Molded connectors

Abstract

The objective is to provide a technology that improves the waterproofness of connectors. The molded connector comprises: a first terminal unit including a first connector terminal and a first retainer holding the first connector terminal; a second terminal unit including a second connector terminal and a second retainer holding the second connector terminal, the second terminal unit being stacked on top of the first terminal unit; a first wire connected to the first connector terminal; a second wire connected to the second connector terminal; and a connector housing, formed by insert molding with the first terminal unit, the second terminal unit, the end of the first wire, and the end of the second wire as inserting components.

Description

Technical Field

[0001] This disclosure relates to molded connectors. Background Technology

[0002] Patent document 1 discloses a technique for waterproofing a connector by covering the connector housing and the wires extending from the connector housing with a rubber protective cover.

[0003] Prior art literature

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 10-294146 Summary of the Invention

[0006] Summary of the invention

[0007] The problem that the invention aims to solve

[0008] Depending on where the connector is mounted, additional waterproofing is sometimes required.

[0009] Therefore, the aim is to provide a technology that can improve the waterproofness of connectors.

[0010] Solution for solving the problem

[0011] The molded connector disclosed herein comprises: a first terminal unit including a first connector terminal and a first retainer holding the first connector terminal; a second terminal unit including a second connector terminal and a second retainer holding the second connector terminal, the second terminal unit being stacked on the first terminal unit; a first wire connected to the first connector terminal; a second wire connected to the second connector terminal; and a connector housing, which is formed by insert molding with the first terminal unit, the second terminal unit, the end of the first wire, and the end of the second wire as inserting members.

[0012] Invention Effects

[0013] According to this disclosure, the waterproofness of the connector can be improved. Attached Figure Description

[0014] Figure 1 This is a perspective view of the molded connector according to Embodiment 1.

[0015] Figure 2 This is a perspective view of the molded connector according to Embodiment 1.

[0016] Figure 3 This is a top view showing the molded connector of Embodiment 1.

[0017] Figure 4This is a side view showing the molded connector of Embodiment 1.

[0018] Figure 5 yes Figure 3 VV-line sectional view.

[0019] Figure 6 It is a three-dimensional view representing the embedded component.

[0020] Figure 7 It is a three-dimensional view representing the embedded component.

[0021] Figure 8 This is an exploded perspective view of the first terminal unit and the second terminal unit.

[0022] Figure 9 This is an exploded perspective view of the first terminal unit and the second terminal unit.

[0023] Figure 10 This is a side view showing a modified example of the molded connector of Embodiment 1.

[0024] Figure 11 This is a perspective view showing the molded connector of embodiment 2.

[0025] Figure 12 This is a side view showing the molded connector of Embodiment 2.

[0026] Figure 13 This is a schematic cross-sectional view showing the molded connector of Embodiment 2.

[0027] Figure 14 It is a three-dimensional view representing the embedded component.

[0028] Figure 15 This is an exploded perspective view of the first terminal unit, the second terminal unit, and the third terminal unit. Detailed Implementation

[0029] [Description of embodiments of this disclosure]

[0030] First, let's illustrate the implementation forms of this disclosure.

[0031] The molded connector disclosed herein is as follows.

[0032] (1) A molded connector comprising: a first terminal unit including a first connector terminal and a first retainer holding the first connector terminal; a second terminal unit including a second connector terminal and a second retainer holding the second connector terminal, the second terminal unit being stacked on the first terminal unit; a first wire connected to the first connector terminal; a second wire connected to the second connector terminal; and a connector housing formed by insert molding with the first terminal unit, the second terminal unit, the end of the first wire, and the end of the second wire as inserting members. Insert molding of the connector housing with the first terminal unit, the second terminal unit, the end of the first wire, and the end of the second wire as inserting members improves the connector's water resistance.

[0033] (2) In the molded connector of (1), the molded connector may also include a sheath that covers the first wire and the second wire, and the connector housing covers the end of the sheath. This prevents water from seeping into the sheath from the end of the sheath.

[0034] (3) In the molded connector of (1) or (2), the first terminal unit may be formed by insert molding of the first retainer with the first connector terminal as the inserting component, and the second terminal unit may be formed by insert molding of the second retainer with the second connector terminal as the inserting component. Thus, in each terminal unit, the gap between the connector terminal and the retainer can be reduced, and the waterproofness of the molded connector is improved.

[0035] (4) In the molded connector of (3), the first wire connection portion of the first connector terminal connected to the first wire may protrude outward from the first retainer, and the second wire connection portion of the second connector terminal connected to the second wire may protrude outward from the second retainer. Thus, after each terminal unit is molded, the wire can be easily connected to the connector terminal.

[0036] (5) In the molded connector of (4), the first wire connection portion may have a first base plate that connects the core wires of the first wire, and the second wire connection portion may have a second base plate that connects the core wires of the second wire, with the first base plate and the second base plate interposed between the core wires of the first wire and the core wires of the second wire. Thus, the core wires can be separated by the highly rigid base plate, thereby suppressing short circuits between the core wires.

[0037] (6) In any of the molding connectors in (1) to (5), a hole may be formed in the portion of the connector housing that covers the first retainer and the second retainer, the hole being recessed in the stacking direction of the first terminal unit and the second terminal unit. Thus, during the molding of the connector housing, the positioning pin can be positioned at the hole, thereby suppressing the deviation of multiple terminal units along the stacking direction during the molding of the connector housing.

[0038] (7) In any of the molded connectors in (1) to (6), a locking part may also be provided in the first retainer and the second retainer, the locking part positioning the first terminal unit and the second terminal unit in a direction intersecting the stacking direction. This can suppress the situation where multiple terminal units deviate along a direction intersecting the stacking direction during the molding of the connector housing.

