Electrical wire having connector and manufacturing method thereof

Abstract

In an electric wire (1) having a connector, the entire periphery of a second portion (14b) of the electric wire (10) is surrounded by an adhesive (60). The entire periphery of the connecting part (23) is surrounded by an adhesive (60). The recess (34) is disposed in at least either the first housing (40) or the second housing (50). The conductor connection part (21) is sealed in a space (S) formed by a recess (34), the entire periphery of which is surrounded by the first housing (40), the second housing (50), and the adhesive (60).

Description

Technical Field

[0001] The invention relates to an electric wire with a connector and a method for manufacturing the electric wire with a connector. Background Art

[0002] There is a conventionally known electric wire with a terminal, which has an electric wire and a conductor terminal connected to the electric wire. If such an electric wire with a terminal is used in a location where water may enter, such as an engine compartment of an automobile, water may adhere to a connection portion between the terminal and a conductor of the electric wire, and the terminal and the conductor may be corroded. Therefore, there is known an electric wire with a terminal, in which a connection portion between the terminal and the conductor is covered with a heat shrink tube to prevent water from entering the connection portion.

[0003] Patent document 1 discloses a waterproof structure of a ground terminal for automobiles. In this structure, a core wire is compressed and crimped by a core wire crimping barrel, and an insulating sheath of an electric wire is compressed and crimped by an insulating sheath crimping barrel. One end side of a heat shrink tube completely covers the core wire compressed and crimped by the core wire crimping barrel, and the other end side is in close contact with the electric wire. An adhesive is applied to the inner peripheral surface of the heat shrink tube, and the adhesive is bonded to the ground terminal and the electric wire to eliminate the gap.

[0004] Reference List

[0005] Patent Literature

[0006] Patent Document 1: JP 2000-285983 A Summary of the invention

[0007] According to Patent Document 1, the adhesive applied to the inner peripheral surface of the heat shrink tube fills the gaps between the core wires to prevent water from entering between the plurality of element wires. However, due to the difference in diameter of each element wire and the diameter of each conductor, the adhesive may not be able to fully penetrate into the center portion of the conductor. In particular, when the electric wire is used in a bent state with gaps left between the conductors, the gaps between the core wires become larger, and there is a risk that water easily enters the end of the electric wire.

[0008] The present invention is designed in view of the problems of the prior art. An object of the present invention is to provide an electric wire with a connector, which can prevent water from entering the end of the electric wire.

[0009] According to aspects of the present invention, an electric wire with a connector includes an electric wire, the electric wire includes a conductor and an insulating sheath covering the outer periphery of the conductor, and the electric wire includes a conductor exposed portion and a conductor covered portion, in which the conductor is exposed from the insulating sheath, and in which the conductor is covered by the insulating sheath. The electric wire with a connector includes a terminal, the terminal including a conductor connection portion, a terminal connection portion, and a connecting portion, the conductor connection portion is connected to the conductor exposed portion, the terminal connection portion is configured to be connected to a mating terminal, and the connecting portion connects the conductor connection portion and the terminal connection portion. The electric wire with a connector includes a housing, the housing includes a first housing and a second housing, and the housing has an adhesive provided between the entire periphery of the edge of the first housing and the entire periphery of the edge of the second housing. The first part of the conductor covered portion and the terminal connection portion are exposed from the housing. The second part of the conductor covering part is closer to the conductor exposed part than the first part, and the second part is sandwiched between a part of the edge of the first shell and a part of the edge of the second shell by an adhesive, and since the entire periphery of the second part of the wire is surrounded by the adhesive, water is prevented from entering from between the shell and the wire. The connecting part is sandwiched between a part of the edge of the first shell and a part of the edge of the second shell by the adhesive, and since the entire periphery of the connecting part is surrounded by the adhesive, water is prevented from entering from between the shell and the connecting part. The recess is arranged in at least either the first shell or the second shell. The conductor connecting part is sealed in the space formed by the recess, the entire periphery of the recess is surrounded by the first shell, the second shell and the adhesive, and the adhesive prevents water from entering from between the first shell and the second shell.

[0010] According to another aspect of the present invention, a method for manufacturing an electric wire with a connector comprises: a step of connecting a conductor exposure portion to a conductor connection portion, wherein the conductor is exposed from an insulating sheath covering the outer periphery of the conductor in the conductor exposure portion, wherein the conductor connection portion is configured to be connected to the conductor exposure portion, wherein the conductor exposure portion is included in an electric wire, wherein the electric wire comprises the conductor and the insulating sheath, and wherein the electric wire comprises the conductor exposure portion and a conductor covering portion, wherein the conductor is covered by the insulating sheath, wherein the conductor connection portion is included in a terminal, wherein the terminal comprises the conductor connection portion, a terminal connection portion and a connecting portion, wherein the terminal connection portion is configured to be connected to a mating terminal, and wherein the connecting portion connects the conductor connection portion and the terminal connection portion; and the following steps: utilizing the entire edge portion of a first housing to connect the conductor connection portion to the conductor connection portion; wherein the conductor connection portion is connected to the conductor connection portion by means of a first housing ... The steps of sandwiching the entire circumference of the conductor covering portion and the entire circumference of the connecting portion by a self-adhesive adhesive formed on the circumference, an adhesive formed on at least the edge to which the conductor covering portion of the second shell is attached, and an adhesive formed on at least the edge to which the connecting portion of the second shell is attached; preventing water from entering between the wire and the shell including the first shell and the second shell, between the shell and the connecting portion, and between the first shell and the second shell by using the adhesive formed on the edge of the first shell and the adhesive formed on the edge of the second shell; and sealing the conductor connecting portion in a space formed by a recess, the entire circumference of the recess being surrounded by the first shell, the second shell and the adhesive, and the recess being arranged in at least any one of the first shell or the second shell.

