Connector

Abstract

[Solution] A connector (3) has a resin body (10) and a flexible conductor (20) formed from a flexible material. The resin body (10) closes an opening (2a) in a housing (2). The flexible conductor (20) comprises a connection end (20a) inside the resin body (10) and extends from the resin body (10) to one side. The flexible conductor (20) is covered with an insulating coating (21). A connected end (22b) of a connection conductor (22) is connected to the connection end (20a) of the flexible conductor (20). The connected end (22b) is insert-molded into the resin body (10) together with the flexible conductor (20) and the insulating coating (21). The connection conductor (22) extends from the resin body (10) to the other side.

Description

connector

[0001] The present disclosure relates to connectors.

[0002] A motor has a housing that encloses a drive mechanism, such as a rotor. Oil, such as lubricating oil, is stored within the housing. As the rotor rotates, the stored oil is stirred up and dispersed within the housing as a mist or vapor. This cools the housing. The opening of the housing is sealed with a connector. For example, as disclosed in Japanese Utility Model Laid-Open Publication No. 58-37759, the connector comprises a resin body and a conductor (insert metal fitting). The resin body seals against oil leakage due to internal pressure or permeation. The conductor is insert-molded into the resin body and electrically connects the internal conductor within the housing with the external conductor outside the housing. This increases the airtightness between the inside and outside of the housing while allowing power to be supplied from outside the housing to the inside of the housing.

[0003] FIG. 7 shows a structure in which conductors 120, insert-molded into a resin body 110, extend into the housing interior 104 without an insulating coating. In this structure, the extensions of adjacent conductors 120 must be spaced apart by at least the insulation distance (Z1) to ensure insulation. Furthermore, the distance between the extensions must be narrower than the shortest distance through the space through which the extensions pass. Furthermore, the ends of the conductors 120 protruding from the resin body 110 must be spaced apart by at least the creepage distance (L) to ensure insulation. When the creepage distance (L) is greater than the spatial distance (the distance between the extensions), the creepage distance (L) is essentially the key to determining the insulation distance. In other words, (Z1) = (L). A certain creepage distance (L) is necessary to prevent short circuits. This could result in the resin body 110 becoming larger in the direction of the conductors 120. This, in turn, could result in the connector 103 becoming larger. Therefore, a compact connector 103 has been in demand.

[0004] In one aspect of the present disclosure, the connector has a resin body and a flexible conductor formed from a flexible material. The resin body closes the opening of the housing. The flexible conductor has a connecting end inside the resin body and extends in one direction from the resin body. The flexible conductor is covered with an insulating coating. A connected end of a connection conductor is connected to the connecting end of the flexible conductor. The connected end together with the flexible conductor and the insulating coating are insert-molded into the resin body. The connection conductor extends in the other direction from the resin body.

[0005] Therefore, the insulation distance (Z2), i.e., creepage distance, required for a flexible conductor extending from the resin body to one side (e.g., inside the housing) is (α) + (β) as shown below. As shown in Figure 3, (α) is twice the thickness (A) of the insulating coating covering the extended flexible conductor and twice the distance (B) the insulating coating is inserted into the resin body. (β) is the distance (C) along the surface of the insulator between the opposing edges of the insulating coating of adjacent flexible conductors on the surface of the resin body. In other words, (Z2) = 2(A + B) + (C). Therefore, even if (C) is sufficiently packed, (Z2) can be sufficiently ensured as long as (B) is sufficiently secured. Therefore, the resin body does not become larger in the direction of arrangement of the flexible conductors, and the insulation distance required for the flexible conductors can be secured. As a result, the connector can be made compact.

[0006] In another aspect of the present disclosure, the flexible conductor is electrically connected to a load device within the housing, and the connecting conductor is electrically connected to the inverter, so that power can be supplied from the inverter to the load device.

[0007] In another feature of the present disclosure, the connecting end of the flexible conductor and the connected end of the connection conductor overlap in the thickness direction. Therefore, a step is created in the thickness direction at this overlapping portion. Therefore, even when gas within the housing flows into the connector due to increased pressure inside the flexible conductor or along the surface of the insulating coating, pressure loss occurs in this inflow path. In other words, this inflow path has a labyrinth structure. Therefore, gas leakage to the outside of the housing can be suppressed, and airtightness functions. Furthermore, even if oil penetrates the inside of the flexible conductor through capillary action and enters the connector, further penetration is prevented because the connecting end of the flexible conductor and the connected end of the connection conductor are joined within the connector, preventing further oil leakage and providing watertightness.