[0039] (8) In any of the molded connectors in (1) to (7), the molded connector may further include: a third terminal unit including a third connector terminal and a third retainer for retaining the third connector terminal, the third terminal unit being stacked between the first terminal unit and the second terminal unit; and a third wire connected to the third connector terminal, wherein the ends of the third terminal unit and the third wire serve as the embedded members of the connector housing. Thus, the terminal unit and the wire can be configured in three or more layers.

[0040] [Details of the embodiments of this disclosure]

[0041] The following describes specific examples of the molded connectors of this disclosure with reference to the accompanying drawings. It should be noted that this disclosure is not limited to these examples, but is disclosed by the claims and is intended to include all modifications within the meaning and scope equivalent to the claims.

[0042] [Implementation Method 1]

[0043] The following describes the molded connector of Embodiment 1. Figure 1 and Figure 2 This is a perspective view of the molded connector 10 according to Embodiment 1. Figure 1 and Figure 2 It is a diagram viewed from opposite directions. Figure 3 This is a top view showing the molded connector 10 of Embodiment 1. Figure 4 This is a side view showing the molded connector 10 of Embodiment 1. Figure 5 yes Figure 3 VV-line sectional view.

[0044] The molded connector 10 includes a first terminal unit 20, a second terminal unit 40, a first wire 60, a second wire 64, and a connector housing 70. The connector housing 70 is formed by insert molding with the ends of the first terminal unit 20, the second terminal unit 40, the first wire 60, and the second wire 64 as inserting members. In the molded connector 10, the first terminal unit 20 and the second terminal unit 40 are stacked. Hereinafter, the stacking direction of the first terminal unit 20 and the second terminal unit 40 will sometimes be referred to simply as the stacking direction. Locking portions are provided in the first terminal unit 20 and the second terminal unit 40. During the molding of the connector housing 70, the locking portions position the first terminal unit 20 and the second terminal unit 40 in a direction intersecting the stacking direction.

[0045] Regarding the first terminal unit 20, the second terminal unit 40, the first wire 60, and the second wire 64, which become embedded components during the molding of the connector housing 70, except... Figures 1-5 In addition, refer to Figures 6-9 Please provide an explanation. Figure 6 and Figure 7 It is a three-dimensional view representing the embedded component. Figure 8 and Figure 9 This is an exploded perspective view of the first terminal unit 20 and the second terminal unit 40. Figure 6 and Figure 8 From and Figure 1 The same viewpoint observed in the image. Figure 7 and Figure 9 From and Figure 2 The same viewpoint observed in the image.

[0046] The first terminal unit 20 includes a first connector terminal 22 and a first retainer 30. The first retainer 30 holds the first connector terminal 22 in a predetermined posture. The first terminal unit 20 is formed by insert molding the first retainer 30 with the first connector terminal 22 as an insert member. Here, two first connector terminals 22 are provided. The two first connector terminals 22 are held side by side in one first retainer 30. The two first connector terminals 22 are side by side along a direction intersecting the stacking direction.

[0047] The first connector terminal 22 has a first wire connection portion 23 and a first contact portion 26. For example, the first connector terminal 22 is formed as a bent plate conductor. The first connector terminal 22 is formed as an L-shaped bent plate conductor. One end of the first connector terminal 22 is the first wire connection portion 23, and the other end is the first contact portion 26. The first wire connection portion 23 and the first contact portion 26 protrude from the first retainer 30 in opposite directions. The intermediate portion between the first wire connection portion 23 and the first contact portion 26 in the first connector terminal 22 is embedded inside the first retainer 30.

[0048] The first wire connection portion 23 is the portion that connects to the first wire 60. The first wire connection portion 23 includes the corner portion of the L-shaped first connector terminal 22. The connection method between the first wire connection portion 23 and the core wire of the first wire 60 can be arbitrary; for example, it can be soldering, pressure welding, etc. The first wire connection portion 23 has a first base plate 24. The first base plate 24 is a portion that protrudes from the first retainer 30. For example, the core wire of the first wire 60 is soldered to the first base plate 24. Here, the first wire connection portion 23 also has a first wire support portion 25. The first wire support portion 25 protrudes from the front end of the first base plate 24 along the height direction of the first base plate 24. A slit 25h is formed in the first wire support portion 25, recessed from the front end toward the base end along the protruding direction from the first base plate 24. The first wire 60 is supported in the first wire support portion 25 by receiving the first wire 60 in the slit 25h. For example, an opening narrower than the bottom can be formed in the slit 25h.

[0049] The first contact portion 26 is the portion that connects to the opposite conductor. Here, the first contact portion 26 is formed in the shape of a male terminal having a pin portion or a tab portion. For example, the pin portion or tab portion can be inserted into and connected to the cylindrical portion of the opposite conductor, which is formed in the shape of a female terminal (not shown in the figure).

[0050] The first retainer 30 has a first main body portion 31, a first partition portion 32, a first protrusion 33, a first annular rib 34, and locking protrusions 36, 37, and 38. The first main body portion 31 is the portion that retains the first connector terminal 22. The first main body portion 31 is formed in a columnar shape, such as a cuboid or a hexagonal prism. The first wire connection portion 23 protrudes outward from one side (hereinafter referred to as one protruding side 31a) of the first main body portion 31. The first contact portion 26 protrudes outward from the side of the first main body portion 31 opposite to the one protruding side 31a (hereinafter referred to as the other protruding side 31b).

[0051] The first dividing portion 32 is provided protruding from one of the protruding surfaces 31a of the first main body portion 31. The first dividing portion 32 extends parallel to the two first connector terminals 22 and separates the two first connector terminals 22 (between the two first wire connection portions 23). Here, the protrusion dimension of the first dividing portion 32 protruding from one of the protruding surfaces 31a is larger than the protrusion dimension of the first connector terminals 22 protruding from one of the protruding surfaces 31a. Thus, the first dividing portion 32 can also separate the two first wires 60 connected to the two first wire connection portions 23.