[0011] According to the present invention, it is possible to provide an electric wire having a connector capable of preventing water from entering the end of the electric wire. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 is a perspective view schematically showing an example of an electric wire with a connector according to the present embodiment.

[0013] Figure 2 is a side view schematically showing an example of an electric wire with a connector according to the present embodiment.

[0014] Figure 3 is along Figure 2 Schematic cross-sectional view taken along line III-III.

[0015] Figure 4 is along Figure 2 Schematic cross-sectional view taken along line IV-IV.

[0016] Figure 5 is along Figure 4 A cross-sectional view taken along line VV of FIG.

[0017] Figure 6 It is a side view schematically showing an example of a state in which the insulating sheath of the electric wire is stripped.

[0018] Figure 7 is a schematic cross-sectional view showing an example of a state in which a terminal is connected to a conductor of an electric wire.

[0019] Figure 8 It is a side view schematically showing a state where a sealant is applied to the edge portion of the first housing.

[0020] Fig. 9 It is a plan view schematically showing a state where the sealant is applied to the edge portion of the first housing.

[0021] Fig.10 It is a side view schematically showing a state where the sealant is applied to the edge portion of the second housing.

[0022] Fig.11 It is a plan view schematically showing a state where the sealant is applied to the edge portion of the second housing.

[0023] Fig.12 1 is a plan view schematically showing another example of a state in which a sealant is applied to the edge portion of the second housing.

[0024] Fig.13 1 is a plan view schematically showing another example of a state in which a sealant is applied to the edge portion of the second housing.

[0025] Reference Mark List

[0026] 1 Wire with connector

[0027] 10 Wires

[0028] 11 Conductor

[0029] 12 Insulation sheath

[0030] 13 Conductor exposed part

[0031] 14 Conductor coating

[0032] 14a Part 1

[0033] 14b Part 2

[0034] 20 terminals

[0035] 21 Conductor connection part

[0036] 22 Terminal connection part

[0037] 23 Connection

[0038] 30 Shell

[0039] 40 first shell

[0040] 40a Edge

[0041] 44 concave portion (recessed portion 34)

[0042] 50 Second shell

[0043] 50a Edge

[0044] 54 concave portion (recessed portion 34)

[0045] 60 Adhesive

[0046] 70 Sealant DETAILED DESCRIPTION

[0047] The electric wire with a connector and the method for manufacturing the electric wire with a connector according to the present embodiment will be described in detail below with reference to the accompanying drawings. Note that the dimensional ratios in the drawings are exaggerated for ease of description and may differ from the actual ratios. In addition, in the present embodiment, the description will be given by assuming that the X direction is the axial direction of the conductor, the Y direction is the depth direction of the connector perpendicular to the X direction, and the Z direction is the height direction of the connector perpendicular to the X direction and the Y direction.

[0048] [Wire with connector]

[0049] First, the electric wire with connector 1 according to the present embodiment will be described. Figure 1 : is a perspective view schematically showing an example of the electric wire 1 with a connector according to the present embodiment. Figure 2 : is a side view schematically showing an example of the electric wire 1 with the connector according to the present embodiment. Figure 3 is along Figure 2 Schematic cross-sectional view taken along the center line III-III. Figure 4 is along Figure 2 Schematic cross-sectional view taken along line IV-IV. Figure 5 is along Figure 4 A cross-sectional view taken along line VV in FIG.

[0050] like Figures 1 to 5 As shown, the electric wire with connector 1 according to the present embodiment includes an electric wire 10, a terminal 20, and a housing 30. In the present embodiment, the electric wire with connector 1 is a male connector.

[0051] Figure 61 is a side view schematically showing an example of a state in which the insulating sheath 12 of the electric wire 10 is stripped. The electric wire 10 includes a conductor 11 and the insulating sheath 12 covering the outer periphery of the conductor 11. The electric wire 10 has a conductor exposed portion 13 in which the insulating sheath 12 is stripped and the conductor 11 is exposed from the insulating sheath 12. In addition, the electric wire 10 has a conductor covered portion 14 in which the conductor 11 is covered by the insulating sheath 12. The conductor exposed portion 13 is arranged at the end of the conductor 11.

[0052] The conductor 11 may be composed of only one element wire, or may be a bundled twisted wire composed of a plurality of element wires. In addition, the conductor 11 may be composed of only one twisted wire, or may be a composite twisted wire composed of a plurality of bundled twisted wires.

[0053] A highly conductive metal can be used as the material of the conductor 11. The material of the conductor 11 may be copper, aluminum, or an alloy thereof, for example.

