Connector

A connector comprises a connector housing receiving therein a terminal fitting connected to an electrode of a connector-mounting portion and an electrical wire at an end of which the terminal fitting is provided; a cap for the connector housing; and a packing for the cap. The packing includes a mushroom-like locking projection with an enlarged end portion. The cap includes a locking hole into which the end portion of the locking projection is inserted so that the end portion is placed in locking engagement with the locking hole.

TECHNICAL FIELD

The present invention relates to a connector that ensures high retentive strength for retention of a packing and visual confirmation of the presence of the packing.

BACKGROUND ART

Electric vehicles and hybrid automobiles incorporate a three-phase AC motor as a power source, and a battery as a source of electrical energy, and an inverter that converts DC power of the battery into three-phase AC power. The three-phase AC motor is connected via the inverter to the battery. The three-phase AC motor is electrically connected via an electrical wire to the inverter. The inverter is electrically connected to the battery via an electrical wire.

The electrical wire that feeds the three-phase alternate current to the three-phase AC motor is connected via a connector to the inverter, the connector being adapted to be attached to a connector-mounting portion of the inverter. A connector101of this type, as shown inFIG. 5, is known, in which an electrical wire149along with a terminal fitting150provided at an end thereof is received and retained in a shield shell104, the shield shell104being secured by means of a bolt151to a connector-mounting portion102of an inverter (for example, see the patent literature PTL 1).

The connector101as described in the PTL 1 comprises (a) a shield shell104including (i) a terminal fitting accommodating portion108in which the terminal fitting150is received and (ii) an electrical wire accommodating portion107in which the electrical wire149is received, (b) a bolt152that electrically connects a not-shown electrode provided in the connector-mounting portion102to the terminal fitting150for retention thereof, and (c) a cover member129closing the terminal fitting accommodating portion108, and (d) the bolt151adapted to secure the cover member129and the shield shell104to the connector-mounting portion102. Also, the cover member129includes a packing133. The packing133takes a mushroom-like shape and includes a locking projection adapted to be brought into locking engagement with a recessed portion provided on an outer circumferential surface of the cover member129.

CITATION LIST

Patent Literature

SUMMARY OF INVENTION

Technical Problem

In the state of the art connector101as shown in PTL 1, however, the mushroom-like locking projection is caught by the recessed portion to be in locking engagement therewith, so that the packing133is retained by the cover member129. As a result, retentive strength is weak for retention of the locking projection and the recessed portion, and the packing133acted upon by an external force may be inadvertently detached from the cover member129, which is a drawback.

Also, the packing133does not have rigidity. The locking projection does not have rigidity, either. As a result, the retentive strength for retention of the locking projection and the recessed portion may be further decreased, which is another drawback.

Further, as the connector101is secured to the connector-mounting portion102, the packing133is arranged between the cover member129and the terminal fitting accommodating portion108, so that the packing133cannot be visually recognized. As a result, it is not possible to visually confirm the presence of the packing133, which is still another drawback.

The present invention addresses these problems and provides a solution thereto. Specifically, an object of the present invention is to provide a connector that ensures high retentive force for retention of the packing and visual confirmation of the presence of the packing.

Solution to Problem

In order to solve the problems and attain the objective, a first aspect of the invention provides a connector that comprises (a) a connector housing including a terminal fitting adapted to be connected to an electrode of a connector-mounting portion and an electrical wire at an end of which the terminal fitting is provided; (b) a cap applied to the connector housing and having a locking hole; and (c) a packing applied to the cap. The packing includes a locking projection having a mushroom-like shape with enlarged end portion. The end portion of the locking projection is adapted to be inserted into the locking hole of the cap so that the end portion is brought into locking engagement with the locking hole.

A second aspect of the invention provides the above-defined connector whose locking projection includes a pin member adapted to be inserted in the locking projection.

Advantageous Effects of Invention

In accordance with the first aspect of the invention, the connector has the packing that includes the locking projection in the mushroom-like shape with the enlarged end portion and the cap that includes the locking hole into which the end portion of the locking projection is inserted so that the end portion is brought into locking engagement with the locking hole. Accordingly, it is made possible for the enlarged end portion of the locking projection to be reliably placed in locking engagement with the peripheral portion of the locking hole, which increases the retentive strength of the locking projection with the locking hole for reliable retention of the packing to the cap.

