Waterproof connector and power conversion device having the same

Abstract

To provide a waterproof connector capable of securing high waterproofness even under environment where temperature changes are significant, and to obtain a power conversion device with high layout property.SOLUTION: In a waterproof connector 2, a waterproof packing 5 is in contact with an inner surface 43a of a groove 43 at a first packing portion 51 and a second packing portion 52, and has a gap 7 between a packing intermediate portion 53 sandwiched between the first packing portion 51 and the second packing portion 52 and the inner surface 43a of the groove 43. As a result, sufficient reaction force can be maintained with respect to a base portion 42 and a resin case 3, and high waterproofness can be ensured without decrease in adhesion even in environment in which temperature changes are significant. In addition, since the power conversion device 100 having the waterproof connector 2 can be mounted in various places of a vehicle, layout properties are improved.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present disclosure relates to a waterproof connector and a power conversion device including the same. [Background technology]

[0002] Electric vehicles such as hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHVs, PHEVs), electric vehicles (EVs), and fuel cell vehicles (FCVs) are equipped with power conversion devices that include an inverter that drives a drive motor and a converter that boosts the battery power supply voltage. A connector is attached to the housing of the power conversion device to electrically connect it to devices outside the housing.

[0003] In recent years, the increasing power output of electric motors has led to a demand for higher power conversion devices, and high layout flexibility is also required from the perspective of vehicle mountability. To achieve high layout flexibility in power conversion devices, they must be mountable in various locations on a vehicle, and must be designed to withstand harsh external environments. In particular, connectors for electrical connection with external devices in the housing must be highly waterproof against water or saltwater in environments with significant temperature changes.

[0004] A known waterproof structure for electronic device cases is to place a packing in the opening of the case to ensure airtightness. Patent Document 1 discloses an electronic unit case in which a waterproof packing is integrally formed by resin insert molding in the portion of the case body where the connection terminals are embedded. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-66216 Summary of the Invention [Problem to be solved by the invention]

[0006] However, when the waterproof structure disclosed in Patent Document 1 is placed in an environment with significant temperature changes, the difference in the thermal expansion coefficients of the terminals, waterproof gasket, and case body can cause gaps to form between the terminals and waterproof gasket, or between the case body and waterproof gasket, causing the waterproof gasket to lose its reaction force on the terminals and case body.As a result, the adhesion of the waterproof gasket is impaired, waterproofing is reduced, and there is a problem that water or saltwater can enter the inside of the case due to capillary action, etc.

[0007] The present disclosure discloses technology for solving the above-mentioned problems, and aims to provide a waterproof connector that can ensure high waterproofing even in environments with significant temperature changes, and to obtain a power conversion device with excellent layout properties. [Means for solving the problem]

[0008] The waterproof connector of the present disclosure is a waterproof connector that is attached to a housing and is used for electrical connection with equipment outside the housing, and comprises a resin case that is attached to the outer wall of the housing and has a cylindrical opening that opens to the outside, a rod-shaped terminal that is surrounded by the opening and connected to the external equipment, a cylindrical base portion that is arranged between the outer surface of the rear part of the opening of the terminal and the inner surface of the opening, and an annular waterproof gasket that is arranged between the outer surface of the base portion and the inner surface of the opening, the waterproof gasket being arranged in an annular groove provided on the outer surface of the base portion, with one side and the other side of the inner surface of the waterproof gasket in the axial direction of the terminal being in contact with the inner surface of the groove, and there is a gap between the middle part sandwiched between the one side and the other side and the inner surface of the groove. The power conversion device of the present disclosure includes a housing and the waterproof connector of the present disclosure. [Effects of the Invention]

