Stacked connector and wire harness

An object is to provide a technique by which a space in a vehicle in which a wire harness including a plurality of splice circuits is arranged can be reduced and good manufacturability at the time of manufacture can be achieved. A stacked connector is formed by joining a plurality of split connectors to each other. The split connectors each include a split connector housing provided with a plurality of terminal receiving chambers and a plurality of terminal-equipped electric wires that each include a terminal received in the terminal receiving chamber and an electric wire to which the terminal is connected. At least one of the split connector housings is provided with a locking portion having a protruding shape that protrudes outward to be capable of locking the terminal-equipped electric wire received in the split connector housing of a joining counterpart.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a national phase of PCT application No. PCT/JP2017/009602, filed on 9 Mar. 2017, which is incorporated herein in its entirety by reference.

TECHNICAL FIELD

The present invention relates to a short circuit in a wire harness.

BACKGROUND

Conventionally, a joint connector is known as a means for forming a short circuit (also referred to as a splice circuit) for shorting a plurality of electric wires included in a wire harness or the like of an automobile. Such a joint connector is disclosed in Patent Document 1, for example.

The joint connector disclosed in Patent Document 1 includes an insulating housing and a bus bar that is provided in the insulating housing and connects a plurality of male terminals. The insulating housing is provided with a plurality of terminal receiving chambers and one housing fitting portion. The terminal receiving chambers are each capable of receiving a first female terminal connected to an end portion of an electric wire. The housing fitting portion is capable of receiving a female connector provided with a plurality of terminal-equipped electric wires to which second female terminals are connected. The plurality of female terminals are shorted via the bus bar.

PRIOR ART DOCUMENT

Patent Document

SUMMARY OF THE INVENTION

Problems to be Solved

Here, in recent years, the number of splice circuits described above has been on the rise following an increase in the number of circuits in a vehicle. Thus, if the number of joint connectors is increased, accordingly, the installation space increases, and because there is a limit on space in the vehicle in which the wire harness can be arranged, there is a demand for a decrease in the space used for arrangement from the viewpoint of arrangement in the vehicle. It is conceivable to, as a means for realizing a decrease in the space used for arrangement, increase the number of poles in one joint connector and make them more concentrated.

On the other hand, from the viewpoint of manufacturing a wire harness, wire harnesses are more easy to manufacture when the connectors are dispersed during a manufacturing process, and thus dispersion is desired during the manufacturing process.

In view of this, an object of the present invention is to provide a technique by which a space in a vehicle where a wire harness including a plurality of splice circuits is arranged can be reduced, and good manufacturability at the time of manufacture can be achieved.

Means to Solve the Problem

In order to resolve the above-described issues, a stacked connector according to a first aspect is a stacked connector formed by joining a plurality of split connectors to each other, in which the split connectors each include a split connector housing provided with a plurality of terminal receiving chambers, and a plurality of terminal-equipped electric wires that each include a terminal received in the terminal receiving chamber, and an electric wire to which the terminal is connected, and at least one of the split connector housings is provided with a locking portion having a protruding shape that protrudes outward to be capable of locking the terminal-equipped electric wire received in the split connector housing of a joining counterpart.

A stacked connector according to a second aspect is the stacked connector according to the first aspect, in which the split connectors are stacked in three or more layers, and two surfaces of at least one of the split connector housings located at an intermediate position in a stacking direction are provided with the locking portions.

A stacked connector according to a third aspect is the stacked connector according to the first or second aspect, in which a pair of the split connectors that are adjacent to each other include a pair of split connectors that are provided with the locking portions that are capable of locking the terminal-equipped electric wires received in the counterpart split connector housing, and through holes for receiving the counterpart locking portions, the locking portions and the through holes being located in an alternating manner in a direction intersecting the stacking direction.

A wire harness according to a fourth aspect includes the stacked connector according to any one of the first to third aspects, and a joint connector that includes a joint terminal provided with a linking piece and a plurality of tab terminals protruding in parallel to each other from the linking piece, and a joint connector housing in which the joint terminal is housed and by which the joint terminal is supported, the joint connector being capable of being fitted to the stacked connector.

A wire harness according to a fifth aspect is the wire harness according to the fourth aspect, in which a plurality of the stacked connectors are connected to the one joint connector, and the split connector housing located in one surface layer of each of the plurality of stacked connectors is provided with erroneous fitting restricting ribs having different shapes.

A wire harness according to a sixth aspect is the wire harness according to the fifth aspect, in which the split connector housings located in layers other than the one surface layer of each of the plurality of stacked connectors are formed in the same shape.

A wire harness according to a seventh aspect is the wire harness according to any one of the fourth to sixth aspects, in which a plurality of the stacked connectors are connected side-by-side to the one joint connector from one side, and the joint connector housing is capable of receiving, in one receiving space, connector housings of a plurality of the stacked connectors to be connected to the joint connector housing from one side.

A wire harness according to an eighth aspect is the wire harness according to the seventh aspect, in which a plurality of the stacked connectors are connected to the one joint connector from one side, and a plurality of the stacked connectors are connected to the one joint connector from another side.

Effect of the Invention

According to the first to third aspects, as a result of having a split form, the connectors can be dispersed at the time of manufacture. Also, as a result of having a stacked form, the connectors can be concentrated at the time of arrangement in a vehicle. At this time, the locking portion is capable of locking the terminal-equipped electric wire received in a joining counterpart, and thus it is possible to reduce the size of the stacked connector. Accordingly, it is possible to reduce a space in a vehicle in which a wire harness including a plurality of splice circuits is arranged and achieve good manufacturability at the time of manufacture.

