Connector with built-in ferrite core

Abstract

The present disclosure relates to a connector with a built-in ferrite core, which suppresses damage to the ferrite core and has excellent selection freedom of a resin material used. A connector (10) with a built-in ferrite core is provided with a terminal fitting (12), a ferrite core (14) disposed around the terminal fitting (12), and a connector housing (16) that houses the terminal fitting (12) and the ferrite core (14). The connector housing (16) includes a first resin portion (18) that holds the terminal fitting (12) in an embedded state, and a second resin portion (20) that holds the first resin portion (18) and the ferrite core (14) in an embedded state.

Description

Technical Field

[0001] The present invention relates to a connector with a built-in ferrite core. Background Art

[0002] Conventionally, for the purpose of suppressing noise when power is transmitted between vehicle-mounted components, a connector with a built-in ferrite core in which a ferrite core is arranged around a terminal part as disclosed in Patent Document 1 has been used. However, when a connector is formed by embedding the ferrite core together with the terminal part in a connector housing made of synthetic resin through insert molding, there is a problem that the ferrite core is damaged due to the influence of the shrinkage force when the resin is cured. For this reason, Patent Document 1 proposes a countermeasure in which a core molded body is preliminarily surrounded by a protective portion made of a resin material softer than the connector housing, the terminal part is assembled to the core molded body, and the connector housing is molded as an insert molded product. According to the above method, since the ferrite core is surrounded by a protective portion made of a resin material softer than the connector housing, the shrinkage force of the connector housing during the molding of the connector housing is absorbed by the protective portion, thereby suppressing damage to the ferrite core. Prior art literature Patent Literature

[0003] Patent Document 1: Japanese Patent Application Publication No. 2015-53202 Summary of the invention Problems to be solved by the invention

[0004] However, the structure of Patent Document 1 requires that the protection part must be formed of a resin material softer than the connector housing. Therefore, for example, when the connector is required to have high heat resistance, the resin material of the protection part may not meet the heat resistance requirement. Therefore, further improvement is needed.

[0005] In view of this, a connector having a built-in ferrite core is disclosed, in which damage to the ferrite core is suppressed and the degree of freedom in selecting a resin material to be used is excellent. Solutions for solving problems

[0006] The connector with a built-in ferrite core disclosed in the present invention comprises: a terminal part; a ferrite core arranged around the terminal part; and a connector housing which accommodates the terminal part and the ferrite core, the connector housing comprising a first resin portion for holding the terminal part in an embedded state and a second resin portion for holding the first resin portion and the ferrite core in an embedded state. Effects of the Invention

[0007] According to the present disclosure, it is possible to provide a connector having a built-in ferrite core, in which damage to the ferrite core is suppressed and in which the degree of freedom in selecting a resin material to be used is excellent. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 This is a perspective view showing the connector with built-in ferrite core according to the first embodiment in a see-through state in which the first and second resin portions can be seen through. Figure 2 yes Figure 1 A top view of a connector with a built-in ferrite core is shown. Figure 3 yes Figure 2 III-III sectional view. Figure 4 yes Figure 2 IV-IV cross-sectional view. Figure 5 It means composition Figure 1 A perspective view of a terminal part of a connector with a built-in ferrite core is shown. Figure 6 The structure is represented by the buried state of the terminal parts Figure 1 A perspective view of the first resin portion of the connector having a built-in ferrite core shown. Figure 7 This is a perspective view showing a connector with a built-in ferrite core according to the second embodiment. Figure 8 It is a perspective view showing a connector with a built-in ferrite core according to the third embodiment. DETAILED DESCRIPTION

[0009] [Description of Embodiments of the Present Disclosure] First, embodiments of the present disclosure will be described by way of examples. The connector with a built-in ferrite core disclosed in the present invention comprises: a terminal part; a ferrite core arranged around the terminal part; and a connector housing which accommodates the terminal part and the ferrite core, the connector housing comprising a first resin portion for holding the terminal part in an embedded state and a second resin portion for holding the first resin portion and the ferrite core in an embedded state.

[0010] According to the connector with built-in ferrite core disclosed in the present invention, the connector housing is divided into a first resin portion for holding the terminal parts in an embedded state and a second resin portion for holding the first resin portion and the ferrite core in an embedded state. Therefore, after forming the first resin portion for holding the terminal parts in an embedded state as a primary molded product, the primary molded product and the ferrite core are injection molded into the second resin portion as an insert molded product, and then the connector with built-in ferrite core is formed as a secondary molded product. Thus, since the amount of resin in the secondary molded product containing the ferrite core as an insert molded product can be reduced by the amount corresponding to the first resin portion, the contraction force of the resin material of the second resin portion acting on the ferrite core during curing can be reduced, thereby preventing or suppressing damage to the ferrite core.

[0011] Originally, it is not necessary to cover the ferrite core with a resin material softer than the connector housing as in Patent Document 1, and the first resin portion and the second resin portion can be made of any material. Therefore, even if a hard material with high heat resistance such as PBT (polybutylene terephthalate) is selected, a connector with a built-in ferrite core can be provided, which can reduce the risk of damage to the ferrite core and has excellent freedom in selecting the resin material used.