Also, since the connector has the locking projection that is brought into locking engagement with the locking hole in the cap, it is made possible to visually confirm the presence of the packing on the basis of the presence of the end portion of the locking projection that is inserted into and passed through the locking hole so as to protrude to an outside, and thus prevent failure to provide the packing that should exist there.

In accordance with the second aspect of the invention, the connector can increase the stiffness of the locking projection by virtue of the pin member, and thus the retentive strength for retention of the locking projection with the locking hole is substantially increased, making it possible to reliably retain the packing to the cap.

DESCRIPTION OF EMBODIMENTS

One embodiment of the present invention is described hereinbelow with reference toFIGS. 1 to 4. A connector1in accordance with one embodiment of the present invention comprises, as shown inFIG. 1, a connector housing3adapted to be attached to a connector-mounting portion2of an inverter. The connector1in this embodiment is adapted to be attached to the connector-mounting portion2provided in a case of the inverter. Meanwhile, it is also contemplated that the connector1may be attached to a connector-mounting portion of an electronic component other than such an inverter.

The connector housing3comprises, as shown inFIGS. 2 and 3, (A) a shield shell4serving as an outer housing and (B) an inner housing11.

The shield shell4comprises (a) a terminal fitting accommodating portion8in which a terminal fitting50is received and (b) an electrical wire accommodating portion7in which an electrical wire49is received, the electrical wire49having the terminal fitting50provided at an end thereof. The terminal fitting accommodating portion8and the electrical wire accommodating portion7are provided in parallel with each other. The shield shell4is made of conductive metal such as copper, copper alloy, aluminum and aluminum alloy.

The terminal fitting accommodating portion8comprises (i) a cylindrical terminal accommodating space39having both ends formed in a shape of an arc, (ii) a packing member40provided on and along an outer circumferential surface of the terminal accommodating space39, (iii) a rib41provided at an opening portion of the terminal accommodating space39and is formed in a shape of a ring extending along the peripheral portion of the opening portion, and (iv) and a cap15provided at the opening portion and adapted to close the opening portion.

A plurality of terminal fittings50are arranged in the terminal accommodating space39to be spaced from each other at even intervals (three terminal fittings50are illustrated in the figure). When the connector1is attached to the connector-mounting portion2(of the inverter), a plurality of electrodes are arranged in the terminal accommodating space39, the electrodes being provided in the connector-mounting portion2and adapted to be electrically connected to the plurality of terminal fittings50.

The terminal fittings50arranged in the terminal accommodating space39are made by press-working of a metal plate made from conductive metal selected from copper, copper alloy, aluminum, and aluminum alloy and subsequent bending of the same metal plate. The terminal fitting50comprises (i) an electrode-contacting portion provided in the connector-mounting portion2so as to be in contact with the electrode, and (ii) a wire-connecting portion adapted to be connected to an end of the later-described electrical wire49by caulking thereto. The terminal fitting50takes a shape of an L with the electrical contact portion arranged in the terminal accommodating space39substantially orthogonal to the later-described wire-accommodating space10. The electrical contact portion includes a bolt hole50afor securing the electrical contact portion to the electrode by means of a bolt52. The wire-connecting portion includes (i) a core-wire-caulking piece for caulking of the later-described core wire of the electrical wire49and (ii) a cover-portion-caulking piece for caulking of the cover portion.

The packing member40is made from synthetic rubber having rubber elasticity such as nitrile rubber and is formed in a ring-like manner. The packing member40is attached to a recessed groove provided in the outer circumferential surface of the terminal accommodating space39.

The rib41is provided protruding from the peripheral portion of the opening portion of the terminal accommodating space39along the peripheral portion thereof in a ring-like manner. The rib41has such an amount of protrusion that it is brought into locking engagement with a later-described flange portion16aof the cover of the cap15.

The cap15comprises a cap body29, a packing33provided on a lateral side of the cap body29, and the cover16adapted to cover a top surface of the cap body29.

