening 111a closed by the cover 12 to prevent water or foreign matter from entering the connector body 11 when the capped connector 1 is free and not mating with a mating connector. On the other hand, when using the capped connector 1 by mating with a mating connector, the cover 12 and the protective component 13 are removed to allow mating with the mating connector.

[0045] The connector body 11 includes a cylindrical connector housing 111, within which connector terminals 112 are housed. In this embodiment, two connector terminals 112 are housed within the connector housing 111. Each connector terminal 112 is connected to an end of a wire 21 constituting the wire harness 2.

[0046] The cover 12 is a component formed of a malleable material 12a, which is plastic before curing and is cured under predetermined conditions. In this embodiment, dental impression materials used in dentistry to make dental molds, etc., are used as the malleable material 12a, and more specifically, alginate impression materials are used. The cover 12 is a component made of malleable material 12a, which is cured in a state where the malleable material 12a removably closes the opening 111a of the connector housing 111 of the connector body 11 located on the side of the connector housing 111 that mates with the mating connector. When the connector body 11 is used in a state where it is mated with the mating connector, the cover 12 is removed and discarded.

[0047] The protective member 13 is formed of an insulating material and is positioned inside the connector housing 111, which constitutes the connector body 11, on one side of the opening 111a, such that the protective member 13 is positioned between the cover 12 and the connector terminal 112. In this embodiment, the protective member 13 is a sheet member formed of insulating resin, and more specifically, it is an elliptical vinyl sheet formed to conform to the shape of the opening 111a of the connector housing 111. The protective member 13 protects the connector terminal 112 from contact with the malleable material 12a. With the protective member 13 adhered to the inner surface 121 of the cover 12, facing the connector terminal 112 located inside the connector housing 111 of the connector body 11, the protective member 13 is disposed inside the connector housing 111. When the connector body 11 is used in conjunction with a mating connector, the protective member 13 is removed and discarded together with the cover 12.

[0048] The capped connector 1 according to the above embodiment provides the following beneficial effects. Specifically, as will be described in detail later, the capped connector 1 can be obtained simply by pressing the uncured malleable material 12a against the opening 111a of the connector body 11 to close the opening 111a, allowing the malleable material 12a to conform to the shape of the opening 111a, and then curing the malleable material 12a. Furthermore, when the opening 111a is closed, the protective member 13 is arranged between the malleable material 12a and the connector terminal 112, thus preventing contact between the malleable material 12a and the connector terminal 112. Therefore, by using this protective member 13, poor conductivity between the terminals during mating of the connector can be easily prevented due to the uncured malleable material 12a contacting and adhering to the connector terminal 112. According to the above structure, the opening 111a is closed by a malleable material 12a of irregular shape, so no molding mold is required. Furthermore, the operation to prevent poor conductivity can be performed simply by pressing the malleable material 12a, which holds the protective member 13, against the opening 111a, thus reducing manufacturing time and labor. In other words, the capped connector 1 of this embodiment can reduce manufacturing time, labor, and costs.

[0049] In this embodiment, the malleable material 12a is an alginate impression material used as a dental impression material. According to this structure, since an easily obtainable and readily processable dental impression material, especially an alginate impression material, is used as the malleable material 12a forming the cap 12, the time and labor associated with manufacturing can be further reduced.

[0050] Furthermore, in this embodiment, the protective component 13 is a sheet component formed of insulating resin. According to this structure, since the sheet component is easy to handle, the time and labor associated with installing the protective component 13 can be further reduced.

[0051] Furthermore, in this embodiment, with the protective member 13 adhered to the inner surface 121 of the cover 12, the protective member 13 is installed inside the connector body 11. According to this configuration, the cover 12 can be formed and the protective member 13 arranged easily and with reduced time and labor using a method described later, which includes adhering the protective member 13 to a malleable material 12a to which other components can be easily adhered before curing, and then pressing the malleable material 12a toward the opening 111a.

[0052] Next, the description Figure 1 and Figure 2 The manufacturing method of the cover connector 1 shown.