[0012] Preferably, the second resin portion is made of a resin material having a higher heat resistance than PVC. Since the connector housing is divided into the first resin portion and the second resin portion, the shrinkage force during resin solidification has a reduced effect on the ferrite core. Therefore, there is no need to surround the ferrite core with a resin material softer than the connector housing (such as PVC (polyvinyl chloride) etc.) as in the existing structure, and the second resin portion surrounding the ferrite core can be formed with a resin material having a higher heat resistance than PVC. Thus, the heat resistance of the connector with a built-in ferrite core can be improved, and a connector with a built-in ferrite core having excellent heat resistance can be provided. Resin materials having a higher heat resistance than PVC preferably include thermoplastic resins such as PBT, PPS (polyphenylene sulfide), PTFE (polytetrafluoroethylene), and PAI (polyamide-imide), and thermosetting resins such as PI (polyimide).

[0013] Preferably, the ferrite core is arranged in a ring shape around the first resin part; the second resin part includes a filling part filled between the inner peripheral surface of the ferrite core and the opposing surface of the first resin part, and an outer surface covering part covering the outer peripheral surface and a pair of axial end surfaces of the ferrite core, and the filling part and the outer surface covering part are formed as a whole. Since the second resin part is integrally provided with the filling part and the outer surface covering part, the ferrite core can be stably maintained in a buried state around the first resin part. Originally, since the second resin part is provided with the filling part and the outer surface covering part as the configuration area, the resin amount in each area can be advantageously adjusted.

[0014] Preferably, the surface of the first resin portion is provided with a protrusion protruding toward the inner peripheral surface of the ferrite core. Since the surface of the first resin portion is provided with a protrusion protruding toward the inner peripheral surface of the ferrite core, the amount of resin in the filling portion of the second resin portion, where the resin thickness is likely to increase, can be reduced by an amount corresponding to the volume of the protrusion, and the contraction pressure of the second resin portion in the filling portion when solidifying can be reduced, thereby further suppressing damage to the ferrite core.

[0015] Preferably, the plurality of protrusions are dispersedly arranged on the surface of the first resin part in a manner that they are spaced from each other in the circumferential direction. Since the plurality of protrusions are dispersedly arranged on the surface of the first resin part in a manner that they are spaced from each other in the circumferential direction, it is possible to reduce the amount of resin in the filling portion of the second resin part through the plurality of protrusions. In addition, each protrusion can be set smaller, and the following problems can be prevented in advance: when the first resin part is solidified, the first resin part is deformed due to the reduction of the protrusions, thereby causing the terminal parts to be misaligned.

[0016] Preferably, the outer surface coating portion includes an exposure hole for exposing the ferrite core. The exposure hole can reduce the amount of resin in the outer surface coating portion, thereby further advantageously preventing or suppressing damage to the ferrite core due to shrinkage force during curing of the second resin portion.

[0017] <Details of the embodiments of the present disclosure> Specific examples of the connector with built-in ferrite core of the present disclosure are described below with reference to the drawings. Note that the present disclosure is not limited to these examples, but is shown by the claims, and is intended to include all changes within the meaning and scope of the equivalents of the claims.

[0018] <Implementation method 1> Regarding the connector 10 with built-in ferrite core according to the first embodiment of the present disclosure, Figures 1 to 6 The connector 10 with a built-in ferrite core is, for example, a connector for connecting a motor to a PCU (power control unit). One end of the terminal part 12 of the connector 10 with a built-in ferrite core is electrically connected to the motor (not shown), and the other end is electrically connected to the PCU (not shown). In addition, the connector 10 with a built-in ferrite core can be arranged in any direction. Figure 3 The upper part of the Figure 3 The bottom of the as below, Figure 2 The left side in the figure is the front, Figure 2 The right side in the figure is the rear, Figure 2 The upper part of the middle is the left side, Figure 2 In the description, the lower side is referred to as the right side. In addition, for a plurality of identical components, sometimes only some of the components are marked with reference numerals, while the reference numerals of the other components are omitted.

[0019] <Connector with built-in ferrite core 10> The connector 10 with a built-in ferrite core includes a terminal part 12, a ferrite core 14 arranged around the terminal part 12, and a connector housing 16 that accommodates the terminal part 12 and the ferrite core 14. In addition, the connector housing 16 includes a first resin portion 18 that holds the terminal part 12 in an embedded state, and a second resin portion 20 that holds the first resin portion 18 and the ferrite core 14 in an embedded state. Figure 1 In FIG. 1 , the first resin portion 18 and the second resin portion 20 are shown in a state where the internal components can be seen through.

[0020] <Terminal Parts 12> Figure 5 As also shown in the figure, in Embodiment 1, a plurality of terminal parts 12 are provided, which are the first terminal part 12a, the second terminal part 12b, and the third terminal part 12c from left to right. Each terminal part 12 (the first to third terminal parts 12a to 12c) is respectively formed by a busbar, for example, formed by a conductive metal such as copper or copper alloy, aluminum or aluminum alloy. In Embodiment 1, the first to third terminal parts 12a to 12c are provided without any bumps, etc., and are in the shape of a flat plate extending parallel to a horizontal plane (a plane perpendicular to the up and down direction). In particular, in Embodiment 1, the first to third terminal parts 12a to 12c have substantially the same lengthwise dimension (front-to-back dimension) and widthwise dimension (left-to-right dimension) as a whole, and extend in the front-to-back direction respectively.

