Electrical connector

Abstract

An electrical connector (1) has a body section (2) and a busbar (4). The busbar (4) is insert-molded into the body section (2). The busbar (4) has an arm (4a) and a connection terminal (4e). The arm (4a) extends outward from the body section (2). The connection terminal (4e) is provided at the tip (4d) of the arm (4a). A potting material (6) that is made to adhere to the body section (2) and seals the periphery of the base (4b) of the arm (4a) is provided. A holding section (3b) for holding the arm (4a) between the potting material (6) and the connection terminal (4e) is also provided.

Description

electrical connectors

[0001] The present disclosure relates to an electrical connector that relays power or electrical signals. For example, the electrical connector connects an electrical component within a unit to an external power source to relay power. The electrical connector connects an electrical component within a unit to another electrical component to relay electrical signals.

[0002] For example, electric vehicles, hybrid vehicles, etc. are equipped with so-called power control units that perform motor control, etc. This type of unit is a sealed box. The unit is provided with an electrical connector that electrically connects internal electrical components with an external power source. Another electrical connector is provided that electrically connects internal electrical components with external electrical components. The electrical connector includes a conductive member that relays power or electrical signals and a main body that holds the conductive member. The conductive member is, for example, a bus bar or a nut connected to the bus bar. The conductive member is insert-molded into the main body. Connection terminals at the ends of the conductive member are exposed from the main body. The conductive member is attached to the exterior wall of the unit via the main body. The conductive member is arranged to penetrate the interior and exterior of the exterior wall of the unit.

[0003] Japanese Patent Application Laid-Open Nos. 2023-47548 and 2022-132715 describe electrical connectors filled with a potting material to improve the sealing performance inside and outside the unit. The potting material is filled, for example, at the base where the conductive member begins to expose from the main body. The potting material seals the main body by its adhesive force. For example, a connection terminal of the conductive member is connected to an electrical component spaced from the electrical connector with a bolt or the like. Because there are tolerances between the electrical connector and the electrical component, tension may occur around the connection terminal connected to the electrical component. The tension is transmitted to the base of the conductive member and then to the potting material. This transmitted tension may cause the potting material adhered to the main body to peel off.

[0004] Conventionally, when using a crank-shaped (S-shaped) bus bar in an electrical connector, for example, an L-shaped bus bar is insert-molded into the main body. After molding, the tip of the bus bar is bent to form the crank shape. The process of bending the bus bar after insert molding lengthens the manufacturing cycle time.

[0005] Therefore, in electrical connectors in which conductive members are insert-molded into the main body, there is a demand for improved sealing performance around the conductive members.

[0006] According to one aspect of the present disclosure, an electrical connector includes a body and a conductive member. The conductive member is insert molded into the body. The conductive member has an arm and a connection terminal. The arm extends outward from the body. The connection terminal is provided at the tip of the arm. A potting material is provided that is bonded to the body and seals the periphery of the base of the arm. A retaining portion is provided that retains the arm between the potting material and the connection terminal.

[0007] When connecting the connection terminal to another electrical component, tension is generated in the arm. By holding the arm with the holding portion, it is possible to prevent the tension from being transmitted from the connection terminal to the potting material. This prevents the potting material from peeling off from the main body. This improves the sealing performance between the main body and the conductive member insert-molded into the main body.

[0008] According to another feature of the present disclosure, the retaining portion is integrally formed with the main body portion using the same material. Therefore, the conductive member can be insert-molded together with the main body portion and the retaining portion. This improves the productivity of the electrical connector. Furthermore, by being integral with the main body portion, the retaining portion can more stably hold the conductive member. Therefore, peeling of the potting material from the main body portion can be more reliably prevented.

[0009] According to another feature of the present disclosure, the conductive member is plate-shaped. A bent portion is provided in the arm. A potting material is disposed closer to the base than the bent portion. A holding portion is disposed on the tip end side of the arm, including the bent portion. Therefore, the tip end side, including the bent portion of the arm, is easily displaced when connecting to another electrical component. By holding the easily displaced portion with the holding portion, the arm of the conductive member can be more stably held. Therefore, peeling of the potting material from the main body can be more reliably prevented.