[0008] In another feature of the present disclosure, the connector includes a resin body and first and second flexible conductors formed from a flexible material. The resin body closes the opening of the housing. The first and second flexible conductors each have a connecting end inside the resin body. The first flexible conductor extends from the resin body in a first direction. The second flexible conductor extends from the resin body in a second direction. First and second insulating coatings cover the first and second flexible conductors, respectively. The intermediate conductor has first and second connected ends connected to the connecting ends of the first and second flexible conductors, respectively. The first and second connected ends are insert-molded into the resin body together with the first and second flexible conductors and the first and second insulating coatings.

[0009] Therefore, the insulation distance (Z2), i.e., creepage distance, required for flexible conductors extending from the resin body in the first and second directions (e.g., inside and outside the housing) is (α) + (β), respectively. As shown in Figure 6, (α) is twice the thickness (A) of the insulating coating covering the extended flexible conductor and twice the distance (B) the insulating coating is inserted into the resin body. (β) is the distance (C) along the surface of the insulator between the opposing edges of the insulating coating of adjacent flexible conductors on the surface of the resin body. That is, (Z2) = 2(A + B) + (C). Therefore, even if (C) is sufficiently packed, (Z2) can be sufficiently ensured as long as (B) is sufficiently secured. Therefore, the resin body does not become larger in the direction of arrangement of the flexible conductors, and the insulation distance required for the flexible conductors can be secured. As a result, the connector can be made compact.

[0010] In another feature of the present disclosure, a first flexible conductor (e.g., first flexible conductor 20) is electrically connected to an inverter, and a second flexible conductor (e.g., second flexible conductor 20) is electrically connected to a load device within the housing, so that power can be supplied from the inverter to the load device.

[0011] In another feature of the present disclosure, the connecting ends of the first and second flexible conductors and the first and second connected ends of the intermediate conductor overlap in the thickness direction. Therefore, a step is created in the thickness direction at this overlapping portion. Therefore, even when gas within the housing flows into the connector due to increased pressure inside the flexible conductor or along the surface of the insulating coating, pressure loss occurs in this inflow path. In other words, this inflow path has a labyrinth structure. Therefore, gas leakage to the outside of the housing is suppressed, thereby providing airtightness. Furthermore, even if oil penetrates the flexible conductor through capillary action and enters the connector, the connecting ends of the first and second flexible conductors and the first and second connected ends of the intermediate conductor are joined within the connector, preventing further penetration and suppressing oil leakage, thereby providing watertightness.

[0012] Fig. 1 is a perspective view of a state in which the connector according to the first embodiment is attached to a housing. Fig. 2 is a cross-sectional view taken along line II-II in Fig. 1. Fig. 3 is a cross-sectional view taken along line III-III in Fig. 2. Fig. 4 is a perspective view of a state in which the connector according to the second embodiment is attached to a housing. Fig. 5 is a cross-sectional view taken along line V-V in Fig. 4. Fig. 6 is a cross-sectional view taken along line VI-VI in Fig. 5. Fig. 7 is a schematic diagram illustrating problems with the prior art.

[0013] (First Embodiment) The first embodiment will be described with reference to Figures 1 to 3. In the following description, up / down, front / rear, and left / right directions refer to the up / down, front / rear, and left / right directions indicated by arrows in each figure. This also applies to the second embodiment. As shown in Figure 1, a connector 3 of a motor 1 (e.g., a three-phase motor not shown), which is a load device, is attached to a housing 2 of the motor 1.

[0014] As shown in Figures 1 and 3, the housing 2 has an elongated opening 2a. The shape of the opening 2a corresponds to the shape of the resin body portion 11 of the resin body 10 of the connector 3. As shown in Figures 2 and 3, the edge of the opening 2a on the air layer 5 side forms an inclined surface 2b. This allows the resin body portion 11 of the connector 3 to be smoothly inserted into the opening 2a. Only a portion of the housing 2 is shown in Figures 1 to 3. The housing 2 is made of a metal member. As shown in Figure 3, the connector 3 has collar members 17 on the left and right mounting portions 15. The housing 2 has a pair of left and right threaded holes (not shown) formed in positions corresponding to the collar members 17.