[0021] At the front end of each of the first to third terminal parts 12a to 12c, a substantially circular front through hole 22 is formed that penetrates in the plate thickness direction (vertical direction). At the rear end of each of the first to third terminal parts 12a to 12c, a substantially circular rear through hole 24 is formed that penetrates in the plate thickness direction (vertical direction). Thus, the front end of each of the first to third terminal parts 12a to 12c, which is one end, is configured as a single terminal part 26, and each single terminal part 26 is electrically connected to a motor (not shown). In addition, the rear end of each of the first to third terminal parts 12a to 12c, which is the other end, is configured as a single terminal part 28, and each single terminal part 28 is electrically connected to a PCU (not shown). In addition, in each of the first to third terminal parts 12a to 12c, the middle portion in the front-rear direction between each single terminal part 26 and each single terminal part 28 is configured as a middle portion 30 (respectively, the first to third middle portions 30a to 30c).

[0022] In embodiment 1, in the middle portion in the front-to-back direction (the first to third middle portions 30a to 30c) of the first to third terminal parts 12a to 12c arranged side by side in the left-to-right direction, the left-to-right dimension from the left end of the first terminal part 12a to the right end of the third terminal part 12c is smaller than that of other portions (for example, the front end portion or the rear end portion of the first to third terminal parts 12a to 12c).

[0023] That is, the right protrusion 32 protruding to the right relative to the front and rear ends in the middle part of the front-back direction of the first terminal part 12a is bent in a substantially crank shape relative to the front and rear ends. Therefore, in the left end of the first terminal part 12a, a left side recess 33 opening to the left is formed at the formation position of the right protrusion 32. Similarly, in the middle part of the front-back direction of the third terminal part 12c, a left protrusion 34 protruding to the left relative to the front and rear ends is bent in a substantially crank shape relative to the front and rear ends. Therefore, in the right end of the third terminal part 12c, a right side recess 35 opening to the right is formed at the formation position of the left protrusion 34. In addition, in the middle part of the front-back direction of the second terminal part 12b, recesses opening to the left and right directions are provided at both ends in the left and right directions, so that a narrow width portion 36 having a smaller width dimension (left and right dimension) is formed relative to the front and rear ends.

[0024] These right protrusion 32, narrow width portion 36, and left protrusion 34 are respectively arranged at approximately the same position in the front-to-back direction of the first to third terminal parts 12a to 12c, and have approximately the same front-to-back direction dimensions. That is, the right protrusion 32 of the first terminal part 12a is close to the left recess of the narrow width portion 36 constituting the second terminal part 12b (or, the right protrusion 32 enters the left recess of the narrow width portion 36). In addition, the left protrusion 34 of the third terminal part 12c is close to the right recess of the narrow width portion 36 constituting the second terminal part 12b (or, the left protrusion 34 enters the right recess of the narrow width portion 36).

[0025] Thus, in the first to third terminal parts 12a to 12c, the left-right dimension from the left end of the first terminal part 12a to the right end of the third terminal part 12c is smaller than the front end and the rear end at the formation position of the right protrusion 32, the narrow width portion 36, and the left protrusion 34. In addition, the portion with a smaller left-right dimension from the left end of the first terminal part 12a to the right end of the third terminal part 12c is formed with a space inside the left concave portion 33 and the right concave portion 35, constituting a placement area 38 for placing the ferrite core 14.

[0026] <Ferrite core 14> Figure 4As also shown in the figure, the ferrite core 14 is annular as a whole, and the internal space 39 of the ferrite core 14 is an oval cross-section that is long in the transverse direction, wherein the maximum left-right dimension is larger than the maximum up-down dimension. In addition, the ferrite core 14 has a predetermined front-to-back dimension, and the front-to-back dimension of the ferrite core 14 is smaller than the front-to-back dimension of the left and right recesses 33 and 35 that constitute the arrangement area 38. Therefore, as described later, when the ferrite core 14 (upper and lower ferrite cores 48 and 50) are arranged around the first resin portion 18 that holds the first to third terminal parts 12a to 12c, the circumferential ends of the upper and lower ferrite cores 48 and 50 are easily inserted into the left and right recesses 33 and 35. As the ferrite core 14, a conventionally known material can be used. In the first embodiment, the ferrite core 14 is formed of Mn-Zn ferrite.

[0027] The ferrite core 14 is disposed in a portion of the first to third terminal parts 12a to 12c where the left-right dimension decreases from the left end of the first terminal part 12a to the right end of the third terminal part 12c so as to cover the right protrusion 32, the narrow width part 36, and the left protrusion 34. That is, the ferrite core 14 includes an upper portion 40 and a lower portion 42 that cover the right protrusion 32, the narrow width part 36, and the left protrusion 34 from above and below, respectively. In addition, the ferrite core 14 includes a left portion 44 inserted into the left concave portion 33 of the arrangement area 38 of the ferrite core 14 and a right portion 46 inserted into the right concave portion 35 of the arrangement area 38.

[0028] The upper portion 40 is connected to the left portion 44 and the right portion 46 via an upper connecting portion 47a, and the lower portion 42 is connected to the left portion 44 and the right portion 46 via a lower connecting portion 47b. The upper connecting portions 47a and the lower connecting portions 47b are inclined with respect to the up-down direction and the horizontal direction (direction perpendicular to the up-down direction) and extend obliquely.