[0010] According to another feature of the present disclosure, the main body has a first opening and a second opening that open toward a location to be filled with potting material. The first opening and the second opening open in different directions. Therefore, the potting material can be filled from either the first opening or the second opening, or both. By being able to fill the potting material from a preferred direction, the periphery of the base of the conductive member can be more reliably sealed.

[0011] According to another feature of the present disclosure, the retaining portion is spaced apart from the potting material, which more reliably prevents tension generated around the connection terminal from being transmitted to the retaining portion and the potting material, thereby more reliably preventing the potting material from peeling off from the main body portion.

[0012] 5 is a perspective view of an electrical connector. A top view of an electrical connector. A perspective view of a bus bar, a flange bolt, and a nut. A perspective view of an electrical connector that electrically connects the inside and outside of a unit. A cross-sectional view of the electrical connector attached to a unit, taken along line V-V in FIG. 2. A cross-sectional view of the electrical connector, taken along line VI-VI in FIG. 5. A cross-sectional view of the electrical connector and mold, taken along line V-V in FIG. 2. A cross-sectional view of the electrical connector, taken along line V-V in FIG. 2, showing the filling of potting material.

[0013] An embodiment of the present disclosure will be described with reference to FIGS. 1 to 8 . The electrical connector 1 exemplified in the present disclosure is provided in a power control unit mounted on, for example, an electric vehicle or a hybrid vehicle. As shown in FIG. 4 , the electrical connector 1 is provided on an exterior wall 10a of a unit 10. One side (the upper side in the figure) of the exterior wall 10a is the interior of the unit 10, and the other side (the lower side in the figure) is the exterior of the unit 10. The electrical connector 1 electrically connects an internal connection terminal 11 inside the unit 10 to an external connection terminal 12 outside the unit 10. Power or an electrical signal is transmitted between the internal connection terminal 11 and the external connection terminal 12 via the electrical connector 1. In the following description, up, down, front, back, left, and right directions are defined as directions shown in the figures. The inside of the unit 10 is defined as the upper side, and the outside as the lower side. The up, down, front, back, left, and right directions are defined for convenience of explanation and do not specify, for example, the orientation in which the electrical connector 1 is assembled to the unit 10 or the orientation in which the unit 10 is assembled to a vehicle.

[0014] As shown in FIGS. 1 and 4 , the electrical connector 1 includes a main body 2 and a bus bar 4. The main body 2 is an insulator made of synthetic resin. The entire main body 2 is formed of the same material. The main body 2 is attached to the exterior wall 10a of the unit 10. The bus bar 4 is a plate-shaped metal member. The bus bar 4 has an arm 4a extending outward from the upper portion of the main body 2. The arm 4a extends forward toward a tip 4d. The tip 4d is provided with a connection terminal 4e connected to an internal connection terminal 11. As shown in FIG. 3 , the electrical connector 1 includes a flange bolt 5 and a nut 5b. The nut 5b is integrally assembled with the bus bar 4 via the flange bolt 5. As shown in FIG. 4 , the bus bar 4 and the nut 5b are insert-molded into the main body 2 so that they are integrally assembled and electrically conductive to each other. The nut 5b is connected to an external connection terminal 12 via a flange bolt 5 protruding downward from the bottom of the main body 2. This forms an electrical path that sequentially connects the internal connection terminal 11, the bus bar 4, the nut 5b, and the external connection terminal 12. The bus bar 4 or the nut 5b is an example of a conductive member.

[0015] As shown in FIG. 1 , the main body 2 has a flat plate portion 2a, a cylindrical portion 2b, and an outwardly protruding portion 2c. The flat plate portion 2a extends in a flat plate shape generally perpendicular to the vertical direction. A collar 8 is insert-molded into the rear portion of the flat plate portion 2a. The collar 8 is oriented so that the screw hole extends in the vertical direction. The cylindrical portion 2b protrudes upward in a cylindrical shape from the front portion of the flat plate portion 2a. The axial direction of the cylindrical portion 2b is the vertical direction. A recessed groove 2i extends around the entire circumferential direction on the side surface of the cylindrical portion 2b. The outwardly protruding portion 2c protrudes downward in a box shape from the front portion of the flat plate portion 2a. The outwardly protruding portion 2c is positioned at approximately the same front-to-back position as the cylindrical portion 2b. The tip of the flange bolt 5 protrudes downward from the lower end of the outwardly protruding portion 2c.