[0054] As the material of the insulating sheath 12, a thermoplastic resin that can ensure electrical insulation can be used. The material of the insulating sheath 12 can include, for example, at least one of an olefin resin and polyvinyl chloride. The olefin resin can include, for example, at least one resin selected from the group consisting of polyethylene (PE), polypropylene (PP), ethylene copolymers, and propylene copolymers.

[0055] The terminal 20 includes a conductor connection portion 21, a terminal connection portion 22, and a linking portion 23. The conductor connection portion 21 is arranged at one end of the terminal 20, and the terminal connection portion 22 is arranged at the other end of the terminal 20.

[0056] The conductor connection portion 21 is connected to the conductor exposure portion 13. The conductor connection portion 21 is configured to be mechanically and electrically connected to the conductor 11 by being connected to the conductor exposure portion 13 of the electric wire 10. The conductor connection portion 21 covers the conductor exposure portion 13 in a manner surrounding the circumference of the conductor 11.

[0057] The terminal connection portion 22 is configured to be connected to a mating terminal (not shown). Since the terminal connection portion 22 is connected to the terminal connection portion of the mating terminal, the terminal 20 is mechanically and electrically connected to the mating terminal. The terminal connection portion 22 protrudes and is exposed from the surface of the housing 30. In the cut surface obtained by cutting the terminal connection portion 22 in a YZ plane perpendicular to the X direction, the terminal connection portion 22 is in an approximately rectangular shape, wherein the Y direction is the length direction and the Z direction is the thickness direction, and the terminal connection portion 22 extends in the X direction. The end of the terminal connection portion 22 in the X direction is semicircular, and a through hole is formed in the center portion of the end of the terminal connection portion 22. However, the shape of the terminal connection portion 22 is not particularly limited, and the terminal connection portion 22 may have other shapes, such as a prism.

[0058] The connecting portion 23 connects the conductor connecting portion 21 and the terminal connecting portion 22. Specifically, the connecting portion 23 is provided between the conductor connecting portion 21 and the terminal connecting portion 22. In the present embodiment, the terminal 20 is formed by continuously and integrally forming the conductor connecting portion 21, the terminal connecting portion 22, and the connecting portion 23 using one material. However, the terminal 20 may also be formed by combining the conductor connecting portion 21, the terminal connecting portion 22, and the connecting portion 23 that are separate from each other.

[0059] The terminal 20 is formed of a conductive material. The material forming the terminal 20 may include, for example, at least one metal selected from the group consisting of copper, aluminum, iron, and magnesium. The surface of the terminal 20 may be plated or unplated.

[0060] Although an example of the terminal 20 has been described, a specific shape of the terminal 20 is not particularly limited, and a terminal 20 having an arbitrary shape may be used.

[0061] The housing 30 has a first shell 40 and a second shell 50. In the present embodiment, the first shell 40 is an upper shell, and the second shell 50 is a lower shell. However, alternatively, the second shell 50 may be an upper shell, and the first shell 40 may be a lower shell. Fig. 9 As shown, the first housing 40 has an edge 40a, and the adhesive 60 formed by curing the sealant 70 is formed at the edge 40a of the first housing 40 (see Figures 2 to 5 ).like Fig.11 As shown, the second housing 50 has an edge 50a, and the adhesive 60 formed by curing the sealant 70 is formed at the edge 50a in the second housing 50 (see Figures 2 to 5 ). In addition, an adhesive is provided between the entire periphery of the edge 40a of the first shell 40 and the entire periphery of the edge 50a of the second shell 50. Figure 5 As shown, the first portion 14a of the conductor covering portion 14 and the terminal connecting portion 22 are exposed from the housing 30. The first housing 40 and the second housing 50 can be connected by fitting. In order to prevent the first housing 40 and the second housing 50 from being separated, the housing 30 can have a locking structure that engages the first housing 40 and the second housing 50.

[0062] like Figure 2 As shown, the housing 30 includes a wire holding portion 31, a terminal holding portion 32, and a flange 33. The wire holding portion 31 is arranged at one end of the housing 30 in the X direction, and the terminal holding portion 32 is arranged at the other end of the housing 30 in the X direction. The flange 33 is provided between the wire holding portion 31 and the terminal holding portion 32 in the X direction.

[0063] The wire holding portion 31 includes a first wire holding portion 41 of the first shell 40 and a second wire holding portion 51 of the second shell 50. The first wire holding portion 41 and the second wire holding portion 51 of the wire holding portion 31 are connected by an adhesive 60 therebetween, and the wire 10 is sandwiched therebetween. Specifically, the second portion 14b of the conductor covered portion 14 is arranged closer to the conductor exposed portion 13 than the first portion 14a, and the second portion 14b of the conductor covered portion 14 is sandwiched between a portion of the edge 40a of the first shell 40 and a portion of the edge 50a of the second shell 50 by the adhesive 60. Since the entire periphery of the second portion 14b of the wire 10 is surrounded by the adhesive 60, water is prevented from entering from between the housing 30 and the wire 10. The wire holding portion 31 is in the shape of a square tube and covers the periphery of the insulating sheath 12 of the wire 10.