[0029] In Embodiment 1, the ferrite core 14 can be divided in the vertical direction, and the ferrite core 14 is composed of an upper ferrite core 48 located on the upper side and a lower ferrite core 50 located on the lower side. That is, the upper ferrite core 48 and the lower ferrite core 50 are both in the shape of a half-split cylinder, and the upper ferrite core 48 and the lower ferrite core 50 overlap each other in the vertical direction at both circumferential end surfaces, thereby forming an oblong internal space 39 in which the respective openings cover each other.

[0030] In short, the upper portion 40 and the lower portion 42 of the ferrite core 14 each having a predetermined left-right dimension are formed by the circumferential middle portions of the upper ferrite core 48 and the lower ferrite core 50. In addition, the upper connecting portions 47a are formed by the circumferential side portions of the upper ferrite core 48, and the lower connecting portions 47b are formed by the circumferential side portions of the lower ferrite core 50. In addition, the left circumferential end portions of the upper ferrite core 48 and the lower ferrite core 50 overlap each other to form the left portion 44 of the ferrite core 14. Similarly, the right circumferential end portions of the upper ferrite core 48 and the lower ferrite core 50 overlap each other to form the right portion 46 of the ferrite core 14.

[0031] In addition, the inner peripheral surface 52 of the ferrite core 14 is composed of the inner peripheral surface 52a of the upper ferrite core 48 and the inner peripheral surface 52b of the lower ferrite core 50, and the outer peripheral surface 54 of the ferrite core 14 is composed of the outer peripheral surface 54a of the upper ferrite core 48 and the outer peripheral surface 54b of the lower ferrite core 50. Furthermore, the front end surface 56, which is one axial end surface of the ferrite core 14, is composed of the front end surface 56a of the upper ferrite core 48 and the front end surface 56b of the lower ferrite core 50, and the rear end surface 58, which is the other axial end surface of the ferrite core 14, is composed of the rear end surface 58a of the upper ferrite core 48 and the rear end surface 58b of the lower ferrite core 50.

[0032] <Connector housing 16> As described above, the connector housing 16 includes a first resin portion 18 and a second resin portion 20. The material of the synthetic resin constituting the first resin portion 18 and the second resin portion 20 is not limited, but is preferably formed of a resin material with high heat resistance. In addition, the materials of the synthetic resin constituting the first resin portion 18 and the second resin portion 20 may be the same or different from each other. In embodiment 1, the first resin portion 18 and the second resin portion 20 are both made of PBT (polybutylene terephthalate), which is a resin material with higher heat resistance than PVC (polyvinyl chloride). In addition, as a resin material with higher heat resistance than PVC, for example, thermoplastic resins such as PBT, PPS (polyphenylene sulfide), PTFE (polytetrafluoroethylene), PAI (polyamide-imide) or thermosetting resins such as PI (polyimide resin) can be cited. As the material of the first resin portion 18 and the second resin portion 20, these materials can be appropriately used.

[0033] <First resin portion 18> like Figure 6As shown, the first resin portion 18 holds each terminal part 12 (the first to third terminal parts 12a to 12c) in an embedded state. Specifically, the first resin portion 18 substantially completely covers the middle portion (the first to third middle portions 30a to 30c) of each terminal part 12 (the first to third terminal parts 12a to 12c) in the front-to-back direction. In other words, each of the first to third terminal parts 12a to 12c has one terminal portion 26 (front terminal portion) protruding forward from the first resin portion 18, and each of the other terminal portions 28 (rear terminal portions) protruding rearward from the first resin portion 18. In Embodiment 1, Figure 3 , 4 As also shown in the figure, the first resin portion 18 having a substantially constant thickness dimension is substantially fully fixed to the surface of a specified area (the first to third middle portions 30a to 30c) of each terminal part 12 (the first to third terminal parts 12a to 12c).

[0034] Furthermore, leg portions 59 protruding outward in the left-right direction are provided at both end portions in the left-right direction of the rear portion of the first resin portion 18. Each of these leg portions 59 is provided outward in the left-right direction relative to the first terminal part 12a and the third terminal part 12c, and each of the leg portions 59 is provided with a metal collar 62 having a bolt insertion hole 60. That is, at the rear portion of the first resin portion 18, a pair of collars 62, 62 are held by each of the leg portions 59 of the first resin portion 18 at a position outward in the left-right direction relative to the first terminal part 12a and the third terminal part 12c. The connector 10 with a built-in ferrite core is fixed to a motor, a PCU connected to each of the one terminal portions 26 or each of the other terminal portions 28 of each of the terminal parts 12, or a vehicle-mounted component disposed therebetween, by bolts (not shown) inserted through these bolt insertion holes 60.

[0035] In the first embodiment, the first resin portion 18 is formed as an integrally molded product (primary molded product 64) having the first to third terminal parts 12a to 12c and a pair of ferrules 62, 62. That is, when the first resin portion 18 is molded, the first to third terminal parts 12a to 12c and a pair of ferrules 62, 62 are set in the molding cavity of the first resin portion 18, and the resin material (PBT) constituting the first resin portion 18 is molded by injection molding, thereby forming a Figure 6 The primary molded product 64 is shown.