[0009] According to the waterproof connector of the present disclosure, one side and the other side of the inner surface of the waterproof gasket in the axial direction of the terminal come into contact with the inner surface of the groove, and there is a gap between the middle part sandwiched between the one side and the other side and the inner surface of the groove, which allows the waterproof gasket to retain sufficient reaction force, and high waterproofing can be ensured without a decrease in adhesion even in environments with significant temperature changes. Furthermore, the power conversion device of the present disclosure is provided with a waterproof connector that ensures high waterproofing, and therefore can be mounted in various locations, improving layout flexibility. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a perspective view showing a power converter equipped with a waterproof connector according to a first embodiment. [Figure 2] 1 is a cross-sectional view showing a power converter equipped with a waterproof connector according to a first embodiment. [Figure 3] 1 is a cross-sectional view showing a waterproof connector according to a first embodiment. [Figure 4] 1 is an enlarged cross-sectional view illustrating a main part of a waterproof connector according to a first embodiment. [Figure 5] 1 is an enlarged cross-sectional view illustrating a main part of a waterproof connector according to a first embodiment. [Figure 6] 10 is an enlarged cross-sectional view illustrating a main part of a waterproof connector according to a second embodiment. FIG. [Figure 7] 10 is an enlarged cross-sectional view illustrating a main part of a waterproof connector according to a third embodiment. FIG. [Figure 8] 10 is an enlarged cross-sectional view illustrating a main part of a waterproof connector according to a third embodiment. FIG. [Figure 9] 10 is an enlarged cross-sectional view illustrating a main part of a waterproof connector according to a fourth embodiment. FIG. [Figure 10] FIG. 10 is a perspective view showing a metal terminal and a waterproof packing of a waterproof connector according to a fifth embodiment. [Figure 11] 13A to 13C are diagrams illustrating the assembly process of the waterproof connector according to the sixth embodiment. [Figure 12]13 is an enlarged cross-sectional view illustrating a main part of a waterproof connector according to a sixth embodiment. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0011] Embodiment 1 A waterproof connector according to a first embodiment and a power converter equipped with the same will be described below with reference to the drawings. Fig. 1 is a perspective view showing the appearance of a power converter equipped with a waterproof connector according to the first embodiment, Fig. 2 is a cross-sectional view taken at the position indicated by AA in Fig. 1, Fig. 3 is a cross-sectional view showing the waterproof connector according to the first embodiment, and Figs. 4 and 5 are enlarged cross-sectional views of the main parts of the waterproof connector according to the first embodiment taken along a plane passing through the axes of the terminals. In each drawing, the same or corresponding parts are denoted by the same reference numerals.

[0012] The power conversion device 100 according to the first embodiment is provided between a battery and a motor as a power conversion device for driving a vehicle such as an EV or HEV, and performs power phase conversion, output adjustment, etc. Inside the housing 1 of the power conversion device 100, a power module having a power semiconductor, a current detection circuit that detects the output current from the power module, a drive circuit for driving the power semiconductor, a control circuit that issues commands to the drive circuit, a smoothing capacitor, a discharge circuit, etc. (none of which are shown) are housed.

[0013] As shown in Figures 1 and 2, a waterproof connector 2 is attached to a housing 1 for electrically connecting to a device external to the housing 1. As shown in Figure 3, the waterproof connector 2 includes a resin case 3, a metal terminal 4 having a terminal 41 and a base portion 42, and a waterproof packing 5. In the figure, an arrow X indicates the axial direction of the terminal 41. In the following description, the axial direction refers to the axial direction of the terminal 41.

[0014] The resin case 3 is a case for accommodating and protecting the metal terminals 4, and is made of an insulating material. The resin case 3 is attached to the outer wall 1a of the housing 1, and has a cylindrical opening 31 that opens to the outside. A communication hole 1b through which the bus bar 6 passes is provided at the location of the housing 1 where the resin case 3 is attached.

[0015] Rod-shaped terminal 41 is surrounded by opening 31 of resin case 3 and is connected to an external device. The base of terminal 41, located at the back of opening 31, has a hole through which bus bar 6 passes, and is electrically connected to bus bar 6 that extends from inside housing 1 to the outside through communication hole 1b. This electrically connects the external device and the device inside housing 1 via terminal 41.

[0016] The cylindrical base portion 42 is disposed between an outer peripheral surface 41a of the terminal 41 at the rear side of the opening 31 and the inner peripheral surface 31a of the opening 31. The annular waterproof gasket 5 is disposed in an annular groove 43 provided in the outer peripheral surface 42a of the base portion 42, and is disposed between the outer peripheral surface 42a of the base portion 42 and the inner peripheral surface 31a of the opening 31.

[0017] In the first embodiment, the terminals 41, base 42, and waterproof gasket 5 are insert parts that are formed integrally with the resin case 3 by insert molding. In the molding process of the resin case 3, the base 42 and terminals 41, into which the waterproof gasket 5 has already been fitted, are placed in a mold, and resin is injected around them. The material of the waterproof gasket 5 is selected to have a hardness that can withstand the molding pressure during insert molding, and heat resistance and cold resistance that can withstand use in an environment with significant temperature changes.

[0018] The configuration and function of the waterproof connector 2 according to the first embodiment will be described in detail with reference to Figures 4 and 5. In Figure 4, the side indicated by arrow S1 with respect to a dotted line parallel to the axial direction passing through approximately the center of the waterproof gasket 5 is the inner peripheral side of the waterproof gasket 5, and the side indicated by arrow S2 is the outer peripheral side of the waterproof gasket 5. Similarly, arrow S1 indicates the inner peripheral side of the cylindrical base portion 42, and arrow S2 indicates the outer peripheral side of the cylindrical base portion 42. In Figure 5, arrow Fr indicates the reaction force (contact pressure).