[0052] A first protrusion 33 is provided protruding from another protruding surface 31b in the first main body portion 31. The protrusion dimension of the first protrusion 33 from the other protruding surface 31b is smaller than the protrusion dimension of the first connector terminal 22 from the other protruding surface 31b. A first protrusion 33 is provided around each of the two first connector terminals 22. The first protrusion 33 covers the area around the base end of the portion of the first connector terminal 22 protruding from the other protruding surface 31b, and the area around the first protrusion 33 is covered by the connector housing 70.

[0053] The first annular rib 34 is disposed on the surface of the first main body 31 facing the stacking direction, opposite to the second terminal unit 40 (hereinafter referred to as one main surface 31c). A hole 74, described later in the connector housing 70, is located at the center of the first annular rib 34, and no resin material constituting the connector housing 70 is disposed there. Here, three annular ribs of different sizes are concentrically disposed at one position on one main surface 31c as the first annular rib 34. Furthermore, the first annular rib 34 is provided in a circular protrusion shape. However, the number and shape of the first annular rib 34 are not limited to the above-described case and can be appropriately set. For example, the first annular rib 34 may only have one or two loops. Moreover, for example, the first annular rib 34 may also be formed into a polygonal protrusion shape, etc.

[0054] The locking protrusions 36, 37, and 38 are parts of the locking portion used to maintain the stacked state when the two terminal units 20 and 40 are stacked. The locking protrusions 36, 37, and 38 are respectively fitted into corresponding portions of the locking recesses 56, 57, and 58 of the second terminal unit 40, which will be described later.

[0055] The locking protrusion 36 is provided such that a portion of the edge of the first main body 31, which includes a side opposite to one main surface 31c (hereinafter referred to as the other main surface 31d) and a protruding surface 31a, protrudes toward the second terminal unit 40. The locking protrusion 36 extends in a flat, integral manner in the width direction of the first main body 31. The locking protrusion 36 is fitted into the locking recess 56.

[0056] The locking protrusion 37 is provided such that a portion of the edge of the first main body 31, including one protruding surface 31b and the other main surface 31d, protrudes toward the second terminal unit 40. The locking protrusion 37 is partially provided in a cuboid shape at the middle portion of the first main body 31 in the width direction (here, between the two first protrusions 33). The locking protrusion 37 is fitted into the locking recess 57.

[0057] The locking protrusion 38 is provided in the first partition 32 on the side facing the second terminal unit 40. The locking protrusion 38 is fitted into the locking recess 58. The locking protrusion 38 has a portion whose width gradually increases from the front end to the middle part along the protruding direction protruding from one of the protruding surfaces 31a.

[0058] The second terminal unit 40 includes a second connector terminal 42 and a second retainer 50. The second retainer 50 holds the second connector terminal 42 in a predetermined posture. The second terminal unit 40 is formed by insert molding the second retainer 50 with the second connector terminal 42 as the insert component. Here, two second connector terminals 42 are provided. The two second connector terminals 42 are held side by side in one second retainer 50. The two second connector terminals 42 are arranged in a direction intersecting the stacking direction. The side-by-side direction of the first connector terminal 22 is parallel to the side-by-side direction of the second connector terminals 42.

[0059] The second connector terminal 42 has a second wire connection portion 43 and a second contact portion 46. For example, the second connector terminal 42 is formed as a bent plate-shaped conductor. Here, the second connector terminal 42 is formed as an L-shaped bent plate-shaped conductor. One end of the second connector terminal 42 is the second wire connection portion 43, and the other end is the second contact portion 46. The second wire connection portion 43 and the second contact portion 46 protrude from the second retainer 50 in opposite directions. The intermediate portion between the second wire connection portion 43 and the second contact portion 46 in the second connector terminal 42 is embedded inside the second retainer 50.

[0060] The second wire connection portion 43 is the portion that connects to the second wire 64. The second wire connection portion 43 is the portion of the L-shaped second connector terminal 42 including the corner portion. The connection method between the second wire connection portion 43 and the core wire of the second wire 64 can be arbitrary; for example, it can be welding, pressure welding, etc. The second wire connection portion 43 has a second base plate 44. The second base plate 44 is a portion that protrudes from the second retainer 50. For example, the core wire of the second wire 64 is welded to the second base plate 44. Here, the second wire connection portion 43 also has a second wire support portion 45. The second wire support portion 45 protrudes from the front end of the second base plate 44 along the height direction of the second base plate 44. A slit 45h is formed in the second wire support portion 45, recessed from the front end toward the base end along the protruding direction from the second base plate 44. The second wire 64 is supported in the second wire support portion 45 by receiving the second wire 64 in the slit 45h. For example, in the slit 45h, the opening may be narrower than the bottom.

[0061] The second contact portion 46 is the portion that connects to the opposite conductor. Here, the second contact portion 46 is formed in the shape of a male terminal with a pin portion or a tab portion. For example, the pin portion or tab portion can be inserted into and connected to the cylindrical portion of the opposite conductor, which is formed in the shape of a female terminal (not shown in the figure).

[0062] The second retainer 50 has a second main body portion 51, a second partition portion 52, a second protrusion 53, second annular ribs 54 and 55, and locking recesses 56, 57, and 58. The second main body portion 51 is the portion that retains the second connector terminal 42. The second main body portion 51 is formed in a columnar shape, such as a cuboid or a hexagonal prism. The second wire connection portion 43 protrudes outward from one side (hereinafter referred to as one protruding side 51a) of the second main body portion 51. The second contact portion 46 protrudes outward from the side of the second main body portion 51 opposite to the one protruding side 51a (hereinafter referred to as the other protruding side 51b).