[0036] Here, in the first resin portion 18, a protrusion 68 is provided which protrudes from the upper surface 66a and the lower surface 66b which are the surfaces of the first resin portion 18 to both sides in the upper and lower directions in the portion covering the right protrusion 32, the narrow width portion 36 and the left protrusion 34 of the first to third terminal parts 12a to 12c. In the first embodiment, a plurality of (five) protrusions 68 are provided on each of the upper surface 66a and the lower surface 66b of the first resin portion 18, and these protrusions 68 are dispersedly arranged in a manner spaced from each other along the width direction (left-right direction) which is the circumferential direction on the surface of the first resin portion 18. The protrusions 68 have the same shape as each other, and in the first embodiment, each protrusion 68 is formed into a substantially rectangular flat plate shape.

[0037] As described later, in the first resin portion 18, the ferrite core 14 (upper and lower ferrite cores 48, 50) is arranged on the outer peripheral side relative to the portion covering the right protrusion 32, the narrow width portion 36, and the left protrusion 34 of the first to third terminal parts 12a to 12c, so that each protrusion 68 protrudes toward the inner peripheral surface 52 of the ferrite core 14. That is, each protrusion 68 protruding upward protrudes toward the inner peripheral surface 52a of the upper ferrite core 48, and each protrusion 68 protruding downward protrudes toward the inner peripheral surface 52b of the lower ferrite core 50. In other words, the right protrusion 32, the narrow width portion 36, and the left protrusion 34 of the first to third terminal parts 12a to 12c, the first resin portion 18 covering them, and the protrusions 68 protruding vertically and outwardly from the first resin portion 18 are all arranged in the internal space 39 of the ferrite core 14. Thus, the ferrite core 14 is arranged in a ring shape around the first resin portion 18.

[0038] In addition, the protruding tip of each protrusion 68 protruding outward in the vertical direction from the surface (upper surface 66a and lower surface 66b) of the first resin portion 18 may abut against the inner peripheral surface 52 (inner peripheral surfaces 52a, 52b) of the ferrite core 14, or may be separated by a predetermined distance. In the first embodiment, the protruding tip of each protrusion 68 and the inner peripheral surface 52 (inner peripheral surfaces 52a, 52b) of the ferrite core 14 are opposed to each other in the vertical direction with a small gap.

[0039] <Second resin portion 20> Next, in a state where the ferrite core 14 is arranged on the outer peripheral side of the first resin portion 18 holding the first to third terminal parts 12a to 12c, the second resin portion 20 is provided on the outer peripheral side of the ferrite core 14. The second resin portion 20 holds the first resin portion 18 and the ferrite core 14 in an embedded state. That is, the second resin portion 20 has an outer surface covering portion 70 covering the outer peripheral surface 54 of the ferrite core 14 and the front end surface 56 and the rear end surface 58 as a pair of axial end surfaces. In the first embodiment, Figure 3 , 4As also shown in the figure, the outer surface covering portion 70 having a substantially constant thickness is substantially entirely fixed to the outer peripheral surface 54 , the front end surface 56 , and the rear end surface 58 of the ferrite core 14 .

[0040] Furthermore, the second resin portion 20 is also filled in the internal space 39 of the ferrite core 14. Specifically, the second resin portion 20 has a filling portion 72 that is filled between the inner peripheral surface 52 of the ferrite core 14 and the opposing surface of the first resin portion 18, that is, between the inner peripheral surface 52a of the upper ferrite core 48 and the upper surface 66a of the first resin portion 18 in the vertical direction opposing surface, and between the inner peripheral surface 52b of the lower ferrite core 50 and the lower surface 66b of the first resin portion 18 in the vertical direction opposing surface. That is, the filling portion 72 is fixed to each of the inner peripheral surfaces 52a, 52b of the upper and lower ferrite cores 48, 50 and each of the upper surface 66a and the lower surface 66b of the first resin portion 18. Such second resin portion 20 includes an outer surface coating portion 70 provided on the outer side of ferrite core 14 and a filling portion 72 provided on the inner side of ferrite core 14 , which are integrally provided.

[0041] In the first embodiment, the second resin portion 20 is formed as an integrally molded product (secondary molded product) having a primary molded product 64 and a ferrite core 14, and the connector 10 with a built-in ferrite core is formed by the secondary molded product. That is, when the second resin portion 20 is molded, the ferrite core 14 (upper and lower ferrite cores 48, 50) is arranged on the outer peripheral side of the primary molded product 64 in the molding cavity of the second resin portion 20, and the resin material (PBT) constituting the second resin portion 20 is molded by injection. Thus, while the second resin portion 20 and the connector housing 16 are formed, Figures 1 to 4 A connector 10 with a built-in ferrite core is shown.

[0042] <Method for manufacturing connector 10 having built-in ferrite core> A specific example of a method for manufacturing the connector 10 with a built-in ferrite core will be described below. The method for manufacturing the connector 10 with a built-in ferrite core is not limited to the method described below.

[0043] First, prepare the first to third terminal parts 12a to 12c and a pair of ferrules 62, 62. Then, Figure 5 As shown, in the molding cavity of the first resin part 18, the first to third terminal parts 12a to 12c are arranged side by side in the left-right direction, and a pair of ferrules 62, 62 are arranged outside the first terminal part 12a and the third terminal part 12c in the left-right direction. After that, the resin material (PBT) constituting the first resin part 18 is injected into the molding cavity of the first resin part 18 for molding. After molding, the molding mold is opened to obtain a primary molded product 64.