[0064] The terminal holding portion 32 includes a first terminal holding portion 42 of the first housing 40 and a second terminal holding portion 52 of the second housing 50. The first terminal holding portion 42 and the second terminal holding portion 52 of the terminal holding portion 32 are connected by an adhesive 60 therebetween, and the terminal 20 is sandwiched therebetween. Specifically, the connecting portion 23 is sandwiched between a portion of the edge 40a of the first housing 40 and a portion of the edge 50a of the second housing 50 by the adhesive 60. Since the entire periphery of the connecting portion 23 is surrounded by the adhesive 60, water is prevented from entering between the housing 30 and the connecting portion 23.

[0065] The flange 33 includes the first flange 43 of the first housing 40 and the second flange 53 of the second housing 50. The flange 33 is formed of the first flange 43 and the second flange 53. The flange 33 extends so that the flange 33 expands further toward the Y direction and the Z direction than the terminal holding portion 32.

[0066] When viewed from the XY plane, the first shell 40 has a recess 44 (recess 34), and the entire periphery of the recess 44 (recess 34) is surrounded by an adhesive 60 arranged at the edge 40a. In addition, when viewed from the XY plane, the second shell 50 has a recess 54 (recess 34), and the entire periphery of the recess 54 (recess 34) is surrounded by an adhesive 60 arranged at the edge 50a. When viewed from the XY plane, the edge 40a is arranged to surround the recess 44, and the edge 50a is arranged to surround the recess 54. The edge 40a and the edge 50a are arranged to face each other in the Z direction. The first shell 40 is connected to the second shell 50 by the adhesive 60 therebetween, and the recess 44 of the first shell 40 of the housing 30 and the recess 54 of the second shell 50 face each other. Thus, a continuous space S formed by combining the recess 44 and the recess 54 is formed.

[0067] The conductor connection portion 21 is sealed in the space S formed by the recess 34, and the entire periphery of the recess 34 is surrounded by the first housing 40, the second housing 50, and the adhesive 60. In addition, the adhesive 60 prevents water from entering from between the first housing 40 and the second housing 50. With such a configuration, liquid such as water can be prevented from entering the space S from the outside of the housing 30. Therefore, since liquid can be prevented from adhering to the conductor connection portion 21, water can be prevented from entering the electric wire 10.

[0068] In the present embodiment, an example is described in which the recess 34 includes the recess 44 and the recess 54. However, the present embodiment is not limited to such an example, and the recess 34 may be arranged only in either the first housing 40 or the second housing 50. That is, it is sufficient if the recess 34 is arranged in at least either the first housing 40 or the second housing 50.

[0069] Adhesive 60 is bonded to first housing 40 and second housing 50. Adhesive 60 is directly bonded to edge 40a of first housing 40, edge 50a of second housing 50, the entire circumference of insulation sheath 12, and the entire circumference of terminal 20. Adhesive 60 is integrally and continuously formed.

[0070] The adhesive 60 has self-adhesiveness. Here, self-adhesiveness means that the adhesive 60 is bonded and integrated to each other due to diffusion of molecular chains. The adhesive 60 may be a pressure-sensitive adhesive. Here, the pressure-sensitive adhesive means an adhesive having adhesiveness at normal temperature (23° C.).

[0071] The glass transition temperature of the adhesive 60 may be 0° C. or lower. Since the glass transition temperature of the adhesive 60 is 0° C. or lower, the adhesiveness of the adhesive 60 can be improved.

[0072] The adhesive 60 may be at least one adhesive selected from the group consisting of a silicone adhesive, an acrylic adhesive, a rubber adhesive, and a polyurethane adhesive. The adhesive 60 may be a UV curable resin or a thermosetting resin. However, from the perspective of processability, the adhesive 60 is preferably a UV curable resin.

[0073] Acrylic adhesive is an adhesive containing a (meth)acrylic polymer. Acrylic adhesive contains a polymer obtained by polymerizing at least one monomer of acrylate and methacrylate, and has (meth)acrylate as a structural unit. (Meth)acrylate is a concept including acrylate and methacrylate. The (meth)acrylate used in the acrylic adhesive may contain at least one selected from the group consisting of ethyl (meth)acrylate, propyl (meth)acrylate, butyl (meth)acrylate, hexyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, octyl (meth)acrylate, isooctyl (meth)acrylate, nonyl (meth)acrylate, isononyl (meth)acrylate, and decyl (meth)acrylate.

[0074] The rubber adhesive may include at least one rubber selected from the group consisting of butyl rubber, ethylene propylene rubber (EPM), ethylene propylene diene monomer rubber (EPDM), and natural rubber.

[0075] The silicone adhesive comprises silicone rubber. The silicone rubber has a main chain composed of siloxane bonds. The side chains of the silicone rubber may be substituted by at least one substituent selected from the group consisting of methyl, phenyl and vinyl. The silicone adhesive may comprise, for example, an organopolysiloxane having dimethylsiloxane as a main structural unit.

[0076] The polyurethane adhesive includes polyurethane. Polyurethane is a polymer having a urethane bond and can be obtained by condensing an isocyanate group and a compound having a hydroxyl group.