In particular, according to the second aspect, even if split connector housings are stacked in three or more layers, terminal-equipped electric wires of each layer can be locked by the locking portions.

In particular, according to the third aspect, terminal-equipped electric wires of two counterpart split connectors can be locked by the locking portions.

According to the fourth to eighth aspects, as a result of the stacked connector having a split form, the connectors can be dispersed at the time of manufacture. Also, as a result of the stacked connector having a stacked form, the connectors can be concentrated at the time of arrangement in a vehicle. At this time, the locking portion is capable of locking the terminal-equipped electric wire received in a joining counterpart, and thus it is possible to reduce the size of the stacked connector. Accordingly, it is possible to reduce a space in a vehicle in which a wire harness including a plurality of splice circuits is arranged and achieve good manufacturability at the time of manufacture.

In particular, according to the fifth aspect, it is possible to suppress erroneous fitting between the joint connector and the plurality of stacked connectors.

In particular, according to the sixth aspect, it is possible to suppress an increase in the number of types of components.

In particular, according to the seventh aspect, it is possible to suppress a decrease in the number of connectors while making them more concentrated. At this time, the connector housings of the plurality of stacked connectors connected from one side are received in one receiving space. Thus, walls for partitioning the plurality of stacked connectors are omitted, and thus it is possible to reduce the external size of the joint connector housing.

In particular, according to the eighth aspect, it is possible to suppress a decrease in the number of connectors while making connectors more concentrated.

DETAILED DESCRIPTION TO EXECUTE THE INVENTION

Embodiments

The following will describe a stacked connector according to an embodiment and a wire harness that includes the stacked connector.FIG. 1is an exploded perspective view showing a wire harness10according to an embodiment.FIG. 2is a front view showing the wire harness10according to the embodiment. Note that terminal-equipped electric wires15are not shown inFIGS. 1 and 2. Also, the terminal-equipped electric wires15may not be shown inFIG. 3onward.

The wire harness10includes a plurality of stacked connectors12, and a joint connector40to which the plurality of stacked connectors12are to be connected. Here, in the wire harness10, circuits of the plurality of stacked connectors12are shorted by being connected to the joint connector40.

Stacked Connector

FIG. 3is an exploded perspective view showing a stacked connector12.FIG. 4is an exploded front view showing the stacked connector12.FIG. 5is a diagram illustrating surfaces of the stacked connector12that face each other in a joined state.FIG. 6is a longitudinal cross-sectional view showing the stacked connector12.FIG. 7is a diagram illustrating how the stacked connector12is formed by combining split connectors.

The stacked connector12is formed by joining a plurality of split connectors14to each other. Here, the split connectors14are stacked in three layers to form the stacked connector12. The split connectors14may be stacked in two layers, or may be stacked in four or more layers.

The split connectors14each include a split connector housing24provided with a plurality of terminal receiving chambers25, and a plurality of terminal-equipped electric wires15that include terminals20received in the terminal receiving chambers25and electric wires16to which the terminals20are connected. At least one of the split connector housings24is provided with a locking portion (a second terminal locking portion28here) formed in a protruding shape that protrudes outward and is capable of locking the terminal-equipped electric wire15received in the split connector housing24of a joining counterpart.

Here, the terminal-equipped electric wire15will be described first. Here, as shown inFIG. 6, the terminal-equipped electric wire15is formed with the terminal20being connected to a leading end of an electric wire16.

The electric wire16includes a core wire17and an insulating coating18covering the core wire17. The core wire17is made of a material such as aluminum, an aluminum alloy, copper, or a copper alloy. The core wire17may be constituted by one wire, or may also be constituted by a plurality of wires. If the core wire17is constituted by a plurality of wires, the wires may or may not be twisted. The insulating coating18is formed by extruding a resin such as polyethylene or polyvinyl chloride around the core wire17, for example. The electric wires16are each provided with a core wire exposure portion where the core wire17is exposed, at an end portion thereof. The terminals20are connected to the core wire exposure portions.

The terminal20is made of any metal material such as copper or a copper alloy. The terminal20may be plated with any metal such as tin or nickel. The terminal20is formed by pressing a metal plate material into a predetermined shape and bending the resulting material, for example. The terminal20includes an electric wire connection portion21and a counterpart connection portion22.

The electric wire connection portion21is formed in a shape including a crimping portion in which a crimping piece is crimped to the electric wire16. The example shown inFIG. 6includes a core wire crimping piece that is crimped to the core wire17as the crimping piece, and a coating crimping piece that is crimped to the insulating coating18, but the electric wire connection portion21may also be constituted by only a core wire crimping piece. Naturally, the shape of the electric wire connection portion21is not limited thereto. For example, the terminal20may also be joined to the core wire17through welding or the like. Also, for example, the terminal20may be formed in a so-called pressure-contact terminal shape in which the terminal20pierces through the insulating coating18and is connected to the core wire17.

The counterpart connection portion22is connected to a counterpart connection member. Here, the terminal20is connected to a tab terminal64of a joint terminal60, which will be described later, in the joint connector40. Specifically, the counterpart connection portion22is formed in a box shape and a so-called female terminal shape according to which the counterpart connection portion22is connected to the counterpart tab terminal64inserted into this box. Thus, the tab terminal64of the joint terminal60that is to be connected to the terminal20is formed in a male terminal shape.

Here, the counterpart connection portion22formed in a box shape is provided with a lance engaging portion (not shown) that engages with a lance formed in the split connector housing24.

Next, the split connector housing24will be described.