[0019] As shown in Fig. 4, an annular groove 43 is provided on the outer peripheral surface 42a of the base portion 42 to fit the waterproof gasket 5. The waterproof gasket 5 is an O-ring having an elliptical cross section in the axial direction, and provides a seal between the inner peripheral surface 5a and the outer peripheral surface 5b. However, the cross section of the waterproof gasket 5 is not limited to an elliptical shape and may be circular or another shape.

[0020] Because the base portion 42 and the waterproof gasket 5 are insert parts, the resin that constitutes the resin case 3 surrounds the waterproof gasket 5, and the entire outer peripheral surface 5b and part of the inner peripheral surface 5a of the waterproof gasket 5 are in contact with the resin case 3. The base portion 42, the waterproof gasket 5, and the resin case 3 each have a different coefficient of thermal expansion, and generally, resin undergoes greater dimensional change due to temperature changes in the usage environment than metal.

[0021] The waterproof gasket 5 has a first gasket portion 51, which is a portion on one side of the inner peripheral surface 5a of the waterproof gasket 5 in the axial direction of the terminal 41, and a second gasket portion 52, which is a portion on the other side, in contact with the inner surface 43a of the groove 43. Also, a gap 7 is formed between the inner surface 43a of the groove 43 and a gasket intermediate portion 53, which is a middle portion sandwiched between the first gasket portion 51 and the second gasket portion 52.

[0022] A first groove portion 431, which is a portion on one side of the inner surface 43a of the groove 43 in the axial direction of the terminal 41, and a second groove portion 432, which is a portion on the other side, are in contact with the first packing portion 51 and the second packing portion 52, respectively. A groove intermediate portion 433, which is an intermediate portion sandwiched between the first groove portion 431 and the second groove portion 432, is recessed toward the inner periphery of the base portion 42 (i.e., the arrow S1 side) relative to the first groove portion 431 and the second groove portion 432, and a gap 7 is formed by the recess of the groove intermediate portion 433 on the inner surface 43a of the groove 43.

[0023] In addition, in embodiment 1, groove 43 has an approximately triangular cross-sectional shape in which the axial groove width (indicated by W in Figure 4) narrows toward the inner periphery of base portion 42, and a gap 7 is formed between groove intermediate portion 433 including triangular apex 43b sandwiched between first groove portion 431 and second groove portion 432, and gasket intermediate portion 53 on the inner periphery surface 5a of waterproof gasket 5.

[0024] In order for the waterproof gasket 5 of the waterproof connector 2 to exhibit a high sealing function, it is necessary that an appropriate pressure is always applied to the waterproof gasket 5, and that a reaction force Fr is always generated, as shown in Figure 5. If the reaction force Fr is lost, the adhesion force of the waterproof gasket 5 will decrease.

[0025] The waterproof gasket 5 is pressed toward the gap 7 by the molding pressure during insert molding, generating a reaction force Fr against the base portion 42 and the resin case 3. Furthermore, even after being integrally formed with the resin case 3, the presence of the gap 7 keeps the waterproof gasket 5 in a state of contraction within the elastic range, and the reaction force Fr is stably maintained. For example, even in a high-temperature environment, even if the waterproof gasket 5 is pressed toward the gap 7 due to expansion of the resin case 3 or the like, the presence of the gap 7 prevents the waterproof gasket 5 from cracking due to compression, and the reaction force Fr is maintained.

[0026] The position of the apex 43b of the groove 43 in the axial direction substantially coincides with the center position of the ellipse of the waterproof packing 5, and the inner surface 43a of the groove 43 is inclined at an angle θ with respect to the axial direction. The apex 43b is also formed of a curved surface. However, the inclination angle θ of the inner surface 43a of the groove 43 and the shape of the apex 43b are not particularly limited, as long as the waterproof packing 5 is in stable contact with the inner surface 43a of the groove 43 and a gap 7 is formed between the packing middle portion 53 and the groove middle portion 433.

[0027] As described above, according to the waterproof connector 2 of embodiment 1, the waterproof gasket 5 contacts the inner surface 43a of the groove 43 at the first gasket portion 51 and the second gasket portion 52, and there is a gap 7 between the gasket middle portion 53 and the inner surface 43a of the groove 43, so that sufficient reaction force can be maintained against the base portion 42 and the resin case 3, and high waterproofing can be ensured without a decrease in adhesion even in environments with significant temperature changes.

[0028] That is, even in an environment with significant temperature changes, where dimensional changes occur due to differences in the thermal expansion coefficients of the base portion 42, the waterproof gasket 5, and the resin case 3, the presence of the gap 7 maintains the reaction force of the waterproof gasket 5 and does not reduce adhesion. Therefore, no gaps are generated between the base portion 42 and the waterproof gasket 5, or between the resin case 3 and the waterproof gasket 5, and water or saltwater can be prevented from entering the interior of the housing 1.