[0053] Figure 3 It is shown Figure 1 and Figure 2The diagram shows a schematic flowchart illustrating the steps involved in manufacturing the capped connector. Furthermore, Figure 4 It is shown Figure 1 and Figure 2 How the capped connector shown passes through Figure 3 A schematic diagram illustrating the manufacturing method shown.

[0054] The manufacturing method of the capped connector according to this embodiment includes a holding step S11, a coating step S12, a pressing step S13, and a curing step S14, as follows: Figure 3 As shown.

[0055] The holding step S11 is as follows: prepare the connector fixture 3, which will be described later, and place the connector body 11 in the connector fixture 3 just before the coating step S12, so that the connector body 11 is held in the connector fixture 3. Figure 4 As shown, the connector clamp 3 includes: a clamp body 31 capable of holding the connector body 11; and a coating plate 32 for a malleable material 12a, which is mounted to the clamp body 31 in a state that can be opened and closed relative to the opening 111a of the connector body 11.

[0056] In this embodiment, the clamp body 31 is a rectangular box-shaped component, one sidewall of which is removed to allow the connector body 11 to be inserted along... Figure 4 The placement hole 311 is positioned in the direction D11 shown. Furthermore, Figure 4 The left sidewall shown has a notch to form a wire lead-out hole 312, which is configured to lead a wire 21 out from the clamp body portion 31, the wire 21 extending from the connector terminal 112 of the connector body 11 placed from the placement hole 311. Furthermore, the sidewall facing the wire lead-out hole 312 is removed to form an opening exposure hole 313 exposing the opening 111a of the connector body 11 to the outside. The coating plate 32 for the malleable material 12a is hinged to allow it to... Figure 4 The switch direction D12 shown is connected to the end of the bottom wall side of the opening exposed hole 313 in an open and closed manner.

[0057] In the holding step S11, the connector body 11 is placed through the placement hole 311 of the clamp body 31, wherein the coating plate 32, which is not coated with the plastic material 12a, is opened. As a result, the wire 21 is led out from the wire lead-out hole 312, and the connector body 11 is held in a state where the opening 111a is exposed from the opening exposure hole 313.

[0058] In the subsequent coating step S12, the uncured malleable material 12a is coated onto the inner surface 321 of the coating plate 32 in the open state, such that the malleable material 12a extends wider than the opening 111a. The inner surface 321 is the surface of the coating plate 32 that faces the opening 111a of the connector body 11 when the coating plate 32 is closed. In this embodiment, the malleable material 12a is coated in an elliptical shape to conform to the shape of the opening 111a of the connector body 11.

[0059] In pressing step S13, with the protective member 13 positioned between the malleable material 12a and the connector terminal 112, the uncured malleable material 12a coated on the coating plate 32 is pressed against the opening 111a of the connector body 11 to close the opening 111a. In this embodiment, the malleable material 12a is pressed by closing the coating plate 32 toward the opening exposure hole 313. At this time, the protective member 13 adheres to the surface of the uncured malleable material 12a facing the connector terminal 112, and then the coating plate 32 is closed to press the malleable material 12a with the protective member 13 attached against the opening 111a.

[0060] The subsequent curing step S14 is the step of curing the plastic material 12a with the opening 111a sealed. In this embodiment, the alginate impression material, which is the plastic material 12a, begins to cure at the point in time when it is removed from the given container, coated onto the coating plate 32, and exposed to the atmosphere. In curing step S14, the plastic material 12a with the opening 111a sealed is exposed to the atmosphere and left for a predetermined period of time, thereby allowing the plastic material 12a to cure naturally. Then, in curing step S14, the coating plate 32 is removed by opening the coating plate 32 after curing, thereby completing the cured cover 12 with the opening 111a removably sealed. With the completion of the cover 12, the cover connector 1 is completed, and Figure 3 and Figure 4 The manufacturing method of the cover connector shown is complete.

[0061] According to the reference Figure 3 and Figure 4 The described embodiment of the method for manufacturing a covered connector enables the production of a covered connector without the need for a molding die, simply by pressing a malleable material holding the protective component against an opening. Therefore, the manufacturing method of the covered connector in this embodiment reduces the associated time, labor, and costs.