[0044] Next, the upper and lower ferrite cores 48 and 50 are arranged from the outside in the vertical direction of each protrusion 68 of the primary molded product 64, and the circumferential end surfaces of the upper and lower ferrite cores 48 and 50 are aligned and overlapped, and the primary molded product 64 and the upper and lower ferrite cores 48 and 50 in this state are set in the molding cavity of the second resin part 20. Then, the resin material (PBT) constituting the second resin part 20 is injected into the molding cavity of the second resin part 20 to mold. In this way, the connector housing 16 can be formed at the same time as the second resin part 20 is formed. After molding, the connector 10 with a built-in ferrite core as a secondary molded product is obtained by opening the molding mold, thereby completing the manufacture of the connector 10 with a built-in ferrite core.

[0045] In the connector 10 with a built-in ferrite core manufactured in this way, each terminal portion 26 (front terminal portion) is electrically connected to a motor not shown in the figure, and the other terminal portion 28 (rear terminal portion) is electrically connected to a PCU not shown in the figure. In addition, by inserting a bolt not shown in the figure into the bolt insertion hole 60 of each ring 62 provided on each leg portion 59, the connector 10 with a built-in ferrite core can be fixed to the motor or PCU, or other appropriate vehicle-mounted components. In addition, in such a connector 10 with a built-in ferrite core, since a ferrite core 14 is arranged around each terminal part 12 (the first to third terminal parts 12a to 12c), the noise during power transmission between the motor and the PCU can be suppressed by the ferrite core 14.

[0046] According to the connector 10 with built-in ferrite core of the first embodiment, the connector housing 16 includes a first resin portion 18 for holding each terminal part 12 in an embedded state and a second resin portion 20 for holding the first resin portion 18 and the ferrite core 14 in an embedded state. The first resin portion 18 is formed as an integrally molded product (primary molded product 64) having each terminal part 12 (first to third terminal parts 12a to 12c). In addition, the second resin portion 20 is formed as an integrally molded product (secondary molded product) having the primary molded product 64 and the ferrite core 14. That is, the interior of the ferrite core 14 is also filled with the filling portion 72 of the second resin portion 20, but since the second resin portion 20 is molded in a state where the primary molded product 64 is arranged on the ferrite core 14, the amount of resin material of the second resin portion 20, especially the amount of resin material of the filling portion 72, can be reduced. That is, by configuring the connector housing 16 to include the first resin portion 18 and the second resin portion 20, the amount of resin material required for primary molding can be reduced, for example, compared to the case where the connector housing is molded with each terminal component disposed inside the ferrite core. Therefore, it is possible to avoid damage to the ferrite core 14 due to shrinkage of the resin material during molding of the second resin portion 20.

[0047] Furthermore, the degree of freedom in selecting the material of the component surrounding the ferrite core 14 is thereby increased, and a resin material having a higher heat resistance than PVC (PBT in the first embodiment) can be adopted as the resin material of the second resin portion 20, which is the component surrounding the ferrite core 14. As a result, a connector 10 having a built-in ferrite core and excellent heat resistance can be provided.

[0048] The ferrite core is arranged in a ring shape around the first resin part, and the second resin part 20 includes a filling part 72 that is integrally filled inside the ferrite core 14 and an outer surface covering part 70 that covers the outer side of the ferrite core 14. By arranging the first resin part 18 (primary molded product 64) inside the ferrite core 14, it is possible to further reliably achieve a reduction in the resin material of the filling part 72. In addition, by molding the second resin part 20 in a state where the primary molded product 64 and the ferrite core 14 are already set in the cavity, the filling part 72 and the outer surface covering part 70 can be formed integrally, thereby contributing to improving the manufacturing efficiency of the second resin part 20 and even the connector 10 with the built-in ferrite core. In particular, by configuring the ferrite core 14 to be divisible up and down, the operation of arranging the ferrite core 14 around the first resin part 18 can also be easily performed.

[0049] The first resin portion 18 has a protrusion 68 protruding toward the inner peripheral surface 52 of the ferrite core 14 on its surface (upper surface 66a and lower surface 66b). This can further reduce the amount of resin material in the filling portion 72 when the second resin portion 20 is molded, and more reliably avoid damage to the ferrite core 14 when the second resin portion 20 shrinks.

[0050] In particular, on the surface (upper surface 66a and lower surface 66b) of the first resin portion 18, a plurality of protrusions 68 are spaced apart from each other and dispersedly arranged in the circumferential direction. As a result, the amount of resin material in the filling portion 72 can be further reduced when the second resin portion 20 is molded, and damage to the ferrite core 14 when the second resin portion 20 shrinks can be further reliably avoided. In addition, compared with the case where a single large protrusion is provided on the surface of the first resin portion, the risk of damage caused by bending of each terminal part 12 (first to third terminal parts 12a to 12c) located inside the first resin portion 18 due to shrinkage of the first resin portion 18 when the first resin portion 18 is molded can be reduced.

[0051] <Implementation method 2> The following use Figure 7 A connector 80 with a built-in ferrite core according to a second embodiment of the present disclosure will be described. The connector 80 with a built-in ferrite core according to the second embodiment has the same structure as the connector 10 with a built-in ferrite core according to the first embodiment, but differs in that an exposure hole 86 for exposing the ferrite core 14 is provided in the outer surface covering portion 84 of the second resin portion 82. In the following description, for components and locations that are substantially the same as those in the first embodiment, detailed descriptions thereof are omitted by marking the same reference numerals as those in the first embodiment in the drawings.