[0077] As described above, the electric wire 1 with a connector includes the electric wire 10. The electric wire 10 includes a conductor 11 and an insulating sheath 12 covering the outer periphery of the conductor 11, and the electric wire 10 also includes a conductor exposed portion 13 and a conductor covered portion 14, in which the conductor 11 is exposed from the insulating sheath 12 in the conductor exposed portion 13, and in which the conductor 11 is covered by the insulating sheath 12 in the conductor covered portion 14. The electric wire 1 with a connector includes a terminal 20. The terminal 20 includes: a conductor connecting portion 21 connected to the conductor exposed portion 13, a terminal connecting portion 22 configured to be connected to a mating terminal, and a connecting portion 23 for connecting the conductor connecting portion 21 and the terminal connecting portion 22. The electric wire 1 with a connector includes a housing 30. The housing 30 includes a first shell 40 and a second shell 50, and in the housing 30, an adhesive 60 is provided between the entire periphery of the edge 40a of the first shell 40 and the entire periphery of the edge 50a of the second shell 50. The first portion 14a of the conductor covering portion 14 and the terminal connecting portion 22 are exposed from the housing 30. The second portion 14b of the conductor covering portion 14 is arranged closer to the conductor exposed portion 13 than the first portion 14a, and the second portion 14b of the conductor covering portion 14 is sandwiched between a portion of the edge 40a of the first housing 40 and a portion of the edge 50a of the second housing 50 by an adhesive 60. Since the entire circumference of the second portion 14b of the electric wire 10 is surrounded by the adhesive 60, water is prevented from entering between the housing 30 and the electric wire 10. The connecting portion 23 is sandwiched between a portion of the edge 40a of the first housing 40 and a portion of the edge 50a of the second housing 50 by the adhesive 60. Since the entire circumference of the connecting portion 23 is surrounded by the adhesive 60, water is prevented from entering between the housing 30 and the connecting portion 23. The recess 34 is arranged in at least either the first housing 40 or the second housing 50. The conductor connection portion 21 is sealed in a space S formed by the recess 34, and the entire periphery of the recess 34 is surrounded by the first housing 40, the second housing 50, and the adhesive 60. The adhesive 60 prevents water from entering between the first housing 40 and the second housing 50.

[0078] In the electric wire with connector 1 according to the present embodiment, the entire circumference of the second portion 14b of the electric wire 10, the entire circumference of the coupling portion 23, and the entire circumference of the recess 34 are surrounded by the adhesive 60. The conductor connecting portion 21 is sealed in the space S, wherein the recess 34 is surrounded by the first housing 40, the second housing 50, and the adhesive 60. Therefore, it is possible to prevent water from entering the terminal of the electric wire 10.

[0079] In addition, since the entire circumference of the second portion 14b of the electric wire 10, the entire circumference of the coupling portion 23, and the entire circumference of the recess 34 are surrounded by the adhesive 60 in the electric wire 1 with the connector according to the present embodiment, the size and weight of the electric wire 1 with the connector can be reduced. When the portion between the terminal 20 and the housing 30 is mechanically sealed by a rubber member such as a seal, it is necessary to use a rubber member having a diameter that matches the width of the coupling portion 23, for example. In addition, when the portion between the electric wire 10 and the housing 30 is mechanically sealed with a rubber member such as a rubber plug, it is necessary to provide a rear retainer, for example, in the housing 30. Therefore, when these rubber members are used for mechanical sealing, there is a risk that the size of the electric wire 1 with the connector may increase. However, the adhesive 60 is used in the electric wire 1 with the connector according to the present embodiment, which eliminates the necessity of providing, for example, a rear retainer in the housing 30. Therefore, the size and weight of the electric wire 1 with the connector can be reduced. For example, when the electric wire 1 with the connector is mounted on a moving body such as a car, the weight of the moving body can be reduced. This can improve the energy efficiency required for mobility and reduce the amount of carbon dioxide emitted into the atmosphere.

[0080] In addition, compared with the case of using a conventional heat shrink tube in which an adhesive is coated on the inner peripheral surface, it is possible to reduce the amount of adhesive used. In this case, it is possible to contribute to improving environmental issues.

[0081] [Method for manufacturing electric wire with connector]

[0082] Next, a method of manufacturing the electric wire with connector 1 according to the present embodiment will be described. The method of manufacturing the electric wire with connector 1 according to the present embodiment includes a conductor exposing step, a connecting step, an adhesive forming step, and a sealing step.

[0083] Figure 6 1 is a schematic side view showing an example of a state in which the insulating sheath 12 of the electric wire 10 is stripped by performing the conductor exposing step. Figure 7 2 is a schematic cross-sectional view showing an example of a state in which the terminal 20 is connected to the conductor 11 of the electric wire 10 by performing a connecting step. Figure 8 1 is a side view schematically showing a state where the sealant 70 is applied to the edge portion 40 a of the first housing 40 by performing the adhesive forming step. Fig. 9 1 is a plan view schematically showing a state where the sealant 70 is applied to the edge portion 40 a of the first housing 40 by performing the adhesive forming step. Fig.10 It is a side view schematically showing a state where the sealant 70 is applied to the edge portion 50 a of the second housing 50 . Fig.11 1 is a plan view schematically showing a state where the sealant 70 is applied to the edge portion 50 a of the second housing 50 .