[0063] The second dividing portion 52 is provided protruding from one of the protruding surfaces 51a of the second main body portion 51. The second dividing portion 52 extends parallel to the two second connector terminals 42, separating the two second connector terminals 42 (between the two second wire connection portions 43). The protrusion dimension of the second dividing portion 52 from one of the protruding surfaces 51a is larger than the protrusion dimension of the second connector terminals 42 from one of the protruding surfaces 51a. Thus, the second dividing portion 52 can also separate the two second wires 64 connected to the two second wire connection portions 43.

[0064] The second protrusion 53 is provided protruding from the other protruding surface 51b of the second main body portion 51. The protrusion dimension of the second protrusion 53 from the other protruding surface 51b is smaller than the protrusion dimension of the second connector terminal 42 from the other protruding surface 51b. The second protrusion 53 is provided around each of the two second connector terminals 42. The second protrusion 53 covers the area around the base end of the portion of the second connector terminal 42 that protrudes from the other protruding surface 51b, and the area around the second protrusion 53 is covered by the connector housing 70.

[0065] The second annular rib 54 is provided on the surface of the second main body 51 facing the stacking direction, opposite to the first terminal unit 20 (hereinafter referred to as one main surface 51c). The hole 75 of the connector housing 70, described later, is located at the center of the second annular rib 54, and no resin material constituting the connector housing 70 is provided. Here, three annular ribs of different sizes are concentrically provided as the second annular ribs 54 at three positions on one main surface 51c. Furthermore, the second annular ribs 54 are provided in a circular protrusion shape. However, the number and shape of the second annular ribs 54 are not limited to the above-described cases and can be appropriately set. For example, the second annular ribs 54 may only be provided in one or two cycles. Furthermore, for example, the second annular ribs 54 may be provided at one position on one main surface 51c. Furthermore, for example, the second annular ribs 54 may be formed into a polygonal protrusion shape, etc.

[0066] The second annular rib 55 is provided on the surface of the second main body 51 facing the first terminal unit 20 (hereinafter referred to as the other main surface 51d). Similar to the first annular rib 34, the second annular rib 55 has three annular ribs of different sizes concentrically provided at one position on the other main surface 51d. The annular rib 55 is formed as a circular protrusion. The annular rib 55 may also be formed as a polygonal protrusion, etc.

[0067] The annular ribs 34, 54, and 55 are preferably narrower the more they face the protruding front end. Here, a bottomed hole 54h is formed in the center of the second annular rib 54 in one main surface 51c of the second body portion 51 of the second retainer 50. The bottomed hole 54h is sized to allow the locating pin to engage during the molding of the connector housing 70. By inserting the locating pin into the bottomed hole 54h, the second retainer 50 can be positioned more accurately during the molding of the connector housing 70. It should be noted that forming a bottomed hole 54h in the second retainer 50 is not mandatory.

[0068] The locking recesses 56, 57, and 58 are parts of the locking portion used to maintain the stacked state of the two terminal units 20 and 40. The locking recesses 56, 57, and 58 are respectively fitted into corresponding portions of the locking protrusions 36, 37, and 38 provided in the first terminal unit 20.

[0069] The locking recess 56 is provided such that a portion of the edge of the second main body 51, including one protruding surface 51a and the other main surface 51d, is recessed toward the opposite side of the first terminal unit 20. The locking recess 56 is recessed throughout the width direction of the second main body 51. As described above, the locking protrusion 36 engages with the locking recess 56, thereby positioning the two terminal units 20, 40 in the length direction of the connector terminals 22, 42. The locking protrusion 36, which engages with the locking recess 56, is located between the second main body 51 and the second partition 52 along the length direction of the connector terminals 22, 42. Thus, the two terminal units 20, 40 are positioned in two orientations along the length direction of the connector terminals 22, 42.

[0070] The locking recess 57 is provided such that a portion of the edge of the second main body 51, including the other protruding surface 51b and the other main surface 51d, is recessed toward the opposite side of the first terminal unit 20. The locking recess 57 is partially recessed into a cuboid shape at the midpoint of the width direction of the second main body 51 (here, between the two second protrusions 53). By engaging the locking protrusion 37 with the locking recess 57 as described above, the two terminal units 20, 40 are positioned in one orientation in the length direction and in both orientations in the parallel direction of the connector terminals 22, 42.

[0071] The locking recess 58 is provided such that the portion of the second partition 52 facing the first terminal unit 20 is recessed on the opposite side of the first terminal unit 20 side. The two terminal units 20 and 40 are positioned in two directions in the parallel direction of the connector terminals 22 and 42 by the locking protrusion 38 fitting into the locking recess 58 as described above. Here, the locking recess 58 is formed as a groove extending with the same width along the length direction. For example, the width of a portion of the locking protrusion 38 may be formed to be larger than the width of the locking recess 58. Thus, the locking protrusion 38 can be pressed into the locking recess 58.

[0072] The first wire 60 is connected to the first connector terminal 22. The first wire 60 is a sheathed wire comprising a core wire and a sheathing layer. The core wire is, for example, a stranded wire formed by twisting together multiple wires. The sheathing layer covers the periphery of the core wire. The sheathing layer is formed, for example, by extruding an insulating material such as resin around the core wire. The sheathing layer is peeled off at the end of the first wire 60 to expose the core wire. The exposed core wire is then connected to the first wire connection portion 23.

[0073] The second wire 64 is connected to the second connector terminal 42. The second wire 64 includes a core wire and a sheath. The core wire is, for example, a stranded wire formed by twisting together multiple wires. The sheath covers the periphery of the core wire. The sheath is formed by, for example, extruding an insulating material such as resin around the core wire. The sheath is peeled off at the end of the second wire 64 to expose the core wire. The exposed core wire is then connected to the second wire connection portion 43.