Both surfaces of at least one of the split connector housings24located at an intermediate position in the stacking direction are provided with second terminal locking portions28. Also, pairs of split connectors14that are adjacent to each other include at least a pair of split connectors14that are provided with second terminal locking portions28capable of respectively locking terminal-equipped electric wires15received in the counterpart split connector housing24, and through holes29for receiving the counterpart locking portions, in a manner in which the second terminal locking portions28and the through holes29are located in an alternating manner in a direction intersecting the stacking direction.

Also, the split connector housings24located in one surface layer of each of the plurality of stacked connectors12are provided with erroneous fitting restricting ribs38having different shapes. Also, the split connector housings24located in layers other than the one surface layer of each of the plurality of stacked connectors12are formed in the same shape.

More specifically, as described above, here, three split connectors14are stacked to form one stacked connector12. The three split connectors14will be distinguished from each other as needed below, and the split connectors14will be referred to as an upper connector14A, a middle connector14B, and a lower connector14C in this order from the one surface layer side.

The split connector housings24are formed through injection molding using a synthetic resin as a material, for example. The split connector housings24are provided with terminal receiving chambers25for receiving the terminals20of the terminal-equipped electric wires15. The terminal receiving chambers25are formed in a manner to be recessed in a hole shape from one side surface of the split connector housing24toward another side surface. Although an example in which six terminal receiving chambers25are formed in one split connector housing24will be described here, the number of terminal receiving chambers25formed in one split connector housing24is not limited thereto. The number of terminal receiving chambers25formed in one split connector housing24may be five or less. Alternatively, the number of terminal receiving chambers25may also be seven or more. Also, a wall portion defining a terminal receiving chamber25is provided with a recessed surface corresponding to the external shape of the electric wire16. This narrows the pitch of terminal receiving chambers25, and thus it is possible to form portions of the terminal receiving chambers25other than the recessed surfaces in a shape that is slightly smaller (e.g., smaller by about 0.1 to 0.3 mm) than a conventional shape thereof without reducing the thickness of wall portions for partitioning the terminal receiving chambers25as much as possible (without making the wall portions other than the recessed surface smaller). Accordingly, the width of the split connector housing24can be reduced while an electric wire16having the same diameter as a conventional electric wire can be received by the terminal receiving chamber25.

Also, a wall surface of each split connector housing24located forward of the terminal receiving chambers25(another side surface of the split connector housing24) is provided with insertion holes26. The insertion holes26are formed to allow passage of the tab terminals64of the joint terminal60in the joint connector40. As a result of the tab terminals64inserted into the insertion holes26coming into contact with the terminals20received in the terminal receiving chambers25, the joint terminal60and the terminal-equipped electric wires15are electrically connected to each other.

Also, the split connector housings24are provided with first terminal locking portions27for locking the terminals20housed in the terminal receiving chambers25. The first terminal locking portions27are portions referred to as a so-called lance. Here, the first terminal locking portions27are formed integrated with the split connector housing24. Thus, the first terminal locking portions27are made of resin. Specifically, the first terminal locking portion27is formed to be capable of locking to a peripheral edge of a locking hole (not shown) serving as a lance engaging portion formed in a box-shaped counterpart connection portion22provided at the leading end of the terminal20. The first terminal locking portion27is formed in a cantilever shape, for example, and is elastically deformable to pivot about the base end portion thereof. In the example shown inFIG. 6, the first terminal locking portion27extends toward the back side of the terminal receiving chamber25with a portion on the opening side of the terminal receiving chamber25being supported. The first terminal locking portion27is pressed by the terminal20inserted through the opening of the terminal receiving chamber25and elastically deforms to retract from the terminal receiving chamber25, and when the terminal20is inserted to a predetermined position of the terminal receiving chamber25, the first terminal locking portion27elastically returns and locks the terminal20.

Also, at least one of the split connector housings24is provided with the second terminal locking portions28for locking the terminals20housed in the terminal receiving chambers25of the joining counterpart. The second terminal locking portions28are portions that are referred to as a so-called retainer. Here, the second terminal locking portions28are formed integrated with the split connector housing24. Thus, the second terminal locking portions28are made of resin. Specifically, the second terminal locking portions28are formed in a protruding shape protruding toward the counterpart split connector housing24. At this time, the counterpart split connector housing24is provided with through holes29for receiving the second terminal locking portions28. The through holes29are formed in all of the split connector housings24.

More specifically, here, the second terminal locking portion28is formed so as to fit into a half region of one terminal receiving chamber25in the width direction. Also, the second terminal locking portion28can protrude into the terminal receiving chamber25through the through hole29. The second terminal locking portion28locks a rear end side of the terminal20that is located rearward of a portion of the terminal20that locks to the first terminal locking portion27. Here, the second terminal locking portion28is formed to catch on and lock a rear edge portion of the counterpart connection portion22formed in a box shape.

Here, the second terminal locking portions28are formed on a lower surface of the upper connector housing24A, and upper and lower surfaces of the middle connector housing24B. Also, the through holes29are formed in the lower surface of the upper connector housing24A, the upper surface of the middle connector housing24B, and the upper surface of the lower connector housing24C. Also, as shown inFIG. 5, the second terminal locking portions28formed on the lower surface of the upper connector housing24A protrude into the terminal receiving chambers25of the middle connector housing24B through the through holes29formed in the upper surface of the middle connector housing24B, and lock the terminals20housed in the terminal receiving chambers25of the middle connector housing24B. Similarly, the second terminal locking portions28formed on the upper surface of the middle connector housing24B protrude into the terminal receiving chambers25of the upper connector housing24A through the through holes29formed in the lower surface of the upper connector housing24A, and lock the terminals20housed in the terminal receiving chambers25of the upper connector housing24A. Also, the second terminal locking portions28formed on the lower surface of the middle connector housing24B protrude into the terminal receiving chambers25of the lower connector housing24C through the through holes29formed in the upper surface of the lower connector housing24C, and lock the terminals20housed in the terminal receiving chambers25of the lower connector housing24C.