[0029] Furthermore, the terminals 41, base 42, and waterproof packing 5 are insert parts that are formed integrally with the resin case 3 by insert molding, making it possible to manufacture a highly accurate and reliable waterproof connector 2. Furthermore, no additional parts or processes are required to form the gap 7 between the packing middle part 53 and the inner surface 43a of the groove 43, and there is no increase in the number of parts or processes, making it possible to suppress increases in manufacturing costs.

[0030] The power conversion device 100 equipped with the waterproof connector 2 and housing 1 according to the first embodiment can be mounted in various locations on a vehicle, improving layout flexibility. Furthermore, since the power conversion device 100 can withstand use in harsh environments where there are significant temperature changes, for example, a significant temperature gradient of about -40°C to 125°C, or in environments where it is exposed to salt water, it can be mounted on vehicles such as automobiles and outboard motors that are used in such environments.

[0031] Embodiment 2 Figure 6 is an enlarged cross-sectional view of the waterproof connector according to embodiment 2, taken along a plane passing through the center of the terminal. In Figure 6, arrow Fr indicates the reaction force (contact pressure). Note that although reference numerals for parts that are the same as or equivalent to those in Figure 4 may be omitted in Figure 6, the reference numerals in Figure 4 will be used in the following explanation. The waterproof connector of embodiment 2 is a modified example of the waterproof connector of embodiment 1, and a power conversion device equipped with the waterproof connector of embodiment 2 is similar to the power conversion device 100 of embodiment 1, so a description thereof will be omitted here.

[0032] Similar to the waterproof connector according to the first embodiment (see FIG. 4), the waterproof connector according to the second embodiment has a waterproof gasket 5 disposed in a groove 43 provided in an outer peripheral surface 42a of a base portion 42, and a first gasket portion 51 and a second gasket portion 52 on the inner peripheral surface 5a thereof contact an inner surface 43a of the groove 43. A first groove portion 431 and a second groove portion 432 on the inner surface 43a of the groove 43 contact the first gasket portion 51 and the second gasket portion 52, respectively. Also, a gap 7 is formed between a gasket intermediate portion 53 sandwiched between the first gasket portion 51 and the second gasket portion 52 and the inner surface 43a of the groove 43.

[0033] Moreover, the groove 43 has a substantially triangular cross-sectional shape in which the groove width W in the axial direction narrows toward the inner periphery of the base portion 42, and a gap 7 is formed between a groove intermediate portion 433 including an apex 43b of the triangle sandwiched between the first groove portion 431 and the second groove portion 432, and a packing intermediate portion 53 on the inner periphery surface 5a of the waterproof packing 5. In other words, the gap 7 is formed by a depression in the groove intermediate portion 433 on the inner periphery surface 43a of the groove 43.

[0034] Furthermore, as shown in Figure 6, the packing intermediate portion 53 is recessed toward the outer periphery (toward the arrow S2 in Figure 4) relative to the first packing portion 51 and the second packing portion 52, and a gap 7 is formed by the recess 54 in the packing intermediate portion 53.

[0035] In this way, the gap 7 is formed by the recess in the groove middle portion 433 and the recess 54 in the packing middle portion 53, so that the gap 7 is secured larger and maintained efficiently. Also, as shown in Fig. 6, the recess 54 in the packing middle portion 53 stabilizes the posture of the waterproof packing 5 and stabilizes the direction of the reaction force Fr against the base portion 42, so that the gap 7 is maintained efficiently.

[0036] According to the waterproof connector of embodiment 2, in addition to the same effects as the waterproof connector of embodiment 1, by providing a recess 54 in the middle part 53 of the packing, the gap 7 is efficiently maintained, stabilizing the posture of the waterproof packing 5 and stabilizing the direction of the reaction force against the base part 42.

[0037] Embodiment 3 7 and 8 are enlarged cross-sectional views of the main parts of the waterproof connector according to embodiment 3, taken along a plane passing through the axis of the terminal. In Fig. 7, the side indicated by arrow S1 with respect to a dotted line parallel to the axial direction passing through approximately the center of the waterproof gasket 5 is the inner peripheral side of the waterproof gasket 5, and the side indicated by arrow S2 is the outer peripheral side of the waterproof gasket 5. Also, in Fig. 8, arrow Fr indicates the reaction force (contact pressure).

[0038] The waterproof connector of embodiment 3 is a modified example of the waterproof connector of embodiment 1, and a power conversion device equipped with the waterproof connector of embodiment 3 is similar to the power conversion device 100 of embodiment 1, so a description thereof will be omitted here.

[0039] The waterproof connector 2 includes a resin case 3, a metal terminal 4 having a terminal 41 and a base portion 42, and a waterproof gasket 5. An annular groove 43 is provided on the outer peripheral surface 42a of the base portion 42 to fit the waterproof gasket 5. The terminal 41, the base portion 42, and the waterproof gasket 5 are insert parts, and are formed integrally with the resin case 3 by insert molding.