[0074] Here, the first wire 60 will be described as a signal wire and the second wire 64 as a power wire. For example, the first wire 60 can also be used as a signal wire in an ABS (Anti-Lock Brake System) to transmit signals from sensors used to detect wheel speed. For example, the second wire 64 can also be used as a power wire to supply power to an EPB (Electric Parking Brake) or EMB (Electro-Mechanical Brake) system. Moreover, here, the second wire 64 will be described as being thicker than the first wire 60. This is to accommodate a larger current flow in the second wire 64 as a power wire compared to the first wire 60 as a signal wire.

[0075] Here, the two first wires 60 are covered by a sheath 61 and treated as a single cable 62. For example, the sheath 61 is formed by extruding an insulating material such as resin around the two first wires 60.

[0076] Furthermore, here, the three wires—one cable 62 and two second wires 64—are covered by a sheath 66 and treated as a single cable 68. For example, the sheath 66 is formed by extruding an insulating material such as resin around the three wires. The sheath 66 is an example of a sheath covering the first wire 60 and the second wire 64.

[0077] Thus, when the sheaths 61 and 66 are two layers, the inner sheath 61 is sometimes referred to as the inner sheath 61, and the outer sheath 66 as the outer sheath 66. It should be noted that one or both of the sheaths 61 and 66 can be omitted.

[0078] Two first wires 60 extend from the ends of the inner sheath 61 and the outer sheath 66, and connect to the first connector terminal 22. Two second wires 64 extend from the end of the outer sheath 66 and connect to the second connector terminal 42. It should be noted that, here, the end of the inner sheath 61 is located closer to the first connector terminal 22 than the end of the outer sheath 66. That is, the inner sheath 61 extends from the end of the outer sheath 66. However, the end of the inner sheath 61 may also be located at the same position as the end of the outer sheath 66.

[0079] The sheath of the first wire 60 is peeled off at a position closer to the front end than the end of the inner sheath 61. At this time, the end of the sheath of the first wire 60 can be at the same position as the end of the inner sheath 61, or it can be located closer to the front end than the end of the inner sheath 61. The end of the sheath of the first wire 60 can also be located at the same position as the front end of the protruding part of the first partition 32, or closer to the first main body 31. The portion of the first wire 60 containing the sheath can also be separated by the first partition 32.

[0080] The sheath of the second wire 64 is peeled off at a position closer to the front end than the end of the outer sheath 66. At this time, the end of the sheath of the second wire 64 can be at the same position as the end of the outer sheath 66, or it can be located closer to the front end than the end of the outer sheath 66. The end of the sheath of the second wire 64 can also be located at the same position as the front end of the protruding part of the second partition 52, or closer to the second main body 51. The portion of the second wire 64 containing the sheath can also be separated by the second partition 52.

[0081] Here, one of the first base plate 24 and the second base plate 44 (here, the second base plate 44) is located between the first wire 60 and the second wire 64, thereby suppressing short circuits between the first wire 60 and the second wire 64. More specifically, the first wire 60 and the second wire 64 are more flexible than the first connector terminal 22 and the second connector terminal 42. If the first connector terminal 22 and the second connector terminal 42 are positioned at two points, the portion between those two points can easily maintain a certain shape due to its rigidity. Even if the first wire 60 and the second wire 64 are positioned at two points, the portion between those two points is difficult to maintain a certain shape due to its rigidity. Therefore, by having one of the first base plate 24 and the second base plate 44 between the core wire of the first wire 60 and the core wire of the second wire 64, short circuits between the core wires of the first wire 60 and the second wire 64 are easily suppressed.

[0082] The connector housing 70 exposes the first contact portion 26 of the first connector terminal 22 and the second contact portion 46 of the second connector terminal 42, and covers the ends of the first terminal unit 20, the second terminal unit 40, the first wire 60, and the second wire 64. At this time, the connector housing 70 covers the ends of the sheath 66. The first wire 60 and the second wire 64 extend from the ends of the sheath 66 inside the connector housing 70.

[0083] The outer surface of the portion of the connector housing 70 covering the first retainer 30 and the second retainer 50 is formed in a quadrilateral shape. The outer surface of the portion of the connector housing 70 covering the sheath 66 is formed in a circular shape.

[0084] The portion of the connector housing 70 covering the first contact portion 26 and the second contact portion 46 is configured as a protective cover portion 72 with an internal cavity. The other protruding surface 31b of the first retainer 30 and the other protruding surface 51b of the second retainer 50 are covered by the connector housing 70 and are not exposed inside the protective cover portion 72. The front ends of the first protrusion 33 in the first retainer 30 and the second protrusion 53 in the second retainer 50 are not covered by the connector housing 70 and are exposed inside the protective cover portion 72.

[0085] The portion of the connector housing 70 covering the first retainer 30 and the second retainer 50 has recessed holes 74 and 75 in the stacking direction of the first terminal unit 20 and the second terminal unit 40. The holes 74 and 75 are located on one and the other main surfaces of the connector housing 70, respectively, at positions corresponding to the centers of the annular ribs 34 and 54. The holes 74 and 75 reach the first retainer 30 and the second retainer 50.

[0086] A hole 74 is provided on one main surface of the connector housing 70, and three holes 75 are provided on the other main surface of the connector housing 70. For example, in a top view, the center of the hole 74 is located inside the triangle connecting the centers of the three holes 75. The aforementioned holes 74 and 75 are the parts where the positioning pins of the molding die are arranged during the molding of the connector housing 70.