[0015] As shown in Figure 2, the housing 2 is a box-shaped member that covers the drive mechanism (not shown), such as the rotor of the motor 1. Oil, such as lubricating oil, is stored inside the housing 2. This stored oil is stirred up as the rotor rotates, and is dispersed inside the housing 2 as mist or vapor. This allows the inside of the housing 2 to be cooled. The inside of the housing 2 is an oil layer 4, in which oil is stored as described above and dispersed as mist or vapor. The outside of the housing 2 is an air layer 5 (atmospheric layer). As the temperature of the oil layer 4 rises, it can become pressurized relative to the outside.

[0016] As shown in Figures 2 and 3, the connector 3 has a resin body 10 and three joining conductors 30. The joining conductors 30 have a flexible conductor 20, a bus bar 22, and a terminal board 23. The flexible conductor 20 is made of a flexible material, such as a twisted wire or a braided wire, and is conductive. The outer surface of the flexible conductor 20 is covered with an insulating coating 21. In other words, the flexible conductor 20 is a coated conductor. The insulating coating 21 is heat-resistant and oil-resistant.

[0017] 2 and 3 , one end 20a and the other end 20b of the flexible conductor 20 are exposed and not covered with the insulating coating 21. This "one end 20a of the flexible conductor 20" may correspond to the "connecting end" described in the claims. The bus bar 22 is, for example, approximately L-shaped and has rigidity and conductivity. One end 22a of the bus bar 22 has a screw hole 22c that penetrates in the thickness direction. This "bus bar 22" and "the other end 22b of the bus bar 22" may correspond to the "connecting conductor" and "connected end" described in the claims.

[0018] 2 and 3 , the other end 22b of the bus bar 22 is electrically connected to one end 20a of the flexible conductor 20 by ultrasonic welding so as to overlap with the one end 20a in the thickness direction. For example, one end 20a of the flexible conductor 20 is compaction-welded to form an ingot from loose stranded wires, and then joined to the other end 22b of the bus bar 22. A small portion of the one end 20a of the flexible conductor 20 is not compaction-welded between the other end 22b of the bus bar 22 and one end 21a of the insulating coating 21.

[0019] As shown in Figures 2 and 3, the other end 20b of the flexible conductor 20 is connected to a terminal plate 23. The terminal plate 23 is, for example, flat and rigid and conductive. The other end 20b of the flexible conductor 20 and the other end 23b of the terminal plate 23 are electrically connected by ultrasonic welding so that they overlap in the thickness direction. For example, the other end 20b of the flexible conductor 20 is compaction-welded to form an ingot by solidifying loose stranded wires, and then joined to the other end 23b of the terminal plate 23. A small portion of the other end 20b of the flexible conductor 20 is not compaction-welded between the other end 23b of the terminal plate 23 and the other end 21b of the insulating coating 21. One end 23a of the terminal plate 23 has a screw hole 23c penetrating in the thickness direction. When molding the resin body 10, the three joining conductors 30 are set in a predetermined position in a molding die (not shown) so that they are aligned laterally, and are insert-molded into the resin body 11.

[0020] As shown in FIGS. 1 and 3 , the resin body 10 is made of an insulating material. The resin body 10 has a resin main body portion 11 and a pair of mounting portions 15 extending from both the left and right sides of the resin main body portion 11. As shown in FIGS. 2 and 3 , one end 20 a of the flexible conductor 20 and one end 21 a of the insulating coating 21 are inserted into the other end 11 b of the resin main body portion 11. The bus bar 22 extends from one end (upper end) 11 a of the resin main body portion 11 outward from the housing 2. The other end 22 b of the bus bar 22 is inserted into the one end 11 a of the resin main body portion 11. The other end 20 b of the flexible conductor 20, the terminal board 23, and the other end 21 b of the insulating coating 21 extend from the other end (lower end) 11 b of the resin main body portion 11 inward from the housing 2.