[0040] As shown in FIG. 7, the groove 43 of the waterproof connector 2 according to the third embodiment is a square groove having a constant axial groove width W and a flat bottom, and the inner surface 43a of the groove 43 includes a side surface 434 on one side and a side surface 435 on the other side.

[0041] In the waterproof connector, a waterproof gasket 5 is disposed in a groove 43 provided on the outer peripheral surface 42a of a base portion 42, and a first gasket portion 51 and a second gasket portion 52 on the inner peripheral surface 5a thereof contact the inner surface 43a of the groove 43. A first groove portion 431 and a second groove portion 432 on the inner surface 43a of the groove 43 contact the first gasket portion 51 and the second gasket portion 52, respectively. In addition, a gap 7 is formed between a gasket intermediate portion 53 sandwiched between the first gasket portion 51 and the second gasket portion 52 and the inner surface 43a of the groove 43.

[0042] The packing intermediate portion 53 on the inner surface 5a of the waterproof packing 5 is recessed toward the outer periphery (i.e., toward the arrow S2) relative to the first packing portion 51 and the second packing portion 52, and a gap 7 is formed by the recess 54 in the packing intermediate portion 53.

[0043] 7, in the third embodiment, the third packing portion 55 and the fourth packing portion 56 located between the inner peripheral surface 5a and the outer peripheral surface 5b of the waterproof packing 5 are in contact with the side surface 434 on one side and the side surface 435 on the other side of the groove 43, respectively. Furthermore, a gap 7a is formed between the middle part of the packing sandwiched between the first packing portion 51 and the third packing portion 55 and a corner part on one side of the groove 43, and a gap 7b is formed between the middle part of the packing sandwiched between the second packing portion 52 and the fourth packing portion 56 and a corner part on the other side of the groove 43.

[0044] 8, the waterproof packing 5 has gap 7, which stably holds the reaction force Fr against the base portion 42 and the resin case 3. Furthermore, the depression 54 in the packing middle portion 53 stabilizes the posture of the waterproof packing 5, stabilizing the direction of the reaction force Fr against the base portion 42, thereby efficiently holding the gap 7. Note that, although the gaps 7a and 7b formed in the corners of the groove 43 also contribute to stabilizing the reaction force Fr, their contribution is smaller than that of gap 7 because their volume is smaller than that of gap 7.

[0045] When an elliptical waterproof gasket 5 is placed in a groove 43 whose cross section in the axial direction is substantially triangular as in the first embodiment, it is necessary to approximately align the position of the apex 43b of the groove 43 in the axial direction with the center position of the ellipse of the waterproof gasket 5. If the waterproof gasket 5 is misaligned and placed at an angle to the inner surface 43a of the groove 43, it may not be possible to ensure a sufficient gap 7.

[0046] In contrast, in embodiment 3, a waterproof gasket 5 having a recess 54 in the middle part 53 of the gasket is placed in a groove 43 having a flat bottom, making it less likely for the waterproof gasket 5 to become misaligned, and a gap 7 is reliably formed between the middle part 53 of the gasket and the inner surface 43a of the groove 43.

[0047] According to the waterproof connector of the third embodiment, in addition to the same effects as the waterproof connector of the first embodiment, by providing the recess 54 in the packing middle portion 53, it is possible to stabilize the posture of the waterproof packing 5 and the direction of the reaction force against the base portion 42. Furthermore, since the bottom of the groove 43 is flat, the waterproof packing 5 is less likely to shift position and is in stable contact with the base portion 42, thereby stabilizing the reaction force of the waterproof packing 5.

[0048] Embodiment 4 Figure 9 is an enlarged cross-sectional view of the waterproof connector according to embodiment 4, taken along a plane passing through the axis of the terminal. In Figure 9, arrow Fr indicates the reaction force (contact pressure). Note that although reference numerals for parts that are the same as or equivalent to those in Figure 7 may be omitted in Figure 9, the reference numerals in Figure 7 will be used in the following explanation. The power converter including the waterproof connector according to the fourth embodiment is similar to the power converter 100 according to the first embodiment, and therefore a description thereof will be omitted here.

[0049] Similar to the waterproof connector according to the third embodiment (see FIG. 7), the waterproof connector according to the fourth embodiment has a waterproof gasket 5 disposed in a groove 43 provided in an outer peripheral surface 42a of a base portion 42, and a first gasket portion 51 and a second gasket portion 52 on the inner peripheral surface 5a thereof contact an inner surface 43a of the groove 43. A first groove portion 431 and a second groove portion 432 on the inner surface 43a of the groove 43 contact the first gasket portion 51 and the second gasket portion 52, respectively. Also, a gap 7 is formed between a gasket intermediate portion 53 sandwiched between the first gasket portion 51 and the second gasket portion 52 and the inner surface 43a of the groove 43.