[0087] More specifically, when the connector housing 70 is molded using the first terminal unit 20, the second terminal unit 40, the first wire 60, and the second wire 64 as embedded components, the positioning pin passes through the portions corresponding to the holes 74 and 75 and comes into contact with the surfaces of the first retainer 30 and the second retainer 50. Thus, the connector housing 70 is molded while the first terminal unit 20 and the second terminal unit 40 are positioned within the mold assembly. Therefore, the first terminal unit 20 and the second terminal unit 40 are held in a highly precise position relative to the connector housing 70. The front ends of the first wire 60 and the second wire 64, which are connected to the first terminal unit 20 and the second terminal unit 40, are also held in a highly precise position relative to the connector housing 70.

[0088] When molding the connector housing 70, molten resin is injected into the mold. The molten resin cools rapidly and solidifies upon contact with the surface of the insert component. The molten resin at the front ends of the annular ribs 34, 54, 55 (hereinafter referred to as annular ribs 34, etc.) does not cool as rapidly as it does when in contact with the flat surface of the insert component. Therefore, the molten resin used to form the connector housing 70 can fuse with the front ends of the annular ribs 34, etc. That is, when molding the connector housing 70 with the first terminal unit 20 as the insert component, an interface may form at the junction of the broad and flat extended surface of the insert component and the connector housing 70. However, at the front ends of the annular ribs 34, etc., a portion where the resin forming the terminal unit and the resin forming the connector housing 70 fuse together easily forms. In particular, if the annular ribs 34, etc., are formed to be narrower towards the protruding front end, the front ends of the annular ribs 34, etc., easily melt into the resin forming the connector housing 70. Therefore, at the junction of terminal units 20, 40 and connector housing 70, more complete waterproofing is achieved along the annular ribs 34, etc. These annular ribs 34, etc., are sometimes also referred to as metal ribs. To facilitate fusion between the annular ribs 34, etc., and the connector housing 70, the retainers 30, 50, and connector housing 70 are preferably formed of the same material. It should be noted that the materials constituting the retainers 30, 50, and connector housing 70 are not particularly limited, but insulating resin materials such as PBT (polybutylene terephthalate), polyamide, and PE (polyethylene) can be used.

[0089] Especially when the aforementioned positioning holes 74 and 75 are formed, the junction between the retainers 30 and 50 and the connector housing 70 is exposed to the outside through these holes 74 and 75. Therefore, annular ribs 34 and 54 are formed to surround these holes 74 and 75. This prevents water from being transmitted between the retainers 30 and 50 and the connector housing 70 through the holes 74 and 75.

[0090] <Effects of Implementation Method 1, etc.>

[0091] According to the molded connector 10 configured as described above, the connector housing 70 is insert-molded with the first terminal unit 20, the second terminal unit 40, the end of the first wire 60 and the end of the second wire 64 as inserting parts, thereby improving the waterproofness of the connector 10.

[0092] In addition, the connector housing 70 covers the end of the sheath 66. This prevents water from seeping into the sheath 66 from the end of the sheath 66.

[0093] Furthermore, each terminal unit 20, 40 is formed by insert molding of the retainer 30, 50 with the connector terminals 22, 42 as inserting components. As a result, the gap between the connector terminals 22, 42 and the retainer 30, 50 can be reduced in each terminal unit 20, 40, thereby improving the waterproofness of the molded connector 10.

[0094] Furthermore, the wire connection portions 23 and 43 in each connector terminal 22 and 42 that connect to the wires 60 and 64 protrude outwards from the retainers 30 and 50. This allows for easy connection of the wires 60 and 64 to the connector terminals 22 and 42 after the terminal units 20 and 40 are formed. Particularly in the case of cables 68 with sheaths 66, if the first terminal unit 20 and the second terminal unit 40 are formed separately after the wires 60 and 64 are connected to the connector terminals 22 and 42, the amount of sheath stripping required for the sheath 66 increases.

[0095] Furthermore, a second base plate 44 is provided between the core wire of the first wire 60 and the core wire of the second wire 64. This allows the highly rigid second base plate 44 to separate the core wires of the first wire 60 and the second wire 64, thereby suppressing short circuits between the core wires.

[0096] Furthermore, the portion of the connector housing 70 covering the first retainer 30 and the second retainer 50 is formed with recessed holes 74 and 75 in the stacking direction of the first terminal unit 20 and the second terminal unit 40. This allows the positioning pins to be positioned at the holes 74 and 75 during the molding of the connector housing 70, thereby preventing the multiple terminal units 20 and 40 from deviating along the stacking direction during the molding of the connector housing 70.

[0097] Furthermore, the first retainer 30 and the second retainer 50 are provided with locking protrusions 36, 37, and 38 and locking recesses 56, 57, and 58, which are used as locking portions to position the first terminal unit 20 and the second terminal unit 40 in a direction intersecting the stacking direction. As a result, it is possible to suppress the deviation of multiple terminal units 20 and 40 in the direction intersecting the stacking direction during the molding of the connector housing 70.

[0098] [Modification of Implementation Method 1]

[0099] Figure 10 This is a side view showing a modified example of the molded connector 10 according to Embodiment 1.

[0100] exist Figure 10In the molded connector 110 shown, a first base plate 24 and a second base plate 44 are interposed between the core wire of the first wire 60 and the core wire of the second wire 64. It should be noted that, from the viewpoint of suppressing short circuits between the core wire of the first wire 60 and the core wire of the second wire 64, it is preferable to have at least one of the first base plate 24 and the second base plate 44 interposed, and more preferably, as in the molded connector 110, both of them are interposed.

[0101] Furthermore, so far, the case where the connector housing 70 covers the sheath 66 has been described, but this configuration is not mandatory. The end of the sheath 66 may also be located in the portion of the wires 60, 64 extending from the connector housing 70.

[0102] Furthermore, so far, it has been described that each terminal unit 20, 40 is formed by inserting the retainer 30, 50 with the connector terminals 22, 42 as inserting parts; however, this is not a necessary structure. Terminal units can also be provided by inserting or mounting the connector terminals into a retainer separately formed with the connector terminals.