[0016] As shown in FIG. 1 , the main body 2 has a rectangular box-shaped portion 3 above the cylindrical portion 2b. A flat upright wall 3a is provided at the rear of the box-shaped portion 3. The upright wall 3a rises upward from a first surface 2d at the top of the cylindrical portion 2b and extends in the left-right direction. Flat side walls 3c are connected to the left and right ends of the upright wall 3a. The pair of left and right side walls 3c rise upward from the first surface 2d and extend forward from the upright wall 3a. The pair of side walls 3c extend parallel to each other. The upper portions of the pair of side walls 3c are connected by a retaining portion 3b. The retaining portion 3b has a predetermined thickness in the vertical direction and extends approximately parallel to the first surface 2d. The retaining portion 3b surrounds and retains the arm 4a of the bus bar 4. The arm 4a passes through a bus bar retaining hole 3g formed in the retaining portion 3b.

[0017] As shown in FIG. 1 , the retaining portion 3b, the pair of side walls 3c, and the first surface 2d cooperate to form a rectangular first opening 3d. The first opening 3d extends rearward from the front end of the box-shaped portion 3 in a rectangular shape roughly equivalent to the opening edge. The retaining portion 3b and the upright wall 3a are connected by an inclined portion 3h. The inclined portion 3h slopes downward toward the rear. As shown in FIG. 2 , the retaining portion 3b, the pair of side walls 3c, and the upright wall 3a cooperate to form a rectangular second opening 3e. The second opening 3e penetrates the inclined portion 3h and extends downward from the top of the box-shaped portion 3 in a rectangular shape roughly equivalent to the opening edge. As shown in FIG. 5 , the first opening 3d and the second opening 3e are connected roughly perpendicularly by a connecting portion 3f inside the box-shaped portion 3. Therefore, the first opening 3d and the second opening 3e form an L-shaped space when viewed left and right.

[0018] As shown in FIG. 2, a semicircular third opening 2f is provided in the cylindrical portion 2b. The third opening 2f extends downward from the upper end of the cylindrical portion 2b in a semicircular shape that is approximately the same as the opening end. The front surface of the third opening 2f is flat and connected to the rear surface of the upright wall 3a. The rear surface of the third opening 2f has an arc shape that convex rearward. As shown in FIG. 5, the lower end of the third opening 2f extends to the outward protrusion 2c. The head 5a of the flange bolt 5 is disposed at the lower end of the third opening 2f.

[0019] As shown in FIG. 3 , the bus bar 4 is bent in an S-shape. The bus bar 4 has an upper arm 4a and a lower second arm 4g. The base 4b of the arm 4a extends in the up-down direction like a flat plate with a substantially constant width. The tip 4d of the arm 4a extends in the front-rear direction like a flat plate with a substantially constant width. The arm 4a has a bent portion 4c connecting the base 4b and the tip 4d. The arm 4a bends at a substantially right angle from the base 4b to the tip 4d at the bent portion 4c. A circular through-hole 4f is provided in the connection terminal 4e of the tip 4d, penetrating in the up-down direction.

[0020] As shown in FIG. 3 , the second arm 4g extends downward from the base 4b. The second arm 4g has a second bent portion 4h that bends in the opposite direction to the bent portion 4c. The second arm 4g bends rearward at a substantially right angle at the second bent portion 4h. The second arm 4g has a bolt connection end 4i located on the distal end side (rear side) of the second bent portion 4h. As shown in FIG. 5 , the bolt connection end 4i has a circular through-hole 4j that penetrates in the vertical direction. The flange bolt 5 is inserted into the through-hole 4j with its head 5a facing upward. A nut 5b is fastened to the flange bolt 5 extending below the bolt connection end 4i. This allows the busbar 4 and the nut 5b to be integrally assembled so that electricity can be conducted between them.