[0062] Furthermore, in this embodiment, the holding step S11 includes holding the connector body 11 in the clamping body portion 31 of the connector clamp 3, and the pressing step S13 includes closing the coating plate 32 coated with the uncured malleable material 12a. According to this configuration, since the connector body 11 is held in the clamping body portion 31, the opening 111a of the connector body 11 and the malleable material 12a on the coating plate 32 are positioned relative to each other. Then, in this positioned state, the coating plate 32 is closed to seal the opening 111a of the connector body 11 with the malleable material 12a to form a cover 12, thereby enabling the opening 111a to be closed with high precision using the cover 12.

[0063] Furthermore, in this embodiment, the curing step S14 includes naturally curing the plastic material 12a by exposing the plastic material 12a with the opening 111a closed and placing it in the atmosphere for a predetermined period of time. According to this structure, the plastic material is cured simply by placing it in the atmosphere, thus further reducing the time and labor associated with manufacturing.

[0064] Furthermore, in this embodiment, the pressing step S13 includes adhering the protective member 13 to the plastic material 12a before curing, and pressing the plastic material 12a with the protective member 13 adhered to it toward the opening 111a of the connector body 11. According to this structure, using a method including the adhesion of the protective member 13 and subsequent pressing, the formation of the cover 12 and the arrangement of the protective member 13 can be easily performed with reduced time and labor.

[0065] The above embodiments are merely representative examples of the cover connector and its manufacturing method, and the cover connector and its manufacturing method are not limited to these embodiments. That is, the cover connector and its manufacturing method can be modified in various ways without departing from their essence.

[0066] For example, in the above embodiments, as an example of a covered connector and a method for manufacturing a covered connector, a covered connector 1 and a method for manufacturing the same are shown as end connectors for wiring harness 2 disposed inside a vehicle. However, the covered connector and the method for manufacturing the covered connector are not limited thereto, and they may be covered connectors and methods for manufacturing the same as end connectors for wiring harnesses disposed outside a vehicle, or they may employ other mounting methods.

[0067] Furthermore, in the above embodiments, as an example of a covered connector and a method for manufacturing a covered connector, a covered connector 1 comprising two connector terminals 112 housed in a connector housing 111 and a method thereof are shown. However, the covered connector and the method for manufacturing a covered connector are not limited thereto. That is, specific aspects of the connector, such as the number of connector terminals housed, can be arbitrarily set.

[0068] Furthermore, in the above embodiments, dental impression materials were shown as an example of malleable materials, and more specifically, malleable material 12a as an alginate impression material was shown. However, malleable materials are not limited to this, and materials other than dental impression materials, such as UV-curable resins, can be used, as long as they are malleable before curing and can be cured under predetermined conditions. Moreover, even when using dental impression materials, materials other than alginate impression materials, such as silicone impression materials, can be used. However, dental impression materials, especially alginate impression materials, are readily available and easy to handle as described above.

[0069] Furthermore, in the above embodiments, as an example of a protective component, a protective component 13 is shown as a sheet component formed of insulating resin. However, the protective component is not limited to this, and it may also be a component other than a sheet component, such as a plate component or a block component. However, according to the protective component 13 as a sheet component, since it is easy to handle as described above, the time and labor involved in installation can be further reduced.

[0070] Additionally, in the above embodiments, as an example of a protective component, a protective component 13 is shown that is adhered to the inner surface 121 of the cover 12. However, the protective component is not limited to this; it can also be arranged away from the inner surface of the cover, as long as it is located between the cover and the connector terminal. However, as described above, by adhering the protective component 13 to the cover 12, the formation of the cover 12 and the arrangement of the protective component 13 can be easily carried out with reduced time and labor.

[0071] Furthermore, in the above embodiments, as an example of a method for manufacturing a capped connector, a method including a holding step S11 in which the connector body 11 is held in the connector jig 3 is shown. However, the method for manufacturing a capped connector is not limited to this; that is, the connector jig or the like may not be used, and the operator can hold the connector body with one hand and press the malleable part coated on the coating plate toward the opening with the other hand. However, as described above, by using the connector jig 3, the opening 111a of the connector body 11 and the malleable material 12a can be positioned relative to each other, and therefore the opening 111a can be closed with high precision by the cap 12.