At this time, as for one housing, the lower surface of the upper connector housing24A is provided with the second terminal locking portions28and the through holes29in an alternating manner in the width direction. Similarly, the upper surface of the middle connector housing24B is also provided with the second terminal locking portions28and the through holes29in an alternating manner in the width direction. Also, at this time, as for the second terminal locking portions28, the second terminal locking portions28formed on the upper connector housing24A and the second terminal locking portions28formed on the upper surface of the middle connector housing24B are formed in an alternating manner in the width direction. At this time, out of the second terminal locking portions28formed on the upper connector housing24A and the second terminal locking portions28formed on the upper surface of the middle connector housing24B, a second terminal locking portion28located at an end portion in the width direction is formed to have a size capable of locking one terminal20, and a second terminal locking portion28located at an intermediate position in the width direction is formed to have a size capable of locking two terminals20. Also, as for the through holes29, the through holes formed in the upper connector housing24A and the through holes formed in the middle connector housing24B are formed in an alternating manner in the width direction. At this time, out of the through holes29formed in the upper connector housing24A and the through holes formed in the upper surface of the middle connector housing24B, a through hole29located at an end portion in the width direction is formed to have a size corresponding to one terminal receiving chamber25, and a through hole29located at an intermediate position in the width direction is formed to have a size spanning two terminal receiving chambers25.

At this time, the terminals20inserted into the upper connector housing24A and the terminals20inserted into the middle connector housing24B face away from each other about the axis extending in the longitudinal direction of the electric wires16, as per the relationship between positions where the second terminal locking portions28are provided. More specifically, the core wires17of the terminals20inserted into the upper connector housing24A are exposed downward. Accordingly, the second terminal locking portions28of the middle connector housing24B located below the terminals20inserted into the upper connector housing24A can lock the terminals20inserted into the upper connector housing24A. Also, the core wires17of the terminals20inserted into the middle connector housing24B are exposed upward.

Accordingly, the second terminal locking portions28of the upper connector housing24A located above the terminals20inserted into the middle connector housing24B can lock the terminals20inserted into the middle connector housing24B. Note that the terminals20inserted into the lower connector housing24C and the terminals20inserted into the middle connector housing24B face each other.

Also, the split connector housing24is provided with a function of joining two counterpart split connector housings24and maintaining a joined state. Here, one of two counterpart split connector housings24is provided with leading end side protrusions30, and the other of the two counterpart split connector housings24is provided with leading end side grooves32in which the leading end side protrusions30are to be housed. Similarly, one of two counterpart split connector housings24is provided with rear end side protrusions33, and the other of the two counterpart split connector housings24is provided with rear end side grooves34in which the rear end side protrusions33are to be housed.

Specifically, here, the leading end side protrusions30are formed on the leading end side (the insertion hole26side) of side surfaces that are located on both sides of the upper connector housing24A and the middle connector housing24B in the width direction and are oriented outward in the width direction, in a manner in which the leading end side protrusions30have a protruding shape oriented outward in the width direction. Also, the middle connector housing24B and the lower connector housing24C are provided with protruding side wall portions31that protrude upward from the upper surfaces thereof at both end portions in the width direction. A leading end side groove32is formed in a shape recessed in the width direction on the leading end side (the insertion hole26side) of a width-direction inward surface of this protruding side wall portion31. The front portion of the leading end side groove32is open in a direction in which the terminal20is inserted. The leading end side protrusion30can be inserted into the leading end side groove32through this opening. As shown inFIG. 7, counterpart split connector housings24can pivot in a state in which the leading end side protrusions30are housed in the leading end side grooves32and the rear end side protrusions33are not housed in the rear end side grooves34. This is achieved due to the leading end side protrusions30being formed shorter than the rear end side protrusions33and surfaces of the leading end side protrusions30that face the leading ends in the terminal inserting direction and extend from a side surface to a lower surface thereof being curved.

Here, the leading end side protrusions30and the leading end side grooves32are portions housed in a housing receiving portion43of the joint connector40. At this time, in order to avoid an increase in the size, in the width direction, of portions of the stacked connector12in which the leading end side protrusions30and the leading end side grooves32are formed, peripheral portions of the leading end side protrusions30of side surfaces oriented outward in the width direction in the split connector housings24are recessed, thus forming the leading end side protrusions30. Also, a portion of the wall of the width-direction inward surface of the protruding side wall portion31that defines the leading end side groove32protrudes from the peripheral portion, thus forming the leading end side groove32.

Also, here, the rear end side protrusions33are formed on the rear end side (the opening side of the terminal receiving chamber25) of side surfaces that are located on both sides of the upper connector housing24A and the middle connector housing24B in the width direction and are oriented outward in the width direction, in a manner in which the rear end side protrusions33have a protruding shape that is oriented outward in the width direction. Also, the rear end side grooves34formed in a shape recessed in the width direction are formed on the rear end side (the opening side of the terminal receiving chamber25) of the width-direction inward surfaces in the protruding side wall portions31of the middle connector housing24B and the lower connector housing24C. As described above, as shown inFIG. 7, counterpart split connector housings24can pivot in a state in which the leading end side protrusions30are housed in the leading end side grooves32and the rear end side protrusions33are not housed in the rear end side grooves34. Also, in the split connector housing24that has been pivoted, the rear end side protrusions33can be fitted to the rear end side grooves34. Here, this is achieved through elastic deformation of peripheral edge portions of the rear end side protrusions33and the rear end side grooves34. At this time, the surface of the rear end side protrusion33that extends from a width-direction outward side surface to the lower surface thereof is a curved surface. Accordingly, the rear end side protrusions33can be easily fitted to the rear end side grooves34.