[0021] As shown in FIG. 5 , the base 4b of the arm 4a extends outward from the upper end of the cylindrical portion 2b to the outside of the main body 2. The base 4b is exposed outward from the main body 2 at the communication portion 3f of the box-shaped portion 3. The rear portions of the bent portion 4c and the tip portion 4d are held by the holding portion 3b by being positioned inside the busbar holding hole 3g. The entire outer periphery of the bent portion 4c and the rear portion of the tip portion 4d is covered by the holding portion 3b. The second arm 4g is positioned inside the main body 2, spanning the cylindrical portion 2b, the flat portion 2a, and the outward protruding portion 2c. The entire second arm 4g is covered by the main body 2 over the entire outer periphery. The front portion of the tip portion 4d, including the connection terminal 4e, is exposed outward from the main body 2.

[0022] As shown in Figure 5, the upper part of the flange bolt 5 and the nut 5b are mostly covered by the outward protruding portion 2c. Only the lower part of the flange bolt 5 is exposed. A portion of the upper surface of the head 5a of the flange bolt 5 is located at the bottom of the third opening 2f. The lower part of the flange bolt 5 has a tip that protrudes downward from the bottom surface 2j of the outward protruding portion 2c, and the tip is exposed. A nut 5b is screwed onto the flange bolt 5 from below. Only the bottom surface 5c of the lower end of the nut 5b is exposed from the outward protruding portion 2c. The bottom surface 5c of the nut 5b is approximately flush with the bottom surface 2j of the outward protruding portion 2c.

[0023] As shown in Figure 5, the lower part of the base 4b is covered with potting material 6. The potting material 6 covers and seals the portion of the base 4b where it begins to extend outward from the first surface 2d. This prevents water from entering the inside of the unit 10 via the periphery of the base 4b. The potting material 6 is bonded to the main body 2 across the first surface 2d and the second surface 2e that forms the front surface of the upright wall 3a. The surface 6a of the potting material 6 slopes downward toward the front. The potting material 6 is spaced apart from the retaining portion 3b and is not bonded to the retaining portion 3b.

[0024] As shown in Figure 6, the potting material 6 covers the entire periphery of the lower part of the base 4b. The upper part of the base 4b exposed upward from the potting material 6 has a gap between it and the upright wall 3a in the front-to-rear direction. The upper part of the base 4b has a gap between it and each of the pair of side walls 3c in the left-to-right direction. In other words, the base 4b does not contact either the upright wall 3a or the pair of side walls 3c.

[0025] As shown in Figure 5, the potting material 7 is loaded through the third opening 2f and covers the heads 5a of the flange bolts 5. The potting material 7 thus seals the bottom of the third opening 2f. This prevents water from entering the inside of the unit 10 through the periphery of the flange bolts 5. The potting material 7 is adhered to the main body 2, spanning the front surface 2g and rear surface 2h of the third opening 2f and the heads 5a of the flange bolts 5. The surface 7a of the potting material 7 slopes downward toward the front. The surfaces 6a, 7a of the potting materials 6, 7 are inclined at approximately the same angle.

[0026] As shown in Figures 4 and 5, when the electrical connector 1 is attached to the unit 10, the cylindrical portion 2b is inserted into the through-hole 10b in the exterior wall 10a. An O-ring 9 is attached to the recessed groove 2i of the cylindrical portion 2b. The O-ring 9 seals the gap between the cylindrical portion 2b and the wall surface of the through-hole 10b. The flat portion 2a conforms to the outer surface of the exterior wall 10a. A mounting bolt 13 is fastened to the collar 8 (see Figure 1) of the flat portion 2a. The mounting bolt 13 is also fastened to a threaded hole in the bolt fastening portion 10c provided in the exterior wall 10a. In this way, the main body 2 of the electrical connector 1 is attached to the exterior wall 10a while ensuring sealing between the inside and outside of the unit 10.

[0027] As shown in FIG. 4 , a bolt 11a is inserted through the connection terminal 4e of the bus bar 4 and the internal connection terminal 11 of the unit 10. The bolt 11a is fastened to a bolt fastening hole 10e in an inner wall 10d provided at a predetermined position of the unit 10. As a result, the connection terminal 4e and the internal connection terminal 11 are held by the inner wall 10d and electrically connected to each other. The internal connection terminal 11 is electrically connected to internal electrical components of the unit 10, for example, by a harness. An external connection terminal 12 is inserted through the tip of the flange bolt 5. A nut 12a is fastened to the flange bolt 5, bringing the external connection terminal 12 into contact with the nut 5b. As a result, the nut 5b and the external connection terminal 12 are integrally connected and electrically connected to each other. The external connection terminal 12 is electrically connected to electrical components external to the unit 10. Thus, an electrical path is formed to transmit power or an electrical signal between the inside and outside of the unit 10 via the internal connection terminal 11, the bus bar 4, the nut 5b, and the external connection terminal 12.