[0021] 2, the portion where the connecting end of flexible conductor 20 and the connected end of bus bar 22 are joined is inserted into resin main body 11. Therefore, resin main body 11 can prevent oil from leaking from inside housing 2. Specifically, watertightness is maintained at one end 11a and the other end 11b of resin main body 11. This prevents oil from penetrating into resin main body 11 along the joined portion.

[0022] 2, the outer peripheral surface 12 of the resin body 11 has a recess 13 that continues in the circumferential direction. An elastically deformable seal 14, such as an O-ring, is fitted in the recess 13. The outer diameter of the seal 14 is slightly larger than the inner diameter of the opening 2a of the housing 2.

[0023] As shown in Figure 2, when the connector 3 is attached to the housing 2, the sealant 14 is pressed against the inner wall surface 2c of the opening 2a of the housing 2. The sealant 14 elastically deforms (is crushed), creating a seal between the connector 3 and the housing 2. This improves the sealing performance between the oil layer 4 and the gas layer 5. As shown in Figures 1 and 3, through-holes 16 are formed at the left and right ends of the attachment portion 15, penetrating the attachment portion 15 in the thickness direction. Ring-shaped collar members 17 are fitted into the through-holes 16.

[0024] Next, an example of the procedure for attaching the connector 3 to the housing 2 will be described. First, a first step is performed in which the resin body 11 of the connector 3 is inserted so as to close the opening 2a of the housing 2. Next, a second step is performed in which screws (not shown) are inserted into the pair of left and right collar members 17 of the mounting portion 15 of the connector 3, and the inserted screws are threaded into the pair of left and right threaded holes (not shown) of the housing 2. In this manner, the connector 3 can be attached to the housing 2.

[0025] Thereafter, a third operation is performed in which screws (not shown) are inserted into the through holes (not shown) of the three conductors extending from the drive mechanism and into the screw holes 23c of the terminal plates 23 of the three joining conductors 30, in that order, and the inserted screws are screwed into nuts (not shown). This electrically connects the conductors extending from the drive mechanism to the terminal plates 23 of the connector 3. Therefore, the drive mechanism and the connector 3 are electrically connected.

[0026] Similarly, a fourth operation is performed in which screws (not shown) are inserted into the crimp terminals (not shown) of the three external cables extending from the inverter on the power supply side and into the through holes 22c of the three bus bars 22 of the connector 3, in that order, and the inserted screws are then screwed into nuts (not shown).

[0027] This electrically connects the external cable extending from the inverter to the bus bar 22 of the connector 3. This electrically connects the inverter to the connector 3. Therefore, the resin body 10 of the connector 3 separates the inside and outside of the housing 2 airtightly or watertightly (while isolating the two different layers (oil layer 4 and gas layer 5)), allowing electricity to flow between the inside and outside (the two different layers). This allows power to be supplied from the inverter to the motor 1.

[0028] As described above, the drive mechanism and connector 3 are electrically connected. At this time, the conductors extending from the drive mechanism are electrically connected to the flexible conductors 20 via the terminal plates 23. Therefore, vibrations transmitted from the rotor of the drive mechanism are absorbed by the flexible conductors 20. This makes it possible to prevent the vibrations from being transmitted to the housing 2 or to the outside of the housing 2.

[0029] Furthermore, when performing the third operation described above, even if there is a misalignment between the through hole of the conductor extending from the drive mechanism and the screw hole 23c of the terminal plate 23 of the joining conductor 30, this misalignment can be suppressed by deforming the flexible conductor 20. Therefore, this third operation can be performed smoothly. Furthermore, because one end 20a of the flexible conductor 20 and one end 21a of the insulating coating 21 are inserted, the degree of freedom of movement of the flexible conductor 20 is restricted more than when the entire flexible conductor 20 is not inserted.

[0030] Therefore, the first operation of inserting the resin body 11 of the connector 3 into the opening 2a of the housing 2 can be carried out smoothly. Furthermore, when screwing the screws in the third operation, the screws can be stably screwed into the nuts without causing the terminal board 23 to shake significantly. Furthermore, when inserting the joining conductor 30, the flexible conductor 20 can be held in a direction other than the up-down direction (directly downward).