[0084] (Conductor exposure step)

[0085] In the conductor exposing step, first, the electric wire 10 is prepared. The electric wire 10 includes a conductor 11 and an insulating sheath 12 covering the outer periphery of the conductor 11. Next, a portion of the insulating sheath 12 of the electric wire 10 is stripped. As a result, as shown in FIG. Figure 6 As shown, the electric wire 10 has a conductor exposed portion 13 in which the conductor 11 is exposed from the insulating sheath 12 , and a conductor covered portion 14 in which the conductor 11 is covered by the insulating sheath 12 .

[0086] (Connection steps)

[0087] In the connecting step, the electric wire 10 having the conductor exposed portion 13 and the conductor covered portion 14 is prepared. In addition, the terminal 20 having the conductor connecting portion 21 configured to be connected to the conductor exposed portion 13, the terminal connecting portion 22 configured to be connected to the mating terminal, and the connecting portion 23 for connecting the conductor connecting portion 21 and the terminal connecting portion 22 is prepared. Figure 7 As shown, the conductor exposed portion 13 of the electric wire 10 is connected to the conductor connecting portion 21 of the terminal 20. This connects the conductor 11 of the electric wire 10 to the terminal 20 mechanically and electrically.

[0088] (Adhesive Forming Step)

[0089] The adhesive forming step includes a first adhesive forming step and a second adhesive forming step. In the first adhesive forming step, Figure 8 and Fig. 9 As shown in FIG. 1 , the sealant 70 is applied and cured to the entire periphery of the edge 40a of the first housing 40. Then, the adhesive 60 having self-adhesiveness is formed on the entire periphery of the edge 40a of the first housing 40. The entire periphery of the recess 44 is surrounded by the adhesive 60 arranged at the edge 40a of the first housing 40. In the second adhesive forming step, as shown in FIG. Fig.10 and 11 As shown, the sealant 70 is applied and cured to the entire circumference of the edge 50a of the second housing 50. Then, the adhesive 60 having self-adhesiveness is formed on the entire circumference of the edge 50a of the second housing 50. The entire circumference of the recess 54 is surrounded by the adhesive 60 arranged at the edge 50a of the second housing 50.

[0090] In the present embodiment, the adhesive 60 can be formed by applying a sealant 70 and curing it. Therefore, the workability in the present embodiment is higher than that of molding using a rubber gasket, and the wire 1 with a connector can be easily manufactured even with a small component with a small mounting area. At least one of the first housing 40 or the second housing 50 may have a positioning structure for the terminal 20. This structure facilitates the assembly of the terminal 20. It is not particularly limited as long as the adhesive 60 can be formed by applying and curing the sealant 70. The sealant 70 applied to the first housing 40 and the sealant 70 applied to the second housing 50 may be the same or different. An example of a sealant 70 is Born2Bond (registered trademark) CIPG AU588 manufactured by Bostik of Arkema.

[0091] The method of applying the sealant 70 to the first housing 40 or the second housing 50 is not particularly limited, and for example, the sealant can be applied using an applicator 80 such as a dispenser. The sealant 70 can be applied to the first housing 40 or the second housing 50 manually, or the sealant 70 can be applied to a predetermined position using an automatic applicator. For example, the sealant 70 can be applied in a straight line. The application width of the sealant 70 can be, for example, 2 mm or more and 4 mm or less.

[0092] The method of curing the sealant 70 is not particularly limited, and for example, the sealant 70 may be cured by irradiating the applied sealant 70 with UV. Examples of light sources capable of emitting UV include xenon lamps, high pressure mercury lamps, metal halide lamps, and LED lamps. Conditions such as the amount of UV irradiation are not particularly limited, and the conditions may be appropriately set according to the specifications of the sealant 70.

[0093] The sealant 70 may have thixotropy. Here, thixotropy refers to a property of having a flow characteristic that changes with time, wherein the apparent viscosity decreases with time under a constant shear rate condition, and when the shear stress is removed, the viscosity gradually recovers.

[0094] The thixotropic index (TI) value of the sealant 70 may be 2 or more. Since the TI value of the sealant 70 is 2 or more, the shape of the applied sealant 70 can be prevented from being deformed due to dripping. The TI value of the sealant 70 may be 3 or more, 4 or more, 5 or more, or 6 or more. Although the upper limit of the TI value is not particularly limited, the TI value may be, for example, 20 or less. In the specification, the TI value refers to the ratio of the viscosity of the sealant 70 at 5 rpm and the viscosity at 0.5 rpm at 25°C. The TI value of the sealant 70 can be obtained according to JIS K6833-1:2008. In addition, the viscosity of the sealant 70 can be measured using a rotational viscometer based on JIS K7117-2.

[0095] For example, the viscosity of the sealant 70 at 25° C. and 0.5 rpm may be 400,000 Pa·s or more and 1,100,000 Pa·s or less. The viscosity of the sealant 70 at 25° C. and 0.5 rpm may be 500,000 Pa·s or more, or 800,000 Pa·s or more. In addition, the viscosity of the sealant 70 at 25° C. and 0.5 rpm may be 1,000,000 Pa·s or less, or 900,000 Pa·s or less.