[0028] As shown in FIG. 4 , the fastening force of the bolt 11a acts on the connection terminal 4e of the busbar 4. There are also tolerances for assembling the connection terminal 4e to the internal wall 10d and tolerances for assembling the main body 2 to the exterior wall 10a. Due to these tolerances, the position at which the connection terminal 4e is assembled varies from product to product. The fastening force of the bolt 11a shown in FIG. 4 and the displacement of the connection terminal 4e due to variations in the assembly position cause tension, as indicated by the arrows in FIG. 5 , to be generated at the tip 4d of the busbar 4. The tension acts, for example, vertically in the thickness direction of the tip 4d. While the tension acts on the arm 4a closer to the connection terminal 4e than the portion held by the holding portion 3b, transmission of the tension to the arm 4a held by the holding portion 3b and to the arm 4a closer to the base 4b is suppressed.

[0029] 7, the mold used for insert molding includes a lower mold 20, a front slide mold 21, an upper mold 22, and a rear slide mold 23. The front slide mold 21 has a first opening forming portion 21a that forms the first opening 3d in front of the base 4b of the bus bar 4. The upper mold 22 has a second opening forming portion 22a that forms the second opening 3e behind the base 4b of the bus bar 4. The upper mold 22 has a third opening forming portion 22b that forms the third opening 2f.

[0030] As shown in Figure 8, the potting materials 6 and 7 are filled in a state in which the bus bar 4, nut 5b, etc. are insert-molded into the main body 2. The electrical connector 1 is held in an inclined position with the tip 4d of the bus bar 4 facing forward and inclined upward relative to the horizontal. The potting material 6 is filled from the first opening 3d, the second opening 3e, or both, to cover the lower part of the base 4b. The potting material 7 is filled from the third opening 2f to cover the head 5a of the flange bolt 5. The filled potting materials 6 and 7 are bonded to the main body 2, for example, by heat curing. In this way, the potting materials 6 and 7 are formed with surfaces 6a and 7a inclined relative to the front-to-rear direction.

[0031] As described above, the electrical connector 1 has a main body 2 and a bus bar (conductive member) 4, as shown in Figures 1 and 5. The bus bar 4 is insert-molded into the main body 2. The bus bar 4 has an arm 4a and a connection terminal 4e. The arm 4a extends outward from the main body 2. The connection terminal 4e is provided at a tip 4d of the arm 4a. A potting material 6 is provided that is adhered to the main body 2 and seals the periphery of the base 4b of the arm 4a. A holding portion 3b is provided that holds the arm 4a between the potting material 6 and the connection terminal 4e.

[0032] Therefore, tension is generated in the arm 4a when the connection terminal 4e is connected to another electrical component, for example, the internal connection terminal 11 shown in FIG. 4. By holding the arm 4a with the holding portion 3b, it is possible to prevent the tension from being transmitted from the connection terminal 4e to the potting material 6. This prevents the potting material 6 from peeling off from the main body 2. This improves the sealing performance between the main body 2 and the bus bar 4 insert-molded into the main body 2.

[0033] 1 and 5, the retaining portion 3b is integrally formed with the main body 2 using the same material. Therefore, the bus bar 4 can be insert-molded together with the main body 2 and the retaining portion 3b. This improves the productivity of the electrical connector 1. Furthermore, by being integral with the main body 2, the retaining portion 3b can more stably hold the bus bar 4. Therefore, peeling of the potting material 6 from the main body 2 can be more reliably prevented.

[0034] As shown in Figures 3 and 5, the bus bar 4 is plate-shaped. A bent portion 4c is provided on the arm 4a. The potting material 6 is disposed closer to the base 4b than the bent portion 4c. The holding portion 3b is disposed on the tip 4d side of the arm 4a, including the bent portion 4c. Therefore, the tip 4d side of the arm 4a, including the bent portion 4c, is easily displaced when connecting to the internal connection terminal 11. By holding the easily displaced portion with the holding portion 3b, the arm 4a of the bus bar 4 can be stably held. This more reliably prevents the potting material 6 from peeling off from the main body 2.