The cap body29has an elliptic cylindrical shape having both ends in a shape of an arc. The cap body29is provided along the inner circumferential surface of the terminal accommodating space39. The cap body29is made from synthetic resin such as polyvinyl chloride resin. The cap body29includes (i) a groove portion30provided on the outer circumferential surface for attachment of the later-described packing33thereto; (ii) notched portions27,27provided at both ends of the top surface into which locking projections of the packing33are each fitted; (iii) protrusions19,19protruding from the top surface and adapted to be inserted into and passed through insertion holes23,23of the later-described cover16respectively; and (iv) a screw hole26into which a screw member17of the cover16is screwed.

The groove portion30is provided in a shape of a ring extending along the outer circumferential surface of the cap body29, and a top surface portion and a lower surface portion of the cap body29are enlarged. The top surface portion is more enlarged than the lower surface portion.

The notched portions27,27are, as shown inFIGS. 3 and 4, provided corresponding to the outer shape of the locking projections20of the packing33. The notched portions27,27each include a small-diameter portion adapted to be brought into abutment on the column portion20bof the later-described locking projection20, and a large-diameter portion adapted to be brought into abutment on the base portion20cof the locking projection20, the small-diameter portion continuing to the large-diameter portion.

The protrusions19,19are arranged spaced from each other in the longitudinal direction of the cap body29(two protrusions are illustrated in the figure). The protrusions19,19each include a tapering surface whose end portion is tapered.

The screw hole26is provided in the centre of the top surface of the cap member29. The screw hole26is threaded in accordance with the screw member17.

The packing33has a ring shape slightly smaller than the outer shape of the groove portion30provided in the outer circumferential surface of the cap body29. The thickness of the packing33is defined such that the inner circumferential surface of the terminal accommodating space39and the inner circumferential surface of the rib41are pressed by the packing33so that they are in firm contact with the packing33when the packing33is attached to the groove portion30and the terminal fitting accommodating portion8is closed by the cap body29. The packing33includes a protruding portions36provided on the lateral side thereof and a locking projection20provided at the upper peripheral edge portion.

The protruding portions36are provided in a shape of a ring on and along the peripheral surface of the packing33. Six protruding portions36are illustrated in the figure.

The locking projections20are provided at the upper peripheral edge of the packing33(two locking projections20are illustrated in the figure). The locking projections20are each provided at opposite positions at the peripheral edge portion on the circumferential surface of the packing33. The locking projections20protrude to an extent that it is more elevated than the peripheral edge portion. The locking projections20each include a connecting portion22substantially orthogonal to the outer circumferential surface of the packing33and extended in the direction away from the outer circumferential surface; a base portion20cprovided at the connecting portion22; a column portion20bextended from the base portion20cin the direction orthogonal to the direction in which the connecting portion22is extended; and an end portion20aprovided at the end of the column portion20bwith an enlarged width so that the locking projection20as a whole takes a mushroom-like shape. The locking projections20each include an intrusion hole21into which a later-described pin member35is fitted, the intrusion hole21extending from the base portion20cthrough to the end portion20a.

The base portion20chas such a large width that the base portion20cis allowed to be brought into abutment on the wide portion of the pin member35and thereby accommodate the wide portion therein. The column portion20bhas such a small diameter that the column portion20bis allowed to press the inside of the notched portion27of the cap body29. The end portion20ahas such a large diameter that the end portion20apresses the inner circumferential surface of the locking hole24of the cover16and is brought into locking engagement with the peripheral edge portion of the locking hole24. In this manner, the retentive strength for retention of the locking projection20with the locking hole24, and the retentive strength for retention of the locking projection20with the notched portion27are increased.

The pin member35is made from synthetic resin having stiffness such as polyvinyl chloride resin. The pin member35includes a pin portion adapted to be fitted in the intrusion hole21, and the wide portion adapted to be brought into abutment on the intrusion hole21at the base portion20cthereof. Accordingly, by virtue of the pin member35fitted in the intrusion hole21, the stiffness of the locking projection20is substantially increased, and the retentive strength for retention of the locking projection20with the locking hole24as well as the retentive strength for retention of the locking projection20with the notched portion27are substantially increased.