[0096] For example, the viscosity of the sealant 70 at 25°C and 5 rpm may be 50,000 Pa·s or more and 200,000 Pa·s or less. The viscosity of the sealant 70 at 25°C and 5 rpm may be 80,000 Pa·s or more, or 100,000 Pa·s or more. In addition, the viscosity of the sealant 70 at 25°C and 5 rpm may be 190,000 Pa·s or less, or 180,000 Pa·s or less.

[0097] (Sealing Step)

[0098] In the sealing step, the conductor connection portion 21 is sealed in the space S in the housing 30. Specifically, the entire circumference of the conductor coating portion 14 and the entire circumference of the coupling portion 23 are sandwiched by the adhesive 60 having self-adhesiveness formed on the entire circumference of the edge 40a of the first housing 40 and the adhesive 60 formed on the entire circumference of the edge 50a of the second housing 50. In addition, the adhesive 60 formed on the entire circumference of the edge 40a of the first housing 40 and the adhesive 60 formed on the entire circumference of the edge 50a of the second housing 50 prevent water from entering between the electric wire 10 and the housing 30 including the first housing 40 and the second housing 50, between the housing 30 and the coupling portion 23, and between the first housing 40 and the second housing 50.

[0099] This forms the housing 30 including the first shell 40 and the second shell 50, wherein the adhesive is arranged between the entire periphery of the edge 40a of the first shell 40 and the entire periphery of the edge 50a of the second shell 50. The second portion 14b of the conductor covered portion 14 is arranged closer to the conductor exposed portion 13 than the first portion 14a, and the second portion 14b of the conductor covered portion 14 is sandwiched between a portion of the edge 40a of the first shell 40 and a portion of the edge 50a of the second shell 50 by the adhesive 60. Since the entire periphery of the second portion 14b of the electric wire 10 is surrounded by the adhesive 60, water is prevented from entering from between the housing 30 and the electric wire 10. In addition, the coupling portion 23 is sandwiched between a portion of the edge 40a of the first shell 40 and a portion of the edge 50a of the second shell 50 by the adhesive 60. Since the entire periphery of the coupling portion 23 is surrounded by the adhesive 60, water is prevented from entering from between the housing 30 and the coupling portion 23. Furthermore, the first portion 14 a of the conductor covering portion 14 and the terminal connecting portion 22 are exposed from the housing 30 .

[0100] In addition, the conductor connection portion 21 is sealed in the space S formed by the recess 34, and the entire periphery of the recess 34 is surrounded by the first housing 40, the second housing 50, and the adhesive 60. The recess 34 is arranged in at least any one of the first housing 40 or the second housing 50. Therefore, the adhesive 60 prevents water from entering from between the first housing 40 and the second housing 50. By performing the above steps, the electric wire 1 with the connector can be manufactured.

[0101] In the second adhesive forming step, as Fig.10 and 11 As shown in FIG. 1 , the sealant 70 is applied and cured to the entire circumference of the edge portion 50a of the second housing 50. However, it is sufficient if the sealant 70 is applied and cured to at least the edge portion to which the conductor covering portion 14 of the second housing 50 is attached and at least the edge portion to which the connecting portion 23 of the second housing 50 is attached. More specifically, as Fig.12 As shown, the sealant 70 may be applied and cured to one side of the edge portion to which the conductor covering portion 14 of the second housing 50 is attached. Fig.12 As shown, the sealant 70 may be applied and cured to one side of the edge portion to which the coupling portion 23 of the second housing 50 is attached. Fig.13 As shown, the sealant 70 may be applied and cured only to the periphery of the edge portion to which the conductor covering portion 14 of the second housing 50 is attached. Fig.13 As shown, the sealant 70 may be applied and cured only to the periphery of the edge portion to which the coupling portion 23 of the second housing 50 is attached. In addition, the application and curing positions of the sealant 70 may be a combination thereof. Even in these aspects, the electric wire 1 having the above-described connector can be manufactured.

[0102] As described above, the method for manufacturing the electric wire 1 with a connector according to the present embodiment includes the step of connecting the conductor exposed portion 13 of the electric wire 10 to the conductor connecting portion 21 of the terminal 20. The electric wire 10 includes the conductor 11 and the insulating sheath 12 covering the outer periphery of the conductor 11, and also includes the conductor exposed portion 13 and the conductor covered portion 14, in which the conductor 11 is exposed from the insulating sheath 12 in the conductor exposed portion 13, and in which the conductor 11 is covered by the insulating sheath 12 in the conductor covered portion 14. The terminal 20 includes: the conductor connecting portion 21 configured to be connected to the conductor exposed portion 13, the terminal connecting portion 22 configured to be connected to the mating terminal, and the connecting portion 23 for connecting the conductor connecting portion 21 and the terminal connecting portion 22. The method for manufacturing the electric wire 1 with a connector includes the step of sealing the conductor connecting portion 21 in the space S. In the sealing step, the entire circumference of the conductor covering portion 14 and the entire circumference of the connecting portion 23 are sandwiched by the adhesive 60 having self-adhesiveness formed on the entire circumference of the edge portion 40a of the first housing 40, the adhesive 60 formed at least on the edge portion to which the conductor covering portion 14 of the second housing 50 is attached, and the adhesive 60 formed at least on the edge portion 50a to which the connecting portion 23 of the second housing 50 is attached. Further, in the sealing step, the adhesive 60 formed on the edge portion 40a of the first housing 40 and the adhesive 60 formed on the edge portion 50a of the second housing 50 prevent water from entering between the electric wire 10 and the housing 30 including the first housing 40 and the second housing 50, between the housing 30 and the connecting portion 23, and between the first housing 40 and the first housing 50. The space S is formed by the recess 34 arranged in at least one of the first housing 40 or the second housing 50, and the entire circumference of the space S is surrounded by the first housing 40, the second housing 50, and the adhesive 60. According to the method of manufacturing the electric wire with connector 1 according to the present embodiment, the electric wire with connector 1 described above can be manufactured.