Here, the leading end side protrusions33and the leading end side grooves34are portions that are not housed in the housing receiving portion43of the joint connector40. Thus, the need to avoid an increase in the size of the rear end side protrusions33and the rear end side grooves34in the stacked connector12in the width direction is less than that of the leading end side protrusions30and the leading end side grooves32. Thus, the rear end side protrusions33protrude more outward in the width direction than the leading end side protrusions30. Also, a portion of the width-direction inward surface of the protruding side wall portion31is recessed from the peripheral portion thereof, thus forming the rear end side groove34.

Also, here, surfaces of the split connector housings24that are to face each other on the rear end side (the opening side of the terminal receiving chamber25) are provided with width-direction protruding portions35that protrude toward counterparts and extend in the width direction, and width-direction recessed portions36in which the counterpart width-direction protruding portions35are housed in the joined state. The width-direction protruding portions35and the width-direction recessed portions36are formed substantially spanning the width thereof in the width direction. As a result of the width-direction protruding portions35of the two counterpart split connector housings24being housed in the width-direction recessed portions36in the joined state, positions of the joined two split connector housings24are unlikely to shift in the direction in which the terminals20are inserted. Specifically, as shown inFIG. 5, the lower surface of the upper connector housing24A is provided with the two width-direction protruding portions35at an interval, and a portion between the two width-direction protruding portions35is provided with the width-direction recessed portions36. Also, the upper surface of the middle connector housing24B is provided with two width-direction recessed portions36at an interval, and a portion between the two width-direction recessed portions36is provided with a width-direction protruding portion35. The lower surface of the middle connector housing24B and the upper surface of the lower connector housing24C are also provided with protruding portions and recessed portions that are similar to the width-direction protruding portions35and the width-direction recessed portions36that are provided on the lower surface of the upper connector housing24A and the upper surface of the middle connector housing24B. Note that here, in order to avoid an increase in the size in the stacking direction in the stacked connector12, as shown inFIG. 5, in a state in which the split connector housing24is a single unit, the terminal receiving chambers25are exposed at portions to be provided with the width-direction recessed portion36. The exposed portions are covered by the width-direction protruding portions35of the joining counterpart.

The plurality of stacked connectors12are each provided with the erroneous fitting restricting ribs38. In order to avoid a mistake in which the positions at which the plurality of stacked connectors12are fitted to the joint connector40shift, the erroneous fitting restricting ribs38are formed at positions that are different from each other. Here, the erroneous fitting restricting ribs38are formed on the upper connector housing24A. Also, here, the erroneous fitting restricting ribs38are laterally arranged, and are provided at different positions of two upper connector housings24A1and24A2that are connected to the joint connector40from one side.

More specifically, the upper surfaces of the upper connector housings24A1and24A2are provided with two erroneous fitting restricting ribs38that are spaced apart from each other in the width direction. As shown inFIG. 2, in the upper connector housing24A1of the stacked connector12to be connected to the joint connector40on the left side when viewed from the front, the left erroneous fitting restricting rib38is formed at the same position as the left rear end side protrusion33in the width direction, and the right erroneous fitting restricting rib38is formed inward in the width direction of the right rear end side protrusion33in the width direction. On the other hand, in the upper connector housing24A2of the stacked connector12to be connected to the joint connector40on the right side when viewed from the front, the left erroneous fitting restricting rib38is formed inward in the width direction of the left rear end side protrusion33in the width direction, and the right erroneous fitting restricting rib38is formed at the same position as the right rear end side protrusion33in the width direction. Note that the middle connector housing24B and the lower connector housing24C in the stacked connector12to be connected to the joint connector40on the left side when viewed from the front have the same shape as the middle connector housing24B and the lower connector housing24C in the stacked connector12to be connected to the joint connector40on the right side when viewed from the front.

Also, the upper surface of the upper connector housing24A is provided with the erroneous fitting restricting ribs38, whereas the lower surface of the lower connector housing24A is not provided with the erroneous fitting restricting ribs38. Accordingly, the upper and lower sides of the stacked connector12can be determined. As a result, the stacked connector12is kept from being connected upside down to the joint connector40.

Note that the upper connector housings24A1and24A2of the two stacked connectors12connected from the opposite side to the front view shown inFIG. 2have the same shape as the upper connector housings24A1and24A2of the two stacked connectors12shown inFIG. 2. Naturally, all of the erroneous fitting restricting ribs38formed on the plurality of stacked connectors12connected to one joint connector40may be formed in different forms. This will be described later in detail.

Also, the stacked connector12is provided with a locking protrusion39for locking to the joint connector housing42after insertion. The locking protrusion39can be inserted into and locked to a locking receiving portion45formed in the joint connector housing42. Here, one locking protrusion39is formed at a position close to the center of the upper surface of the upper connector housing24A. The locking protrusion39can be easily inserted into the locking receiving portion45due to the front surface thereof in the insertion direction being an inclined surface39a. Also, the rear surface of the locking protrusion39in the insertion direction is a catching surface39bthat catches on the locking receiving portion45in a state in which the locking protrusion39is inserted into the locking receiving portion45. Here, a cantilever-shaped operation portion that can be operated by an operator to release locking and can easily deform elastically is omitted from the locking protrusion39. This reduces the size of a portion in the wire harness10where the joint connector40and the stacked connector12are fitted to each other.