The cover16is, as shown inFIGS. 2 and 3, slightly larger than the top surface of the cap body29, and takes a shape of a thin elliptical plate corresponding to the shape of the top surface. The cover16is made from conductive metal. The cover16includes (i) a flange portion protruding from the peripheral edge portion of the cover16; (ii) insertion holes23,23into each of which the protrusions19of the cap body29are inserted to be passed therethrough, respectively; (iii) locking holes24,24into each of which the locking projections20of the packing33are inserted to be brought into locking engagement therewith, respectively; (iv) a screw member17adapted to be screwed into the screw hole26of the cap body29; and (v) bolt-mounting pieces18,18adapted for attachment of the cover16and the shield shell4by means of the bolt51to the connector-mounting portion2(of the inverter).

The flange portion is adapted to be arranged upon the outer circumferential surface of the rib41of the terminal accommodating space39when the terminal fitting accommodating portion8is closed by the cover16. The flange portion protrudes to an extent larger than the amount of protrusion of the rib41.

The insertion holes23are arranged spaced from each other in the longitudinal direction of the cover16(two insertion holes23are illustrated in the figure). The insertion holes23are each provided at positions corresponding to the protrusions19,19of the cap body29.

The locking holes24are provided spaced from each other in a direction orthogonal to the longitudinal direction of the cover16(two holes24are illustrated in the figure). The locking holes24are provided at positions corresponding to the locking projections20,20of the packing33, respectively. The locking hole24has, as shown inFIG. 4, a hole diameter slightly smaller than the end portion20aof the locking projection20, but slightly larger than the column portion20bof the locking projection20.

The screw member17is made of metal and provided at the centre of the cover16such that it is arranged at a position corresponding to the screw hole26of the cap body29.

The bolt-mounting pieces18,18are provided, as shown inFIGS. 2 and 3, extended from the flange portion in the longitudinal direction of the cover16. The bolt-mounting pieces18,18each include a mounting hole18ainto which the bolt51is inserted, the bolt51being for use in securing the cover16and the shield shell4to the connector-mounting portion2.

The electrical wire accommodating portion7comprises (i) a wire-accommodating space10, (ii) an inner housing11fitted in the wire-accommodating space10, and (iii) a shielding member13provided on the outer circumferential surface of the wire-accommodating space10.

The wire-accommodating space10has a shape of a cylinder with both ends in a shape of an arc. The wire-accommodating space10is slightly smaller than the terminal fitting accommodating space39. The wire-connecting portion of the terminal fitting50and the electrical wire49caulked by the wire-connecting portion are received in the wire-accommodating space10.

There are provided three electrical wires49that are to be received in the wire-accommodating space10to supply three-phase AC power to the motor. The electrical wire49includes a conductive core wire and an insulating cover portion. The core wire is obtained by twisted conductors made from conductive metal such as copper, copper alloy, aluminum, or aluminum alloy. The cover portion is made from insulating synthetic resin such as polyvinyl chloride resin and covers the core wire. It is contemplated that the core wire may comprise a single core wire.

The inner housing11is made of insulating synthetic resin such as polyvinyl chloride resin. The inner housing11includes (i) a recessed groove that retains the three electrical wires such that they are spaced from each other, (ii) a locking feature adapted to be engagement with the wire-accommodating space10inside thereof, and (iii) a waterproof feature adapted to prevent entry of liquid such as water into the wire-accommodating space10. Thus, the three electrical wires are retained spaced from each other by virtue of the inner housing11, and the three electrical wires are retained by the wire-accommodating space10. It is contemplated that the locking feature may comprise, as one example, a recessed engagement portion provided in the wire-accommodating space10and an engagement projection provided in the inner housing11. It is also contemplated that the waterproof feature may comprise, as one example, a packing member such as a rubber packing.

The shielding member13is made from conductive metal such as copper, copper alloy, aluminum, and aluminum alloy and is formed in a shape of a strip of a ring extending along the outer shape of the wire-accommodating space10. The shielding member13is in fitting engagement with the outer circumferential surface of the wire-accommodating space10and secured thereto.

The following describes how to assemble the connector1having the above-defined configuration. The connector1is, as shown inFIG. 3, assembled by bringing together the constituent parts in the assembling direction X. More specifically, the terminal fitting50, which is provided at the end of the electrical wire49, is received in the terminal fitting accommodating space39; the electrical wire49is received in the wire-accommodating space10; the shielding member13is brought into fitting engagement with the outer circumferential surface of the wire-accommodating space10; the inner housing11is brought into fitting engagement with the wire-accommodating space10; and the electrical wire49is secured in position.