[0031] The connector 3 according to the first embodiment is configured as described above. According to this configuration, the connector 3 includes a resin body 10, a flexible conductor 20 made of a flexible material, and a bus bar 22. The resin body 10 closes the opening 2a of the housing 2. The flexible conductor 20 has one end 20a located inside the resin body 10 and extends in one direction from the resin body 10. The flexible conductor 20 has an insulating coating 21 that covers the flexible conductor 20. The bus bar 22 has a connected end (other end 22b) that is connected to the connecting end 20a of the flexible conductor 20. The other end 22b of the bus bar 22, together with a portion of the flexible conductor 20 and a portion of the insulating coating 21, is insert-molded into the resin body 10. The bus bar 22 extends in the other direction from the resin body 10.

[0032] Therefore, as shown in FIG. 3 , the insulation distance (Z2), i.e., creepage distance, required for the flexible conductors 20 extending from the resin body 10 to one side (e.g., inside the housing) is (α) + (β), as follows: (α) is twice the thickness (A) of the insulating coating 21 covering the extended flexible conductors 20 and twice the distance (B) through which the insulating coating 21 is inserted into the resin body 10. (β) is the distance (C) along the surface of the insulator between the opposing edges of the insulating coating 21 of adjacent flexible conductors 20 on the surface of the resin body 10. That is, (Z2) = 2(A + B) + (C). Therefore, even if (C) is sufficiently packed, (Z2) can be sufficiently ensured as long as (B) is sufficiently ensured. Therefore, there is no risk of the resin body 10 becoming larger in the arrangement direction of the flexible conductors 20, and the insulation distance required for the flexible conductors 20 can be ensured. As a result, the connector 3 can be made compact. The terminal plates 23 of the joining conductors 30 are connected to a drive mechanism (not shown) at a predetermined distance and insulated from each other by utilizing their flexibility. The ends 20a of the flexible conductors 20 inserted into the resin body 10 are insulated from each other because they are blocked by insulating resin. The bus bars 22 extending from the other side of the resin body are insulated from each other because they are blocked by an insulating wall (not shown) that protrudes from the resin body 10 in the same extending direction.

[0033] Furthermore, with this configuration, the flexible conductor 20 is electrically connected to the drive mechanism of the motor 1 inside the housing 2. The bus bar 22 is electrically connected to the inverter, so that power can be supplied to the motor 1 from the inverter.

[0034] Furthermore, with this configuration, one end 20a of the flexible conductor 20 and the other end 22b of the bus bar 22 overlap in the thickness direction. Therefore, a step is created in the thickness direction at this overlapping portion. Therefore, even when gas within the housing 2 flows into the connector 3 along the interior of the flexible conductor 20 or the surface of the insulating coating 21 as the pressure within the housing 2 increases, pressure loss occurs in this inflow path. In other words, this inflow path has a labyrinth structure. Therefore, the outflow of gas to the outside of the housing 2 can be suppressed, and airtightness functions. Furthermore, even if oil penetrates the interior of the flexible conductor 20 through capillary penetration and enters the connector 3, the one end 20a of the flexible conductor 20 and the other end 22b of the bus bar 22 are joined within the connector 3, preventing further penetration and suppressing the outflow of oil, thereby providing watertightness.

[0035] Second Embodiment A second embodiment will be described with reference to Figures 4 to 6. In the following description, components that are identical or equivalent to those described in the first embodiment are designated by the same reference numerals in the drawings, and redundant description will be omitted. The second embodiment differs from the first embodiment in that the flexible conductor 20 and the insulating coating 21 are inserted into the resin body 11 on only one side (the oil layer 4 side) or both sides (the oil layer 4 and the air layer 5).

[0036] As shown in FIG. 4, a connector 53 of a motor 1 (for example, a three-phase motor not shown) which is a load device is attached to a housing 2 of the motor 1 in the same manner as the connector 3 of the first embodiment.

[0037] 5 and 6 , the connector 53 has a resin body 10 and three joining conductors 70. The joining conductors 70 have two (a pair of) flexible conductors 20, two terminal plates 23, and an intermediate conductor 60. The two flexible conductors 20 are the flexible conductor 20 on the gas layer 5 side (referred to as the "first flexible conductor 20") and the flexible conductor 20 on the oil layer 4 side (referred to as the "second flexible conductor 20"). The two terminal plates 23 are the terminal plate 23 on the gas layer 5 side (referred to as the "first terminal plate 23") and the terminal plate 23 on the oil layer 4 side (referred to as the "second terminal plate 23").