Joint Connector

Next, the joint connector40will be described.FIG. 8is a front view showing the joint connector40.FIG. 9is a rear view showing the joint connector40.FIG. 10is an exploded plan view showing the joint connector40.FIG. 11is a cross-sectional view cut along line XI-XI inFIG. 8.

The joint connector40is formed to be capable of being fitted to the stacked connectors12. The plurality of stacked connectors12are connected to one joint connector40. Specifically, here, a plurality of stacked connectors12are connected side-by-side to one joint connector40from one side. Specifically, here, two stacked connectors12are connected to one joint connector40from one side, and two stacked connectors12are also connected thereto from the other side. At this time, the stacked connectors12are formed to be capable of being independently fitted to the joint connector40. Specifically, the joint connector40includes a joint connector housing42and joint terminal60.

The joint connector housing42receives and supports the joint terminals60. Also, the joint housing is provided with a receiving space44afor receiving the stacked connectors12. Here, the joint connector housing42can receive the connector housings of a plurality (two, here) of stacked connectors12to be connected thereto from one side in one receiving space44a. Also, the joint connector housing42can receive the connector housings of a plurality (two, here) of stacked connectors12to be connected thereto from the other side in one receiving space44a. Specifically, the joint connector housing42includes the housing receiving portions43, the locking receiving portions45, and joint terminal support portions52.

The housing receiving portion43is a portion for receiving the connector housing of the stacked connector12. Here, the joint connector housing42is provided with two receiving spaces44athat are open in opposite directions, thus forming the housing receiving portion43. Each receiving space44acan receive the connector housings of two stacked connectors12disposed side-by-side. Also, the receiving spaces44aare partitioned by a wall portion50, and the wall portion50is provided with the joint terminal support portions52.

At this time, the receiving space44ais not provided with a partition wall portion for partitioning two stacked connectors12housed side-by-side in the receiving space44a. This suppresses an increase in the size of the joint connector housing42in the width direction in a case where two stacked connectors12are to be housed side-by-side in one receiving space44a. The two stacked connectors12housed side-by-side in one receiving space44aare formed longer in the width direction than in the height direction. Also, the two stacked connectors12are housed in one receiving space44ain a manner in which the two stacked connectors12are arranged side-by-side in the lengthwise direction.

Also, here, as described above, the two stacked connectors12connected to one receiving space44aare each provided with erroneous fitting restricting ribs38having different shapes. Thus, the receiving spaces44aare formed to be capable of housing the erroneous fitting restricting ribs38corresponding to the corresponding positions. Thus, here, portions of the housing receiving portion43serve as rib receiving portions43bfor housing the erroneous fitting restricting ribs38. More specifically, the two housing receiving portions43are each provided with four groove-shaped portions44bserving as the rib receiving portions43b. Also, two of the four groove-shaped portions44blocated on the left side receive the erroneous fitting restricting ribs38of the stacked connector12housed on the left side. Also, two of the four groove-shaped portions44blocated on the right side receive the erroneous fitting restricting ribs38of the stacked connector12housed on the right side. Because the positions of these two sets of the groove-shaped portions44bare different from each other with respect to the center of the stacked connector12in the width direction, two stacked connectors12can be housed at the corresponding positions in the receiving space44a.

Note that one of the inward surfaces of the inner circumferential wall portion defining the receiving space44a(here, a surface of the stacked connector12that faces the lower connector14C) is provided with a positioning rib44cfor positioning the two stacked connectors12. Here, in the connector housing of the stacked connector12, the width of a rear end portion protruding outward from the receiving space44aof the joint connector40is set to be larger than the width of a leading end portion housed inside the receiving space44aof the joint connector40. Also, the two stacked connectors12that are connected side-by-side to one receiving space44aare in a state in which the rear end portions thereof are in contact with each other or are located closer to each other than the leading end portions thereof are. The positioning rib44cis housed in a gap between the leading end portions that is formed at this time. Also, the positioning rib44chas a small height, which is the length of the positioning rib44cthat protrudes from the flat surface of the inner surface of the receiving space44a. Specifically, here, the height of the positioning rib44cis set to be smaller than or equal to the width (less than the width here) in the width direction of the joint connector housing42. Thus, the positioning rib44cis unlikely to be damaged or the like.

The locking receiving portion45is a portion for receiving the locking protrusion39. Here, the locking receiving portion45can deform elastically more easily than the locking protrusion39. Specifically, the locking receiving portion45includes a locking receiving piece46and two through holes47and48formed in the periphery of the locking receiving piece46.

The locking receiving piece46is formed on the joint connector housing42. Here, as a result of forming the two through holes47and48in the upper surface of the joint connector housing42, a portion between the two through holes47and48forms the locking receiving piece46. The locking receiving piece46is formed in a cantilever shape extending toward the opening of the housing receiving portion43due to the first through hole47being formed. Also, the locking protrusion39is housed in the second through hole48. Also, the locking receiving piece46is configured such that a force for inserting the locking protrusion39thereto is reduced due to the second through hole48being formed.