[0035] As shown in Figure 5, the main body 2 has a first opening 3d and a second opening 3e that open toward the location to be filled with the potting material 6. The first opening 3d and the second opening 3e open in different directions. Therefore, the potting material 6 can be filled from either or both of the first opening 3d and the second opening 3e. By being able to fill the potting material 6 from a preferred direction, the periphery of the base 4b of the bus bar 4 can be sealed more reliably.

[0036] 5, the holding portion 3b is spaced apart from the potting material 6. Therefore, when tension generated around the connection terminal 4e is transmitted to the holding portion 3b, the tension can be more reliably prevented from being transmitted to the potting material 6. Therefore, the potting material 6 can be more reliably prevented from peeling off from the main body portion 2.

[0037] The electrical connector 1 of the present embodiment described above can be modified in various ways. For example, the electrical connector 1 is provided in a power control unit mounted on an electric vehicle, a hybrid vehicle, or the like. The electrical connector of the present disclosure can be applied to electrical paths in a variety of products, without being limited to this. By applying the electrical connector of the present disclosure to electrical paths in products where water intrusion prevention is particularly desired, the waterproofing effect provided by sealing can be enhanced. It can also be applied to electrical connectors with multiple conductive members arranged in parallel.

[0038] A plate-shaped bus bar 4 is exemplified as the conductive member. Alternatively, the conductive member may be, for example, a rod-shaped or columnar member having a predetermined level of rigidity. An S-shaped bus bar 4 is exemplified. Alternatively, the shape of the insert-molded conductive member may be, for example, an L-shape or an I-shape. A bus bar 4 bent at a substantially right angle at the bend 4c is exemplified. Alternatively, the bend 4c may be curved into an arc shape with a diameter larger than the bend, for example. For example, the bend 4c may be bent at an angle larger or smaller than a substantially right angle.

[0039] The bus bar 4 and the nut 5b connected to the bus bar 4 are shown as examples of conductive members to be insert-molded. In this embodiment, one connection terminal 4e is provided at the tip 4d of the bus bar 4, and the other connection terminal is provided on the bottom surface 5c of the nut 5b. Alternatively, for example, both ends of the bus bar may penetrate the main body, and potting material covering the periphery and a connection terminal may be provided at each end. In this case, a holding portion is provided between both potting materials and the connection terminal.

[0040] In the illustrated example, the holding portion 3b is integrally formed from the same material as the main body 2. Alternatively, the main body and the holding portion may be formed separately. The separate main body and the holding portion may be assembled together. Alternatively, the separate main body and the holding portion may be assembled separately into a unit.

[0041] In the illustrated example, two openings, the first opening 3d and the second opening 3e, open from different directions toward the filling location of the potting material 6. Alternatively, for example, three or more openings may be provided toward the filling location of the potting material 6. In the illustrated example, the first opening 3d and the second opening 3e open substantially perpendicular to each other. Alternatively, for example, the opening directions of the first opening and the second opening may be substantially the same or substantially opposite.

Claims

1. An electrical connector comprising: a main body; and a conductive member insert-molded into the main body, the conductive member having an arm extending outward from the main body and a connection terminal provided at the tip of the arm; a potting material adhered to the main body and sealing the periphery of the base of the arm; and a holding portion for holding the arm between the potting material and the connection terminal.

2. An electrical connector according to claim 1, wherein said holding portion is integrally formed with said main body portion and made of the same material.

3. An electrical connector as claimed in claim 1 or 2, wherein the conductive member is plate-shaped, a bent portion is provided on the arm, the potting material is arranged closer to the base than the bent portion, and the holding portion is arranged on the tip side of the arm including the bent portion.

4. An electrical connector as claimed in claim 1 or 2, wherein the main body has a first opening and a second opening that open towards the location where the potting material is filled, and the first opening and the second opening open in different directions from each other.

5. An electrical connector according to claim 1 or 2, wherein the retaining portion is spaced apart from the potting material.

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