[0038] 5 and 6 , the intermediate conductor 60 is, for example, flat and has rigidity and conductivity. One end 20a of the first flexible conductor 20 and one end 60a of the intermediate conductor 60 are electrically connected by ultrasonic welding so that they overlap in the thickness direction. For example, the one end 20a of the first flexible conductor 20 is compaction-welded to form an ingot-like shape by solidifying loose stranded wires, and then joined to the one end 60a of the intermediate conductor 60. A small portion of the one end 20a of the first flexible conductor 20 is not compaction-welded between the one end 60a of the intermediate conductor 60 and the one end 21a of the insulating coating 21.

[0039] Similarly, the other end 20b of the first flexible conductor 20 and the other end 23b of the first terminal plate 23 are electrically connected by ultrasonic welding so that they overlap in the thickness direction. At this time, there is a small portion of the other end 20b of the first flexible conductor 20 that is not compaction-welded between the other end 23b of the first terminal plate 23 and the other end 21b of the insulating coating 21.

[0040] Similarly, one end 20a of the second flexible conductor 20 and the other end 60b of the intermediate conductor 60 are electrically connected by ultrasonic welding so that they overlap in the thickness direction. At this time, there is a small portion of one end 20a of the second flexible conductor 20 that is not compaction-welded between the other end 60b of the intermediate conductor 60 and one end 21a of the insulating coating 21.

[0041] Similarly, the other end 20b of the second flexible conductor 20 and the other end 23b of the second terminal plate 23 are electrically connected by ultrasonic welding so that they overlap in the thickness direction. At this time, a small portion of the other end 20b of the second flexible conductor 20 is not compaction-welded between the other end 23b of the second terminal plate 23 and the other end 21b of the insulating coating 21. When molding the resin body 10, the three joining conductors 70 are set in predetermined positions in a molding die (not shown) so that they are lined up horizontally, and are insert-molded into the resin body portion 11.

[0042] The "one end 20a of the first flexible conductor 20" and the "one end 20a of the second flexible conductor 20" may correspond to the "connecting ends" described in the claims. Also, the "one end 60a of the intermediate conductor 60" and the "other end 60b of the intermediate conductor 60" may correspond to the "connected ends" described in the claims.

[0043] 4 and 6, the resin body 10 has a resin body portion 11 and a pair of mounting portions 15 extending from both the left and right sides of the resin body portion 11. As shown in Figures 5 and 6, one end 20a of the first flexible conductor 20 (a lower portion of the first flexible conductor 20) and one end 21a of the insulating coating 21 (a lower portion of the insulating coating 21) are inserted into one end (an upper end) 11a of the resin body portion 11. The other end (an upper portion) 20b of the first flexible conductor 20, the first terminal board 23, and the other end (an upper portion) 21b of the insulating coating 21 extend outward from the one end 11a of the resin body portion 11 to the outside of the housing 2.

[0044] 4 and 6 , the entire intermediate conductor 60 is inserted into the resin body 11. One end (upper end) 20a of the second flexible conductor 20 and one end (lower end) 21a of the insulating coating 21 are inserted into the other end (lower end) 11b of the resin body 11. The other end (lower end) 20b of the second flexible conductor 20, the second terminal board 23, and the other end (lower end) 21b of the insulating coating 21 extend from the other end (lower end) 11b of the resin body 11 toward the inside of the housing 2.

[0045] 5, the portion where the connecting end (20a) and the connected ends (60a, 60b) are joined is inserted into the resin body 11, thereby suppressing oil leakage from the joined portion of the first flexible conductor 20. Similarly, oil leakage is also suppressed from the joined portion of the second flexible conductor 20. Therefore, it is possible to suppress a decrease in watertightness on the one end 11a side and the other end 11b side of the resin body 11 caused by inserting both flexible conductors 20 into the resin body 11.