More specifically, the first through hole47is formed in a U-shape in a plan view, in an outer peripheral area of the locking receiving piece46and a portion connected thereto. Also, the second through hole48is formed in a rectangular shape in a plan view, on the inner side of the locking receiving piece46and the portion connected thereto. Accordingly, the locking receiving piece46includes a pair of protruding pieces46aextending from the main body of the joint connector housing42, and a connecting piece46bfor connecting the leading ends of the pair of protruding pieces46a. The lower surface of the connecting piece46bis provided with a recessed portion46c. A gap is formed between the connecting piece46band the locking protrusion39through formation of the recessed portion46c. For example, it is conceivable to insert, into this gap, a jig for releasing locking through elastic deformation of the locking receiving piece46. Also, portions of the connecting piece46bthat are located lateral to the recessed portion46care portions that catch on the inserted locking protrusion39. In the portions of the connecting piece46bthat are located lateral to the recessed portion46c, a surface oriented on the opening side is an inclined surface46dcorresponding to the inclined surface39aof the locking protrusion39. Accordingly, the locking receiving piece46can easily shift to an elastic deformation state at the time of insertion of the locking protrusion39. Also, in the portions of the connecting piece46bthat are located lateral to the recessed portion46c, the surface that is located opposite to the inclined surface46dis a receiving surface46ethat catches on the catching surface39bof the locking protrusion39.

Note that, in the joint connector housing42, an opening edge portion of the receiving space44a, that is, the opening edge portion of the surface provided with the locking receiving portion45is provided with a locking protrusion passing portion49for enabling the groove-shaped locking protrusion39to pass through without coming into contact therewith. At this time, in order to secure the thickness of the above-described opening edge portion, a portion of the opening edge portion that is provided with the locking protrusion passing portion49protrudes upward more than another portion.

The joint terminal support portions52are formed on the wall portion50for partitioning two receiving spaces44athat respectively house the stacked connectors12that are connected thereto from both sides. Specifically, the joint terminal support portions52include a linking piece insertion support portion53and a through hole54.

The linking piece insertion support portion53is a portion into which the linking piece62of the joint terminal60is inserted, and that supports the inserted linking piece62. Here, the wall portion50is provided with two exposure surfaces51aand51b. The two exposure surfaces51aand51bface away from each other. The exposure surfaces51aand51bare exposed to the outside through the receiving spaces44a. Also, one exposure surface51ais provided with a groove53a, as the linking piece insertion support portion53that is recessed toward the other exposure surface51b. The width of this groove53ais set to be approximately the same (slightly smaller here) as the thickness of the linking piece62. Accordingly, the linking piece62can be pressed into the groove53a, and thus the linking piece62into which the linking piece insertion support portion53has been pressed can be supported. A peripheral edge of an opening of the groove53ais an inclined surface53b, and is wide. Accordingly, it is possible to guide the linking piece62that is to be inserted.

A plurality of through holes54that open into the other exposure surface51bare formed in the bottom of the groove53a. The tab terminals64of the joint terminal60protrude into another receiving space44athrough the through holes54.

Note that a cassette portion56is formed on the lower surface of the joint connector housing42that faces away from the upper surface thereof provided with the locking receiving portions45. Accordingly, it is possible to attach the joint connector housing42to a cassette support portion formed on a panel of a vehicle body, for example. Naturally, a configuration in which the joint connector housing42is provided with the cassette portion56is not an essential configuration, and the cassette portion56need not be formed.

The joint terminal60is a member for shorting a plurality of terminals20in the stacked connectors12in a state in which the stacked connectors12and the joint connector40are fitted to each other. The joint terminal60is formed by pressing a flat plate made of a conductive material such as metal. The joint terminal60includes a linking piece62and a plurality of tab terminals64that are arranged in parallel to each other and protrude from the linking piece62. The linking piece62is inserted into and supported by the above-described linking piece insertion support portion53. Here, twelve tab terminals64aprotrude from one longer linking piece62on one side, and twelve tab terminals64balso protrude therefrom on the other side. Six of the twelve tab terminals64aon one side that are located closer to the end portion than the center thereof are connected to one stacked connector12. The same applies to the twelve tab terminals64bon the other side. Here, the tab terminals64bon the other side are formed longer, and protrude into the receiving space44aon the other side through the through holes29. Here, one joint terminal60can short twenty four terminal-equipped electric wires15included in one layer. Also, three joint terminals60are provided, and the terminal-equipped electric wires15included in layers are shorted by the joint terminals60disposed in the layers.

As described above, here, twenty four terminal-equipped electric wires15included in one layer are shorted. Thus, one or more terminal-equipped electric wires15in one of the two stacked connectors12that are connected to the joint connector40from one side and are adjacent to each other and one or more terminal-equipped electric wires15in the other stacked connector12are shorted. Also, one or more terminal-equipped electric wires15in one of the two stacked connectors12that are connected to the joint connector40from both sides, and one or more terminal-equipped electric wires15in the other stacked connector12are shorted. At this time, one or more terminal-equipped electric wires15in two of the four stacked connectors12that are located in an oblique positional relationship are also shorted.

Naturally, the type of terminal-equipped electric wires15shorted by the joint terminal60is not limited thereto. For example, the joint terminal60may also be capable of shorting terminal-equipped electric wires15in a plurality of groups (three groups in the example indicated by vertical lines inFIG. 10) that are different from each other in one layer, as a result of the joint terminal60being cut at positions of the virtual lines (line-double dashed lines) shown inFIG. 10.

Manufacturing Examples

One manufacturing example of the wire harness10including the above-described stacked connectors12and the joint connector40will be described.FIG. 12is a diagram illustrating one manufacturing example of the wire harness10.

For example, as one method for manufacturing the wire harness10, a plurality of sub-harnesses80obtained by splitting the wire harness10, which is to be the finished product, into several circuits are temporarily manufactured, and these sub-harnesses80are assembled. The sub-harnesses80can be manufactured relatively easily because the number of circuits is smaller than that of the finished product. Also, even if different types of wire harnesses are manufactured, some sub-harnesses80can be used as shared components. Thus, in some cases, the wire harness10can be manufactured relatively more easily by way of a plurality of sub-harnesses80than in a case where the wire harness10, which is to be the finished product, is directly manufactured.