[0103] Furthermore, in the case where the retainers 30 and 50 are formed by insert molding using connector terminals 22 and 42 as embedding components to create each terminal unit 20 and 40, the present invention has described a situation where the wire connection portions 23 and 43 and the contact portions 26 and 46 in each terminal unit 20 and 40 protrude outward from the retainers 30 and 50. However, this is not a necessary structure. For example, the wire connection portions may also be embedded inside the retainer in the terminal unit. In this case, with the wire connected to the connector terminal, the retainer may also be insert molded using the wire and connector terminal as embedding components.

[0104] Furthermore, so far, it has been described that the portion of the connector housing 70 covering the first retainer 30 and the second retainer 50 has recessed holes 74 and 75 in the stacking direction of the terminal units 20 and 40. However, this is not a necessary structure, and the holes 74 and 75 may not be formed. Moreover, when the holes 74 and 75 are formed, it has been described that annular ribs 34 and 54 are provided around the holes 74 and 75. However, this is not a necessary structure, and the annular ribs 34 and 54 may not be provided.

[0105] Furthermore, so far, it has been described that the first retainer 30 and the second retainer 50 are provided with locking portions that position the first terminal unit 20 and the second terminal unit 40 in a direction intersecting the stacking direction. However, this configuration is not essential, and the locking portions may not be required. Moreover, even when locking portions are provided, it is not necessary to provide all three sets of locking protrusions 36, 37, and 38 and locking recesses 56, 57, and 58 as locking portions. For example, any one or two sets of the locking protrusions 36, 37, and 38 and locking recesses 56, 57, and 58 may be provided as locking portions.

[0106] [Implementation Method 2]

[0107] The molding connector of embodiment 2 is described. Figure 11 This is a perspective view showing the molded connector 210 of embodiment 2. Figure 12 This is a side view showing the molded connector 210 of embodiment 2. Figure 13 This is a schematic cross-sectional view showing the molded connector 210 according to Embodiment 2. It should be noted that... Figure 13 Is with Figure 5 A sectional view at the same location. Furthermore, in Figure 13 In the middle, annular ribs 34 and 54 and holes 74 and 75 are omitted. Figure 14 It is a three-dimensional view representing the embedded component. Figure 15 This is an exploded perspective view of the first terminal unit, the second terminal unit, and the third terminal unit 80. It should be noted that in the description of this embodiment, elements that are the same as those described so far are labeled with the same reference numerals and their descriptions are omitted.

[0108] In the molded connector 10 described in Embodiment 1, the terminal units 20, 40 and wires 60, 64 are two layers, but the terminal units and wires may also be three or more layers. In the molded connector 210 of this example, the terminal units 20, 40, 80 and wires 62, 64, 90 are three layers. The molded connector 210 also includes a third terminal unit 80 and two third wires 90.

[0109] The third terminal unit 80 is disposed between the first terminal unit 20 and the second terminal unit 40. The third terminal unit 80 serves as an intermediate layer between three or more terminal units 20, 40, and 80. The third terminal unit 80 includes a third connector terminal 81 and a third retainer 82.

[0110] The third connector terminal 81 is formed with the same shape as the first connector terminal 22 and the second connector terminal 42. The third connector terminal 81 has a third wire connection portion 81a and a third contact portion 81b. A third wire 90 is connected to the third wire connection portion 81a. The third contact portion 81b is connected to the terminal on the opposite side.

[0111] The third retainer 82 has a third main body portion 83, a third partition portion 84, and a third protrusion portion 85. The third main body portion 83 is formed with the same shape as the first main body portion 31 and the second main body portion 51. The third partition portion 84 is formed with the same shape as the first partition portion 32 and the second partition portion 52. The third protrusion portion 85 is formed with the same shape as the first protrusion portion 33 and the second protrusion portion 53. The annular rib 34 of the first retainer 30 and the annular ribs 54 and 55 of the second retainer 50 are not provided in the third retainer 82. The third retainer 82 is engaged with the first retainer 30. The first retainer 30 and the third retainer 82 are engaged with each other by the same engaging structure as the engaging structure of the first retainer 30 and the second retainer 50. Moreover, the third retainer 82 is engaged with the second retainer 50 by the same engaging structure as the engaging structure of the first retainer 30 and the second retainer 50. Therefore, the third retainer 82 has a structure for engaging with each other.

[0112] Specifically, the structure of the first retainer 30 side in the third retainer 82 is the same as the structure of the first retainer 30 side in the second retainer 50. That is, the third retainer 82 has a locking recess 86a corresponding to the locking recess 56, a locking recess 87a corresponding to the locking recess 57, and a locking recess 88a corresponding to the locking recess 58. In the first retainer 30 and the third retainer 82, the locking protrusion 36 is locked to the locking recess 86a, the locking protrusion 37 is locked to the locking recess 87a, and the locking protrusion 38 is locked to the locking recess 88a.

[0113] Furthermore, the structure of the second retainer 50 side of the third retainer 82 is the same as the structure of the second retainer 50 side of the first retainer 30. That is, the third retainer 82 has a locking protrusion 86b corresponding to the locking protrusion 36, a locking protrusion 87b corresponding to the locking protrusion 37, and a locking protrusion 88b corresponding to the locking protrusion 38. In the second retainer 50 and the third retainer 82, the locking protrusion 86b is locked to the locking recess 56, the locking protrusion 87b is locked to the locking recess 57, and the locking protrusion 88b is locked to the locking recess 58.