[0046] Next, an example of the procedure for attaching the connector 53 to the housing 2 will be described. First, a first step is performed in which the resin body 11 of the connector 53 is inserted so as to close the opening 2a of the housing 2. Next, a second step is performed in which screws (not shown) are inserted into the pair of left and right collar members 17 of the mounting portion 15 of the connector 53, and the inserted screws are threaded into the pair of left and right threaded holes (not shown) of the housing 2. In this manner, the connector 53 can be attached to the housing 2.

[0047] Thereafter, a third operation is performed in which screws (not shown) are inserted into the through holes (not shown) of the three conductors extending from the drive mechanism and into the screw holes 23c of the second terminal plates 23 of the three joining conductors 70, in that order, and the inserted screws are screwed into nuts (not shown). This electrically connects the conductors extending from the drive mechanism to the second terminal plates 23 of the connector 53, respectively. Therefore, the drive mechanism and the connector 53 are electrically connected.

[0048] Similarly, a fourth operation is performed in which screws (not shown) are inserted into the crimp terminals (not shown) of the three external cables extending from the inverter on the power supply side and into the screw holes 23c of the first terminal plates 23 of the three joining conductors 70, and the inserted screws are then screwed into nuts (not shown). This electrically connects the external cables extending from the inverter to the first terminal plates 23 of the connector 53.

[0049] This electrically connects the inverter to the connector 53. As a result, the resin body 10 of the connector 53 separates the inside and outside of the housing 2 airtightly or watertightly (while isolating the two different layers (oil layer 4 and gas layer 5)), and allows electricity to flow between the inside and outside (the two different layers). This allows power to be supplied from the inverter to the motor 1.

[0050] As described above, the drive mechanism and connector 53 are electrically connected. At this time, the conductors extending from the drive mechanism are electrically connected to the second flexible conductor 20 via the second terminal plate 23. Therefore, vibrations transmitted from the rotor of the drive mechanism are absorbed by the second flexible conductor 20. This makes it possible to suppress transmission of this vibration to the housing 2 or to the outside of the housing 2. The connector 53 also includes the first flexible conductor 20. Therefore, the above-mentioned vibration absorption is also performed by the first flexible conductor 20. This makes it possible to further obtain the above-mentioned vibration suppression effect.

[0051] Furthermore, when performing the third operation described above, even if there is a misalignment between the through hole of the conductor extending from the drive mechanism and the screw hole 23c of the second terminal plate 23 of the joining conductor 30, this misalignment can be suppressed by deforming the second flexible conductor 20. Therefore, this third operation can be performed smoothly. The same applies to the fourth operation. Furthermore, these screws can be screwed in without excessively deforming the first flexible conductor 20 and the second flexible conductor 20.

[0052] Furthermore, because one end 20a of the first flexible conductor 20 and one end 21a of the insulating coating 21 are inserted, the degree of freedom of movement of the first flexible conductor 20 is restricted more than when the entire first flexible conductor 20 is not inserted. Similarly, because one end 20a of the second flexible conductor 20 and one end 21a of the insulating coating 21 are inserted, the degree of freedom of movement of the second flexible conductor 20 is restricted more than when the entire second flexible conductor 20 is not inserted.

[0053] Therefore, the first operation of inserting the resin body 11 of the connector 3 into the opening 2a of the housing 2 can be carried out smoothly. Furthermore, when the screws are screwed into the nuts in the third operation, the screws can be stably screwed into the nuts without causing the second terminal board 23 to shake significantly. This also applies to the fourth operation. Furthermore, when the joining conductor 70 is inserted, the first flexible conductor 20 and the second flexible conductor 20 can be held in a direction other than the vertical direction (directly above or directly below).

[0054] The connector 53 according to the second embodiment is configured as described above. With this configuration, the connector 53 according to the second embodiment can achieve the same effects as the connector 3 according to the first embodiment. That is, the resin body 10 is not likely to become large in the arrangement direction of the second flexible conductors 20, and the insulation distance (Z2), i.e., creepage distance, required for the second flexible conductors 20 can be ensured (see FIG. 6 ). As a result, the connector 53 can be made compact. Furthermore, in the connector 53 according to the second embodiment, the insulation distance (Z2), i.e., creepage distance, between the bus bars 22 according to the first embodiment can be ensured even at the one end 11 a of a portion of the resin body portion 11, thereby enabling the connector 53 to be made compact.