[0050] Furthermore, the groove 43 of the waterproof connector 2 is a square groove with a constant groove width W in the axial direction and a flat bottom, and the inner surface 43a of the groove 43 includes a side surface 434 on one side and a side surface 435 on the other side. A third packing portion 55 and a fourth packing portion 56 located between the inner peripheral surface 5a and the outer peripheral surface 5b of the waterproof packing 5 are in contact with the side surface 434 on one side and the side surface 435 on the other side of the groove 43, respectively.

[0051] In embodiment 4, as shown in Figure 9, the groove intermediate portion 433 sandwiched between the first groove portion 431 and the second groove portion 432 is recessed toward the inner periphery of the base portion 42 relative to the first groove portion 431 and the second groove portion 432, and a gap 7 is formed by the recess 44 of the groove intermediate portion 433 on the inner surface 43a of the groove 43.

[0052] Furthermore, similar to the waterproof connector of the third embodiment (see Figure 7), a gap 7a is formed between the middle part of the packing sandwiched between the first packing part 51 and the third packing part 55 and a corner on one side of the groove 43, and a gap 7b is formed between the middle part of the packing sandwiched between the second packing part 52 and the fourth packing part 56 and a corner on the other side of the groove 43.

[0053] 9, the waterproof gasket 5 has the gap 7, which stably holds the reaction force Fr against the base portion 42 and the resin case 3. Furthermore, because the first groove portion 431 and the second groove portion 432 are flat, the posture of the waterproof gasket 5 is stabilized and the direction of the reaction force Fr against the base portion 42 is stabilized, thereby efficiently holding the gap 7. Note that, although the gaps 7a and 7b formed in the corners of the groove 43 also contribute to stabilizing the reaction force Fr, their contribution is smaller than that of the gap 7 because their volume is smaller than that of the gap 7.

[0054] It is also possible to combine the groove 43 having the recess 44 in the groove intermediate portion 433 in the fourth embodiment with the waterproof packing 5 having the recess 54 in the packing intermediate portion 53 in the third embodiment (see FIG. 8), so that the recess 44 in the groove intermediate portion 433 and the recess 54 in the packing intermediate portion 53 form the gap 7. This ensures a larger gap 7 and allows for more efficient retention.

[0055] According to the waterproof connector of the fourth embodiment, in addition to the same effects as the waterproof connector of the first embodiment, the provision of the recess 44 in the groove intermediate portion 433 stabilizes the posture of the waterproof gasket 5 and the direction of the reaction force against the base portion 42. Furthermore, since the bottom of the groove 43 is flat, the waterproof gasket 5 is less likely to shift position and is in stable contact with the base portion 42, thereby stabilizing the reaction force of the waterproof gasket 5.

[0056] Embodiment 5. 10 is a perspective view showing the metal terminal and waterproof gasket of the waterproof connector according to embodiment 5. In the waterproof connector according to embodiment 5, the base portion 42 of the metal terminal 4 is cylindrical, and the groove 43 is a cylindrical groove. The metal terminal 4 and waterproof gasket 5 according to embodiment 5 can be used in the waterproof connectors according to embodiments 1 to 4. The power converter including the waterproof connector according to the fifth embodiment is similar to the power converter 100 according to the first embodiment, and therefore a description thereof will be omitted here.

[0057] In the waterproof connectors according to the first to fourth embodiments, the shape of the base portion 42 is not limited to a cylindrical shape, and may be any cylindrical shape. However, in order for the waterproof connector to maintain high waterproofness, it is desirable that the reaction force of the waterproof gasket 5 against the base portion 42 and the resin case 3 is uniform. If the reaction force of the waterproof gasket 5 is not uniform, the part of the gasket that has a larger reaction force than the other parts of the gasket will deteriorate, and the adhesion of that part may decrease.

[0058] 10, in the fifth embodiment, the base portion 42 is cylindrical, and the waterproof gasket 5 has a circular shape when viewed from the axial direction. Therefore, a uniform pressure is applied to the waterproof gasket 5, and a uniform reaction force is generated against the base portion 42 and the resin case 3. The base portion 42 and the waterproof gasket 5 according to the fifth embodiment may be used as an insert part or an outsert part.

[0059] According to the waterproof connector having the metal terminals 4 and waterproof gasket 5 of embodiment 5, in addition to the same effects as the waterproof connectors of embodiments 1 to 4 above, the reaction force of the waterproof gasket 5 against the base portion 42 and the resin case 3 is uniform, thereby stabilizing the waterproofness of the waterproof connector 2.