[0114] The third wire 90 is connected to the third terminal unit 80. The connection point of the third wire 90 in the vehicle can be appropriately configured. For example, in a vehicle, the connection point of the third wire 90 can also be a device located near the connection points of the first wire 60 and the second wire 64. The outer sheath 66, which covers the middle portions of the first wire 60 and the second wire 64, also covers the middle portion of the third wire 90. Therefore, in this example, the cable 268 is a six-core cable with six wires 60, 64, and 90 covered by a single sheath 66. The end of the third wire 90 extends from the end of the sheath 66 and connects to the third connector terminal 81. The connection configuration of the third wire 90 to the third connector terminal 81 is the same as the connection configuration of the first wire 60 to the first connector terminal 22 and the connection configuration of the second wire 64 to the second connector terminal 42.

[0115] The connector housing 270 is formed by insert molding with the first terminal unit 20, the second terminal unit 40, the third terminal unit 80, the end of the first wire 60, the end of the second wire 64, and the end of the third wire 90 as inserting components.

[0116] In the molded connector 210, multiple sets of the third terminal unit 80 and the third wire 90 can be provided, forming four or more layers. For example, the molded connector may also have two sets of the third terminal unit 80 and the third wire 90, forming four layers of terminal units and wires. In this case, the molded connector may also be configured to have an eight-core wire, with two-core wires connected to each of the four terminal units. This eight-core wire may also be covered by a sheath, forming an eight-core cable.

[0117] It should be noted that the structures described in the above embodiments and variations can be appropriately combined as long as they do not contradict each other. For example, the structures described in the variations of Embodiment 1 can also be appropriately combined in Embodiment 2.

[0118] Label Explanation

[0119] 10, 110, 210 molded connectors

[0120] 20 First terminal unit

[0121] 22 First connector terminal

[0122] 23 First wire connection part

[0123] 24 First base plate

[0124] 25 First wire support section

[0125] 26 First Contact Section

[0126] 30 First Holder

[0127] 31 First Main Body

[0128] 32 First partition

[0129] 33 First protrusion

[0130] 34 First annular rib

[0131] 36, 37, 38 locking convex parts

[0132] 40 Second terminal unit

[0133] 42 Second connector terminal

[0134] 43 Second wire connection part

[0135] 44 Second base plate

[0136] 45 Second wire support section

[0137] 46 Second Contact Section

[0138] 50 Second Holder

[0139] 51 Second Main Body

[0140] 52 Second partition

[0141] 53 Second protrusion

[0142] 54, 55 Second annular ribs

[0143] 54h has a bottom hole

[0144] 56, 57, 58 locking recessed parts

[0145] 60 First Electric Wire

[0146] 61 Sheath (Inner Sheath)

[0147] 62 Cable

[0148] 64 Second wire

[0149] 66 Sheath (Outer Sheath)

[0150] 68 and 268 cables

[0151] 70, 270 connector housing

[0152] 72 Protective Cover Section

[0153] Holes 74 and 75

[0154] 80 Third terminal unit

[0155] 81 Third connector terminal

[0156] 81a Third wire connection part

[0157] 81b Third Contact Section

[0158] 82 Third Holder

[0159] 83 Third Main Body

[0160] 84 Third Division

[0161] 85 Third protrusion

[0162] 86a, 87a, 88a locking recess

[0163] 86b, 87b, 88b locking convex part

[0164] 90 Third wire.

Claims

1. A molded connector, comprising: The first terminal unit includes a first connector terminal and a first retainer for holding the first connector terminal; The second terminal unit includes a second connector terminal and a second retainer for holding the second connector terminal, and the second terminal unit is stacked on the first terminal unit; The first wire is connected to the first connector terminal; The second wire is connected to the second connector terminal; and The connector housing is formed by insert molding, using the first terminal unit, the second terminal unit, the end of the first wire, and the end of the second wire as inserting components. The molded connector also includes a sheath that covers the first wire and the second wire. The connector housing covers the end of the sheath. A first protrusion is provided on a first protruding surface in the first retainer, and a first contact portion of the first connector terminal protrudes from the first protruding surface. The first protrusion covers the base end portion of the first contact portion that protrudes from the first protruding surface. The second retainer has a second protrusion on its second protruding surface, and the second contact portion of the second connector terminal protrudes from the second protruding surface. The second protrusion covers the base end of the portion of the second contact portion that protrudes from the second protruding surface. The connector housing has a portion that covers the periphery of the first protrusion and the second protrusion and is opposite to the first protruding surface and the second protruding surface.

2. The molded connector according to claim 1, wherein, The first terminal unit is formed by insert molding the first retainer with the first connector terminal as an insert component. The second terminal unit is formed by insert molding the second retainer with the second connector terminal as an insert component.

3. The molded connector according to claim 2, wherein, The first wire connection portion in the first connector terminal, which connects to the first wire, protrudes outward from the first retainer. The second wire connection portion in the second connector terminal, which connects to the second wire, protrudes outward from the second retainer. The connector housing covers the connection portions of the first wire and the first wire connection point, and the connection portions of the second wire and the second wire connection point.

4. The molded connector according to claim 3, wherein, The first wire connection portion has a first base plate, which connects the core wires of the first wire. The second wire connection portion has a second base plate, which connects the core wires of the second wire. The first base plate and the second base plate are interposed between the core wire of the first wire and the core wire of the second wire.

5. The molded connector according to any one of claims 1 to 4, wherein, A hole is formed in the portion of the connector housing that covers the first retainer and the second retainer, the hole being recessed in the stacking direction of the first terminal unit and the second terminal unit.

6. The molded connector according to any one of claims 1 to 4, wherein, The first retainer and the second retainer are provided with locking parts, which position the first terminal unit and the second terminal unit in a direction intersecting the stacking direction.

7. The molded connector according to any one of claims 1 to 4, wherein, The molded connector also features: The third terminal unit includes a third connector terminal and a third retainer for holding the third connector terminal, the third terminal unit being stacked between the first terminal unit and the second terminal unit; and The third wire is connected to the third connector terminal. The third terminal unit and the end of the third wire are used as the embedded part of the connector housing.

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