[0055] Furthermore, with this configuration, the first flexible conductor 20 is electrically connected to the inverter. The second flexible conductor 20 is electrically connected to the drive mechanism inside the housing 2. Therefore, power can be supplied from the inverter to the motor 1.

[0056] Furthermore, with this configuration, one end 20a of the first flexible conductor 20 and one end 60a of the intermediate conductor 60 overlap in the thickness direction. One end 20a of the second flexible conductor 20 and the other end 60b of the intermediate conductor 60 overlap in the thickness direction. Therefore, at each overlapping portion, a step is created in the thickness direction. That is, two steps are created. Therefore, even when gas within the housing 2 flows into the connector 53 through the inside of the first and second flexible conductors 20 or along the insulating coating 21 as the pressure inside the housing 2 increases, more pressure loss occurs in this inflow path. In other words, this inflow path has a more labyrinth structure. Therefore, the outflow of gas to the outside of the housing 2 can be more effectively suppressed, and airtightness is maintained. Furthermore, even if oil penetrates the inside of the second flexible conductor 20 due to capillary action, the one end 20a of the second flexible conductor 20 and the other end 60b of the intermediate conductor 60 are joined within the connector 53, preventing further penetration and suppressing the outflow of oil, thereby maintaining watertightness.

[0057] Although the first and second embodiments have been described with reference to the above structures, it will be apparent to those skilled in the art that many modifications, improvements, and variations are possible without departing from the scope of the present invention. Therefore, the first and second embodiments may include all modifications, improvements, and variations that do not depart from the spirit and scope of the appended claims. For example, the first and second embodiments are not limited to a particular structure and may be modified as follows:

[0058] As described above, the connectors 3, 53 have been described as terminal blocks for the motor 1. However, the connectors 3, 53 may be terminal blocks for components (automotive components) used in automobiles. As described above, two distinct layers (oil layer 4 and gas layer 5) have been described as the space that the resin body 10 divides into an airtight or watertight form. However, the two distinct layers may be any two of the oil layer 4, the water layer, the gas layer 5, etc. As described above, the connectors 3, 53 have been described as having three joining conductors 30, 70. However, the number of joining conductors 30, 70 may be any number as long as they are plural. Compaction welding has been described as an example of joining. However, as long as the electrically joined portion is watertight, methods such as welding, crimping, heat crimping, and adhesive bonding may also be used.

[0059] Furthermore, the first to fourth operations in the example of the procedure for attaching the connectors 3, 53 to the housing 2 do not have to be in this numerical order and may be changed as appropriate. Furthermore, although a shaft seal has been described as the sealing material 14, a surface seal may also be used.

Claims

1. A connector comprising: a resin body that seals an opening of a housing; a flexible conductor formed from a flexible material having a connecting end inside the resin body and extending in one direction from the resin body; an insulating coating that covers the flexible conductor; and a connected end that is connected to the connecting end of the flexible conductor, the connected end being insert-molded into the resin body together with the flexible conductor and the insulating coating, and extending in the other direction from the resin body.

2. A connector according to claim 1, wherein the flexible conductor is electrically connected to a load device within the housing, and the connecting conductor is electrically connected to an inverter.

3. A connector according to claim 1 or 2, wherein the connecting end of the flexible conductor and the connected end of the connection conductor overlap in the thickness direction.

4. A connector comprising: a resin body sealing an opening of a housing; first and second flexible conductors formed from a flexible material each having a connecting end inside the resin body and extending in a first direction and a second direction from the resin body; first and second insulating coatings covering the first and second flexible conductors, respectively; and an intermediate conductor having first and second connected ends connected to the connecting ends of the first and second flexible conductors, respectively, wherein the first and second connected ends are insert molded into the resin body together with the first and second flexible conductors and the first and second insulating coatings.

5. A connector according to claim 4, wherein the first flexible conductor is electrically connected to an inverter, and the second flexible conductor is electrically connected to a load device within the housing.

6. A connector according to claim 4 or 5, wherein the connecting ends of the first and second flexible conductors and the first and second connected ends of the intermediate conductor overlap each other in the thickness direction.

Images