[0072] Furthermore, in the above embodiments, as an example of a holding step, a holding step S11 is shown, which is performed before the coating step S12. However, the holding step is not limited to this, and it can be performed after the coating step.

[0073] Furthermore, in the above embodiments, as an example of a curing step, a curing step S14 for a naturally curing plastic material is shown. However, the curing step is not limited to this; it can be, for example, a step of using an ultraviolet-curing resin as a plastic material and subjecting it to ultraviolet irradiation for curing. However, as mentioned above, the curing step S14 involving natural curing can further reduce the time and labor associated with manufacturing.

[0074] Furthermore, as an example of the pressing step, the above embodiment illustrates a pressing step S13 in which the malleable material 12a to which the protective member 13 is adhered is pressed against the opening 111a of the connector body 11. However, the pressing step is not limited to this; it can be, for example, placing the protective member inside the connector body without adhering the protective member to the malleable material, and pressing the malleable material against the opening. However, as described above, according to the pressing step S13 involving pressing the malleable material 12a to which the protective member 13 is adhered, the formation of the cover 12 and the arrangement of the protective member 13 can be easily performed with reduced time and labor.

Claims

1. A capped connector comprising: a connector body including a tubular connector housing in which a connector terminal is housed; a cap formed of a plastic material that is plastic before curing and is cured under predetermined conditions, the cap being cured in a state in which the cap removably closes an opening of the connector body at a side that mates with a counterpart connector; and a protection member formed of an insulating material and arranged inside the connector body at a side of the opening, such that the protection member is positioned between the cap and the connector terminal, the protection member being configured to protect the connector terminal from the plastic material, wherein the plastic material is a dental impression material. the plastic material is an alginate impression material.

2. The lidded connector of claim 1, wherein, the protection member is a sheet member formed of an insulating resin.

3. The lidded connector of claim 1 or 2, wherein, the protection member is arranged inside the connector body in a state in which the protection member is adhered to an inner face portion of the cap that faces the connector terminal inside the connector body.

4. The lidded connector of claim 1 or 2, wherein, the protection member is arranged inside the connector body in a state in which the protection member is adhered to an inner face portion of the cap that faces the connector terminal inside the connector body.

5. The lidded connector of claim 3, wherein, 6. A manufacturing method of a capped connector, comprising: a coating step of coating a plastic material that is plastic before curing and is cured under predetermined conditions in a state before curing on a coating board such that the plastic material extends wider than an opening of a connector body, wherein the connector body includes a tubular connector housing in which a connector terminal is housed, and the opening is at a side of the connector body that mates with a counterpart connector; a pressing step of pressing the plastic material before curing coated on the coating board toward the opening of the connector body to close the opening in a state in which a protection member is arranged between the plastic material and the connector terminal, wherein the protection member is formed of an insulating material and is configured to protect the connector terminal from the plastic material; and a curing step of curing the plastic material that closed the opening, and removing the coating board, thereby completing a cured cap in a state in which the cap removably closes the opening.

7. The manufacturing method according to claim 6, further comprising: a holding step of preparing a connector jig including a jig body portion capable of holding the connector body, and holding the connector body in the jig body portion of the connector jig before or after the coating step, wherein the coating board is attached to the jig body portion to be openable and closable with respect to the opening of the connector body, and wherein the pressing step includes closing the coating board coated with the plastic material before curing with respect to the opening in a state in which the protection member is arranged between the plastic material and the connector terminal. ​ 8. The production method according to claim 6 or 7, wherein The curing step includes naturally curing the malleable material by exposing the malleable material closing the opening to the atmosphere and leaving for a predetermined period of time.

9. The production method according to claim 6 or 7, wherein The pressing step includes: attaching the protective member to a surface of the malleable material before curing, which is coated on the coating plate, facing the connector terminal; and pressing the malleable material, to which the protective member is attached, toward the opening.

10. The manufacturing method according to claim 8, wherein, The pressing step includes: attaching the protective member to a surface of the malleable material before curing, which is coated on the coating plate, facing the connector terminal; and pressing the malleable material, to which the protective member is attached, toward the opening.

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