[0052] Specifically, in the outer covering portion 84, in particular, in the portion covering the outer peripheral surface 54 (outer peripheral surface 54a, 54b) of the ferrite core 14, an exposure hole 86 is formed that penetrates the outer covering portion 84 in the up-down direction or the left-right direction. In the second embodiment, a plurality of exposure holes 86 that are substantially circular in a plan view or a side view are formed, and the plurality of exposure holes 86 are arranged in a regular pattern at predetermined intervals in the circumferential direction and the front-back direction of the outer covering portion 84. In addition, through these exposure holes 86, the outer peripheral surface 54 (outer peripheral surface 54a, 54b) of the ferrite core 14 is exposed to the outside.

[0053] In addition, a plurality of exposure holes 86 having a substantially circular shape in a side view and penetrating the second resin portion 82 in the left-right direction are formed in the portion of the second resin portion 82 that covers the left portion 44 and the right portion 46 of the ferrite core 14 from the outside in the left-right direction. In addition, a plurality of exposure holes 86 having a substantially circular shape in a plan view and penetrating the second resin portion 82 in the top-bottom direction are formed in other portions of the second resin portion 82 (for example, a portion that covers the upper portion 40 and the lower portion 42 of the ferrite core 14 from the outside, or a portion that covers the upper connecting portions 47a and the lower connecting portions 47b that extend obliquely).

[0054] In the connector 80 with built-in ferrite core of the second embodiment, since the connector housing 16 is also configured to include the first resin portion 18 and the second resin portion 82, the same effect as the connector 10 with built-in ferrite core of the first embodiment can be achieved. That is, since the first resin portion 18 is provided inside the ferrite core 14, the amount of resin material of the second resin portion 82 (filling portion 72) filled inside the ferrite core 14 can be reduced. In addition, in the second embodiment, a plurality of exposure holes 86 are provided in the outer surface covering portion 84 of the second resin portion 82, thereby further reducing the amount of resin material of the second resin portion 82 (outer surface covering portion 84) provided outside the ferrite core 14. As a result, the amount of resin material of the second resin portion 82 can be further reduced, and the risk of damage to the ferrite core 14 due to shrinkage of the resin material when the second resin portion 82 is molded can be further reduced.

[0055] In addition, since the outer peripheral surface 54 (outer peripheral surfaces 54a, 54b) of the ferrite core 14 is exposed to the outside through multiple exposure holes 86, even if the ferrite core 14 generates heat when absorbing noise, the heat can be dissipated to the external space through the multiple exposure holes 86, thereby providing a connector 80 with a built-in ferrite core with excellent thermal performance.

[0056] <Implementation method 3> The following use Figure 8 A connector 90 with a built-in ferrite core according to a third embodiment of the present disclosure will be described. The connector 90 with a built-in ferrite core according to the third embodiment is similar to the connector 80 with a built-in ferrite core according to the second embodiment, and an exposure hole 96 for exposing the ferrite core 14 is provided in the outer surface covering portion 94 of the second resin portion 92. Thus, the connector 90 with a built-in ferrite core according to the third embodiment can achieve the same effect as the connector 80 with a built-in ferrite core according to the second embodiment.

[0057] In the second embodiment, the exposure holes 86 are provided in a substantially circular shape, while in the third embodiment, the exposure holes 96 are provided in a substantially rectangular shape in a plan view or a side view. In the third embodiment, a plurality of exposure holes 96 are provided in the outer surface covering portion 94 at a predetermined distance in the circumferential direction, but the cross-sectional area of ​​each exposure hole 96 is larger than that of the exposure hole 86 in the second embodiment. In the third embodiment, the sum of the cross-sectional areas of the plurality of exposure holes 96 is larger than that of the plurality of exposure holes 86 in the second embodiment. Thus, the resin material constituting the outer surface covering portion 94 in the second resin portion 92 is less than that of the outer surface covering portion 84 in the second embodiment, and as a result, the risk of damage to the ferrite core 14 due to shrinkage of the resin material during molding of the second resin portion 92 can be further reduced.

[0058] <Other embodiments> The technology described in this specification is not limited to the embodiments described in the above description and drawings, and for example, the following embodiments are also included in the technical scope of the technology described in this specification.

[0059] (1) In the above embodiment, each terminal part 12 (the first to third terminal parts 12a to 12c) is provided with a right protrusion 32 (left concave part 33), a narrow width part 36, and a left protrusion 34 (right concave part 35), but at least one of the terminal parts may extend substantially straight in the front-back direction. In addition, in the above embodiment, three terminal parts 12 (the first to third terminal parts 12a to 12c) are provided, but the number of terminal parts is not limited, and may be one, two, or more than four.

[0060] (2) In the above-mentioned embodiment, five roughly rectangular flat-plate-shaped protrusions 68 are provided on the upper surface 66a and the lower surface 66b of the first resin portion 18, but the number and shape of the protrusions are not limited. For example, one to four protrusions may be provided on the upper surface and the lower surface of the first resin portion, and six or more protrusions may be provided. In addition, the shape of the protrusion when viewed from the side is not limited to a roughly rectangular shape, and may also be a triangle, a pentagon or a polygonal shape above, a semicircular shape, or a combination of these shapes. Furthermore, the protrusion may be provided only on the upper surface or the lower surface of the first resin portion, as a substitute for or in addition to the upper surface or the lower surface, for example, on the left end surface or the right end surface of the first resin portion. In addition, in the connector with a built-in ferrite core involved in the present disclosure, the protrusion provided on the first resin portion is not necessarily required.