[0060] Embodiment 6 Fig. 11 is a diagram illustrating the assembly process of a waterproof connector according to embodiment 6, and Fig. 12 is an enlarged cross-sectional view of the main part of the waterproof connector according to embodiment 6, cut along a plane passing through the axis of the terminal. In embodiment 6, the terminal 41 is an insert part formed integrally with the resin case 3, and the base part 42 and the waterproof gasket 5 are outsert parts. The power converter including the waterproof connector according to the sixth embodiment is similar to the power converter 100 according to the first embodiment, and therefore a description thereof will be omitted here.

[0061] In the above embodiments 1 to 5, the terminals 41, base portion 42, and waterproof gasket 5 that constitute the waterproof connector 2 are described as insert parts. However, when the waterproof gasket 5 is formed integrally with the resin case 3 by insert molding, the waterproof gasket 5 loses its elastic deformation due to the molding pressure, and the desired reaction force may not be obtained.

[0062] In the sixth embodiment, the base portion 42 and the waterproof gasket 5 are outsert parts, and in the process of assembling the waterproof connector, the waterproof gasket 5 assembled in the groove 43 on the outer peripheral surface 42a of the base portion 42 is outsert-mounted into the opening 31 of the resin case 3 which is previously formed integrally with the terminal 41, as shown in Fig. 11. As a result, the waterproof gasket 5 is disposed between the outer peripheral surface 42a of the base portion 42 and the inner peripheral surface 31a of the opening 31, as shown in Fig. 12.

[0063] 12, similarly to the waterproof connector according to the second embodiment (see FIG. 6), the groove 43 has a substantially triangular cross-sectional shape, and the waterproof gasket 5 has a recess 54 on its inner peripheral surface 5a, but the shapes of the groove 43 and the waterproof gasket 5 are not limited to this. The assembly process of the waterproof connector according to the sixth embodiment is applicable to the manufacturing processes of the waterproof connectors according to the first to fifth embodiments.

[0064] The state of the contact surface with the resin case 3 differs depending on whether the waterproof gasket 5 is an insert part or an outsert part. When the waterproof gasket 5 is an insert part, the resin that makes up the resin case 3 flows in to cover the waterproof gasket 5 exposed from the groove 43 and then hardens. For this reason, the cross-sectional shape of the contact surface between the waterproof gasket 5 and the resin case 3 in the axial direction is curved (see FIG. 6).

[0065] In contrast, when the waterproof gasket 5 is an outsert part, the waterproof gasket 5 is assembled into the groove 43 on the outer peripheral surface 42a of the base portion 42 and placed in the opening 31 of the pre-molded resin case 3. Therefore, as shown in Fig. 12, the cross-sectional shape of the axial direction of the contact surface between the waterproof gasket 5 and the resin case 3 is linear.

[0066] In addition to the same effects as the waterproof connector according to the first embodiment, the waterproof connector according to the sixth embodiment can prevent the waterproof gasket 5 from losing its elastic deformation due to molding pressure by outserting the base portion 42 and the waterproof gasket 5. Furthermore, when the waterproofness of the waterproof connector is reduced due to deterioration of the waterproof gasket 5 over time, it is possible to replace only the waterproof gasket 5.

[0067] Although various exemplary embodiments and examples are described in this disclosure, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless variations not illustrated are contemplated within the scope of the technology disclosed in this specification. For example, this includes cases where at least one component is modified, added, or omitted, and even cases where at least one component is extracted and combined with components of another embodiment.

[0068] Various aspects of the present disclosure are summarized below as appendices.