[0103] Furthermore, the sealant 70 is used in the method of manufacturing the electric wire 1 with a connector according to the present embodiment. This eliminates the assembly step using a rubber member. Therefore, it can contribute to shortening the production cycle.

[0104] Furthermore, the sealant 70 is used in the method of manufacturing the electric wire 1 with a connector according to the present embodiment, and this can prevent leakage paths from being generated at the bonding portion between the first housing 40 and the second housing 50 , at the periphery of the electric wire 10 , and at the periphery of the terminal 20 .

[0105] The entire contents of Japanese patent application No. 2022-166053 filed on October 17, 2022 are incorporated herein by reference.

[0106] Although the present embodiment has been described above, the present embodiment is not limited to the above description, and various modifications can be made within the scope of the gist of the present embodiment.

Claims

1. An electric wire with a connector, comprising: An electric wire comprising a conductor and an insulating sheath covering the outer circumference of the conductor, wherein the electric wire comprises a conductor exposed portion and a conductor covered portion, wherein the conductor is exposed from the insulating sheath in the conductor exposed portion and the conductor is covered by the insulating sheath in the conductor covered portion; a terminal including a conductor connection portion connected to the conductor exposed portion, a terminal connection portion configured to be connected to a mating terminal, and a connecting portion connecting the conductor connection portion and the terminal connection portion; and A housing comprising a first shell and a second shell, and having an adhesive disposed between the entire periphery of an edge of the first shell and the entire periphery of an edge of the second shell, wherein: The first portion of the conductor covering portion and the terminal connecting portion are exposed from the housing, The second portion of the conductor covering portion is disposed closer to the conductor exposed portion than the first portion, the second portion of the conductor covering portion is sandwiched between a portion of the edge portion of the first shell and a portion of the edge portion of the second shell by an adhesive, and since the entire circumference of the second portion of the electric wire is surrounded by the adhesive, water is prevented from entering from between the shell and the electric wire. The connecting portion is sandwiched between a portion of the edge of the first shell and a portion of the edge of the second shell by the adhesive, and since the entire periphery of the connecting portion is surrounded by the adhesive, water is prevented from entering from between the shell and the connecting portion. A recess is arranged in at least either the first housing or the second housing, and The conductor connection portion is sealed in a space formed by the recess, the entire periphery of the recess is surrounded by the first housing, the second housing, and the adhesive, and the adhesive prevents water from entering from between the first housing and the second housing.

2. A method for manufacturing an electric wire having a connector, comprising: a step of connecting a conductor exposed portion to a conductor connecting portion, wherein, in the conductor exposed portion, a conductor is exposed from an insulating sheath covering an outer periphery of the conductor, the conductor connecting portion is configured to be connected to the conductor exposed portion, the conductor exposed portion is included in an electric wire, the electric wire includes the conductor and the insulating sheath, and the electric wire includes the conductor exposed portion and a conductor covered portion, in which the conductor is covered by the insulating sheath, the conductor connecting portion is included in a terminal, the terminal includes the conductor connecting portion, a terminal connecting portion and a coupling portion, the terminal connecting portion is configured to be connected to a mating terminal, the coupling portion coupling the conductor connecting portion and the terminal connecting portion; and The steps include: sandwiching the entire circumference of the conductor covering portion and the entire circumference of the connecting portion by using a self-adhesive adhesive formed on the entire circumference of the edge of the first shell, an adhesive formed at least on the edge to which the conductor covering portion of the second shell is attached, and an adhesive formed at least on the edge to which the connecting portion of the second shell is attached; preventing water from entering between the electric wire and the shell including the first shell and the second shell, between the shell and the connecting portion, and between the first shell and the second shell by using the adhesive formed on the edge of the first shell and the adhesive formed on the edge of the second shell; and sealing the conductor connecting portion in a space formed by a recessed portion, the entire circumference of the recessed portion being surrounded by the first shell, the second shell, and the adhesive, the recessed portion being arranged in at least any one of the first shell or the second shell.

3. The method for manufacturing an electric wire with a connector according to claim 2, further comprising: The step of applying and curing a sealant to the edge of the first shell to form the adhesive; as well as The step of applying and curing the sealant to the edge of the second housing to form the adhesive.

4. The method for manufacturing an electric wire with a connector according to claim 3, wherein: The sealant has a thixotropic index value of 2 or more.

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