[0061] (3) In the above-mentioned embodiment, the protruding tip of each protrusion 68 and the inner peripheral surface 52 (inner peripheral surface 52a, 52b) of the ferrite core 14 are slightly spaced apart and opposed in the vertical direction, but the present invention is not limited to this mode. That is, the protruding tip of each protrusion may also abut against the inner peripheral surface of the ferrite core. Moreover, when the upper ferrite core and the lower ferrite core are arranged from the outside in the vertical direction of the first resin part, the vertical position of the upper ferrite core and the lower ferrite core may be defined by the abutment of each protrusion against each inner peripheral surface of the upper and lower ferrite cores. That is, the circumferential end surfaces of the upper ferrite core and the lower ferrite core may not overlap each other in the vertical direction, or may be slightly spaced apart and opposed in the vertical direction.

[0062] (4) In the above-mentioned embodiments 2 and 3, the exposure holes 86 and 96 penetrating the second resin parts 82 and 92 are provided on the outer surface covering parts 84 and 94 of the second resin parts 82 and 92, but the present invention is not limited to this embodiment. That is, for example, a bottomed recessed part opening toward the outer peripheral side may be provided only on the outer surface covering part of the second resin part, thereby reducing the amount of resin material of the second resin part. In addition, in this case, the recessed part may be provided on the part of the outer surface covering part of the second resin part covering the axial end face of the ferrite core, instead of or in addition to the part of the outer surface covering part of the second resin part covering the outer peripheral face of the ferrite core.

[0063] (5) In the above-mentioned second and third embodiments, each exposure hole 86, 96 is formed by penetrating the second resin portion 82, 92 in the vertical direction or the horizontal direction, but each exposure hole may be formed by penetrating the second resin portion in the thickness direction. That is, in the above-mentioned second and third embodiments, the exposure holes 86, 96 provided in the outer surface covering portion 84, 94 of the second resin portion 82, 92 covering the upper connecting portion 47a and the lower connecting portion 47b extending obliquely are also formed by penetrating the second resin portion 82, 92 in the vertical direction, but the exposure holes provided in these portions may be formed by penetrating the second resin portion obliquely. Description of Reference Numerals

[0064] 10Connector with built-in ferrite core (Implementation 1) 12 terminal parts 12a 1st terminal part 12b 2nd terminal parts 12c 3rd terminal parts 14 Ferrite core 16 Connector housing 181st Resin Department 20The second resin part 22 Front through hole 24 Rear through hole 26 one terminal part (front terminal part) 28 The other terminal part (rear terminal part) 30 Middle 30a1st middle part 30b 2nd middle part 30c 3rd middle part 32 Right protrusion 33 left concave part 34 Left protrusion 35 Right concave part 36 Narrow Width 38 Installation area 39 Interior Space 40 Upper part 42 Lower part 44 Left side 46 Right 47a Upper connection part 47b Lower connection part 48 Upper ferrite core 50 Lower ferrite core 52, 52a, 52b inner circumference 54, 54a, 54b outer peripheral surface 56, 56a, 56b front end face (one axial end face) 58, 58a, 58b rear end face (other axial end face) 59 Feet 60 Bolt through hole 62 Ring 64 One-shot molding 66a Upper surface (surface) 66b Lower surface (surface) 68 protrusion 70 Outer surface covering 72 Filling 80Connector with built-in ferrite core (Implementation 2) 82 2nd resin part 84 outer surface covering part 86 Exposed hole 90Connector with built-in ferrite core (Implementation 3) 92 2nd Resin Department 94 outer surface covering part 96 Exposed Hole

Claims

1. A connector with a built-in ferrite core, comprising: Terminal parts; a ferrite core disposed around the circumference of the terminal part; and a connector housing that accommodates the terminal parts and the ferrite core, The connector housing includes a first resin portion that holds the terminal part in an embedded state, and a second resin portion that holds the first resin portion and the ferrite core in an embedded state.

2. The connector with a built-in ferrite core according to claim 1, wherein: The second resin portion is made of a resin material having higher heat resistance than PVC.

3. The connector with a built-in ferrite core according to claim 1 or claim 2, wherein: The ferrite core is arranged in a ring shape around the first resin portion; The second resin portion includes a filling portion filled between the inner peripheral surface of the ferrite core and the facing surface of the first resin portion and an outer surface covering portion covering the outer peripheral surface and a pair of axial end surfaces of the ferrite core, and the filling portion and the outer surface covering portion are formed integrally.

4. The connector with built-in ferrite core according to claim 3, wherein: A protrusion that protrudes toward the inner peripheral surface of the ferrite core is provided on a surface of the first resin portion.

5. The connector with built-in ferrite core according to claim 4, wherein: The plurality of protrusions are dispersedly arranged on the surface of the first resin portion so as to be spaced apart from each other in a circumferential direction.

6. The connector with built-in ferrite core according to claim 3, wherein: The outer surface covering portion includes an exposing hole exposing the ferrite core.

Images