Next, the shield shell4is attached to the connector-mounting portion2of the inverter. At this point, the terminal fitting accommodating space39is received in the inner bottom portion47aof the accommodating portion47of the connector-mounting portion2, and the terminal fittings50in the terminal fitting accommodating space39are brought into abutment on the electrodes of the connector-mounting portion2, respectively.

Next, the bolt52is inserted in and passed through the bolt hole of the electrical contact portion of the terminal fitting50, and the bolt52is screwed into the electrode, so that the electrode is electrically connected to the terminal fitting50.

Next, the cover16is put on the top surface of the cap body29to cover it, and the screw member17is screwed into the screw hole26. Next, the packing33is attached to the outer circumferential surface of the cap body29, and the locking projection20is fitted in (a) the notched portion27of the cap body29and (b) the locking hole24of the cover16. At this point, as shown inFIG. 4, the end portion20aof the locking projection20protrudes from the cover16, the end portion20ais brought into locking engagement with the peripheral portion and the inner circumferential surface of the locking hole24, and the column portion20bof the locking projection20is brought into locking engagement with the notched portion27. At this point, the presence of the packing33in position can be visually confirmed on the basis of the presence of the end portion20aof the locking projection20protruding from the cover16.

Next, as shown inFIG. 3, the pin member35is fitted in the intrusion hole21of the locking projection20and the cap15is constructed. At this point, stiffness of the locking projection20is substantially increased and thereby the retentive strength is substantially increased.

Next, the opening portion of the terminal fitting accommodating space39of the shield shell4is closed by the cap15; the bolt51is inserted into and passed through (a) the mounting hole18aof the bolt-mounting piece18of the cap15and (b) the mounting hole5aof the bolt mounting portion5of the shield shell4; the bolt51is screwed into the bolt hole6aof the bolt bearing portion6of connector-mounting portion2; and the connector1is secured to the connector-mounting portion2. At this point, the presence of the packing33in position can be visually confirmed by visually confirming the presence of the locking projection20of the packing33protruding from the cover16.

As the state of attachment of the packing33is visually confirmed, the connector1is manufactured that in a proper manner have the locking projection20protruding from the cover16of the cap15.

In accordance with this embodiment, the connector1comprises the terminal fitting50adapted to be connected to the electrode of the connector-mounting portion2; the connector housing3adapted to receive therein the electrical wire49at the end of which the terminal fitting50is provided; the cap15provided in the connector housing3; and the packing33provided in the cap15. The packing33includes the locking projection20having the mushroom-like shape with the enlarged end portion20a. The cap15includes the locking hole24adapted to be brought into locking engagement with the end portion20aof the locking projection20inserted therein and passed therethrough.

By virtue of this configuration, the connector1has the packing33that includes the mushroom-like locking projection20with the enlarged end portion20a, and has the cap15that includes the locking hole24adapted to be brought into locking engagement with the end portion20awith the end portion20aof the locking projection20inserted therein and passed therethrough. Accordingly, the enlarged end portion20aof the locking projection20is effectively placed in locking engagement with the peripheral portion of the locking hole24, and the retentive strength for retention of the locking projection20with the locking hole24is increased, making it possible to reliably retain the packing33to the cap15.

Also, the connector1allows for visual confirmation of the presence of the packing33provided in the cap15on the basis of the presence of the end portion20aof the locking projection20that is inserted in and passed through the locking hole24and thus protrudes to the outside, for the locking projection20is brought into locking engagement with the locking hole24of the cap15. Accordingly, it is made possible to prevent failure to provide the packing33that should exist there.

Further, in accordance with this embodiment, the locking projection20of the connector1includes the pin member35adapted to be inserted into the locking projection20.

By virtue of this configuration, the connector1allow for substantial increase in the stiffness of the locking projection20by the presence of the pin member35. Accordingly, the retentive strength for retention of the locking projection20with the locking hole24is substantially increased, making it possible to reliably retain the packing33to the cap15.

It is appreciated that the embodiment described herein is a representative one taken from among conceivable embodiments of the invention, and that the invention is in no way limited to the illustrated embodiments. Rather, the invention can be implemented with various modifications made thereto within the range that the spirit of the invention is deviated from.

REFERENCE SIGNS LIST