[0069] (Appendix 1) A waterproof connector attached to a housing for electrically connecting to a device outside the housing, a resin case attached to an outer wall of the housing and having a cylindrical opening that opens to the outside; a rod-shaped terminal surrounded by the opening and connected to the external device; a cylindrical base portion disposed between an outer peripheral surface of a rear portion of the opening of the terminal and an inner peripheral surface of the opening; an annular waterproof packing disposed between an outer peripheral surface of the base portion and an inner peripheral surface of the opening, The waterproof connector is configured such that the waterproof gasket is disposed in an annular groove formed on the outer peripheral surface of the base portion, and one side and the other side of the inner peripheral surface of the waterproof gasket in the axial direction of the terminal are in contact with the inner surface of the groove, and a gap is formed between the intermediate portion sandwiched between the one side and the other side and the inner surface of the groove. (Appendix 2) The waterproof connector described in Appendix 1, characterized in that the middle portion on the inner surface of the waterproof gasket is recessed toward the outer periphery relative to the one side portion and the other side portion, and the recess in the middle portion forms the gap. (Appendix 3) a portion on one side and a portion on the other side in the axial direction of the inner surface of the groove are in contact with a portion on the one side and a portion on the other side of an inner peripheral surface of the waterproof packing, respectively; The waterproof connector described in Appendix 1 or Appendix 2, characterized in that a middle portion of the inner surface of the groove sandwiched between the one portion and the other portion is recessed toward the inner periphery of the base portion relative to the one portion and the other portion of the inner surface of the groove, and the gap is formed by the recess of the middle portion of the inner surface of the groove. (Appendix 4) The groove has a triangular cross-sectional shape in which the groove width in the axial direction narrows toward the inner periphery of the base portion, The waterproof connector according to any one of Supplementary Note 1 to Supplementary Note 3, characterized in that the gap is formed between a middle portion including the apex of the triangle sandwiched between the one side portion and the other side portion on the inner surface of the groove, and the middle portion on the inner peripheral surface of the waterproof gasket. (Appendix 5) The waterproof connector according to any one of Supplementary Note 1 to Supplementary Note 4, wherein the base portion is cylindrical and the groove is a cylindrical groove. (Appendix 6) A waterproof connector described in any one of Appendix 1 to Appendix 5, characterized in that the terminal, the base portion, and the waterproof gasket are insert parts and are formed integrally with the resin case. (Appendix 7) the terminal is an insert part and is formed integrally with the resin case, The waterproof connector according to any one of Supplementary Note 1 to Supplementary Note 5, wherein the base portion and the waterproof gasket are outsert parts. (Appendix 8) A power conversion device comprising the housing and the waterproof connector according to any one of Supplementary Note 1 to Supplementary Note 7. [Industrial Applicability]

[0070] The present disclosure can be used as a waterproof connector and a power conversion device including the same, and in particular as a waterproof connector for a power conversion device mounted on a vehicle. [Explanation of symbols]

[0071] REFERENCE SIGNS LIST 1 housing, 1a outer wall, 1b communication hole, 2 waterproof connector, 3 resin case, 4 metal terminal, 5 waterproof packing, 5a inner peripheral surface, 5b outer peripheral surface, 6 bus bar, 7, 7a, 7b gap, 31 opening, 31a inner peripheral surface, 41 terminal, 41a outer peripheral surface, 42 base portion, 42a outer peripheral surface, 43 groove, 43a inner surface, 43b top portion, 44 recess, 51 first packing portion, 52 second packing portion, 53 packing middle portion, 54 recess, 55 third packing portion, 56 fourth packing portion, 431 first groove portion, 432 second groove portion, 433 groove middle portion, 434 side surface on one side, 435 side surface on the other side, 100 power conversion device

Claims

1. A waterproof connector attached to a housing for electrically connecting to a device outside the housing, a resin case attached to an outer wall of the housing and having a cylindrical opening that opens to the outside; a rod-shaped terminal surrounded by the opening and connected to the external device; a cylindrical base portion disposed between an outer peripheral surface of a rear portion of the opening of the terminal and an inner peripheral surface of the opening; an annular waterproof packing disposed between an outer peripheral surface of the base portion and an inner peripheral surface of the opening, The waterproof connector is configured such that the waterproof gasket is disposed in an annular groove formed on the outer peripheral surface of the base portion, and one side and the other side of the inner peripheral surface of the waterproof gasket in the axial direction of the terminal are in contact with the inner surface of the groove, and a gap is formed between the intermediate portion sandwiched between the one side and the other side and the inner surface of the groove.

2. The waterproof connector according to claim 1, characterized in that the middle portion of the inner peripheral surface of the waterproof gasket is recessed toward the outer peripheral side relative to the one side portion and the other side portion, and the recess in the middle portion forms the gap.

3. a portion on one side and a portion on the other side in the axial direction of the inner surface of the groove are in contact with a portion on the one side and a portion on the other side of an inner peripheral surface of the waterproof packing, respectively; 3. The waterproof connector according to claim 1, wherein a middle portion of the inner surface of the groove sandwiched between the one side portion and the other side portion is recessed toward the inner periphery of the base portion relative to the one side portion and the other side portion of the inner surface of the groove, and the gap is formed by the recess in the middle portion of the inner surface of the groove.

4. The groove has a triangular cross-sectional shape in which the groove width in the axial direction narrows toward the inner periphery of the base portion, 3. The waterproof connector according to claim 1, wherein the gap is formed between an intermediate portion including the apex of the triangle sandwiched between the one side portion and the other side portion on the inner surface of the groove, and the intermediate portion on the inner peripheral surface of the waterproof gasket.

5. 3. The waterproof connector according to claim 1, wherein the base portion is cylindrical, and the groove is a cylindrical groove.

6. 3. The waterproof connector according to claim 1, wherein the terminals, the base portion, and the waterproof packing are insert parts that are integrally formed with the resin case.

7. the terminal is an insert part and is formed integrally with the resin case, 3. The waterproof connector according to claim 1, wherein the base portion and the waterproof packing are outsert parts.

8. A power conversion device comprising the housing and the waterproof connector according to claim 1.

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