However, in a case where the number of poles in one joint connector40is increased, if the wire harness10, which is to be the finished product, is split into a plurality of sub-harnesses80in units that are smaller than the joint connector40or units of connectors connected thereto, there is a risk that a post-insertion terminal will be formed. Here, a “post-insertion terminal” refers to a terminal that is not connected to a connector at the time of manufacturing sub-harnesses80and is connected to a connector at the time of assembling a plurality of sub-harnesses80. If a post-insertion terminal is present, work for inserting the post-insertion terminal into a connector in a separate process, work for separately providing a cover for protecting the post-insertion terminal until the post-insertion terminal is inserted into a connector, and the like are required.

In contrast, here, because the stacked connectors12are adopted, even if the wire harness10, which is to be the finished product, is split into a plurality of sub-harnesses80in units of split connectors14of the stacked connector12, no post-insertion terminal20is present. Specifically, here, it is possible to connect two stacked connectors12to the joint connector40from one side, and thus to make the split connectors14smaller. Here, as described above, four stacked connectors12that are each constituted by three layers of split connectors14are connected to one joint connector40. Thus, as shown inFIG. 12, even if the wire harness10is split into twelve sub-harnesses80at the maximum, it is possible to prevent formation of a post-insertion terminal. Thus, the above-described problems resulting from a case where a post-insertion terminal is formed are unlikely to arise, and the wire harness10can be more easily manufactured by way of sub-harnesses80. Note that, although the sub-harnesses80are illustrated using a simplified configuration in which one end is provided with the split connectors14and the other end is provided with other connectors82in the example shown inFIG. 12, the circuit configuration of the sub-harnesses80is not limited thereto. The sub-harnesses80may also be branched as appropriate, or an earth terminal or the like may be connected to the other end, instead of the connectors82, for example. Also, although one terminal-equipped electric wire15is depicted between the split connector14and the connector82, a plurality of terminal-equipped electric wires15may also be used therebetween.

Also, because the upper connector housing24A, the middle connector housing24B, and the lower connector housing24C can be easily joined, it is possible to easily manufacture the sub-harnesses80b, which are relatively larger units, in which the stacked connector12is formed by joining the split connectors14to each other, from the sub-harnesses80athat have been split into the split connectors14and are relatively smaller units.

According to the above-described configuration, because the stacked connectors12are adopted, the connectors can be dispersed as a result of the stacked connectors12having a split form at the time of manufacture. Also, the connectors can be concentrated as a result of the stacked connectors12having a stacked form at the time of arrangement in a vehicle. At this time, the second terminal locking portion28is capable of locking the terminal-equipped electric wire15received in a joining counterpart, and thus it is possible to reduce the size of the stacked connector12. Accordingly, it is possible to reduce a space in a vehicle in which the wire harness10including a plurality of splice circuits is arranged and achieve good manufacturability at the time of manufacture.

Also, it is possible to connect the plurality of stacked connectors12that have been manufactured separately to one joint connector40, side-by-side. Accordingly, it is possible to suppress a decrease in the number of connectors while making connectors more concentrated. Also, it is possible to disperse connectors at the time of manufacture and make connectors more concentrated at the time of arrangement in a vehicle. Accordingly, it is also possible to reduce a space in a vehicle in which the wire harness10including a plurality of splice circuits is arranged and achieve good manufacturability at the time of manufacture. At this time, the connector housings of a plurality of stacked connectors12connected from one side are received in one receiving space44a. Thus, walls for partitioning the plurality of stacked connectors12are omitted, and thus it is possible to reduce the external size of the joint connector housing42.

Also, two surfaces of the middle connector housing24B located at an intermediate position in the stacking direction are provided with the second terminal locking portions28, and thus the terminal-equipped electric wires15in each layer can be locked by the second terminal locking portions28even if the split connector housings24are stacked in three or more layers.

Also, the upper connector housing24A is provided with the second terminal locking portions28and the through holes29in an alternating manner, and the upper surface of the middle connector housing24B is provided with the second terminal locking portions28and the through holes29in an alternating manner, and thus the terminal-equipped electric wires15of the two counterpart split connectors14can be locked by the second terminal locking portions28.

Also, it is possible to suppress erroneous fitting between the joint connector40and the plurality of stacked connectors12due to the erroneous fitting restricting ribs38being formed.

Also, shared components can be used as the middle connector housing24B and the lower connector housing24C in the plurality of stacked connectors12, and thus it is possible to suppress an increase in the number of types of components.

Also, a plurality of stacked connectors12are connected to one joint connector40from both sides, and thus it is possible to suppress a decrease in the number of connectors while making the connectors more concentrated.

Variations

Although an embodiment has been described in which two stacked connectors12that are provided with the erroneous fitting restricting ribs38and are connected from one side are distinguished, this configuration is not an essential configuration. The erroneous fitting restricting ribs38need not be provided. Also, if the erroneous fitting restricting ribs38are provided, the erroneous fitting restricting ribs38may be formed such that all the stacked connectors12to be connected to one joint connector40can be distinguished.FIG. 13is a diagram illustrating a variation of the stacked connector12. Similarly to the stacked connector12according to the embodiment, two erroneous fitting restricting ribs138are provided on one stacked connector112according to a variation. However, in the stacked connectors112, the positions of the two erroneous fitting restricting ribs138provided on one stacked connector112are respectively disposed selectively at two positions in the width direction, and thus four stacked connectors112can be distinguished.

In addition, although an embodiment in which the locking receiving portions45of the joint connector housing42are formed in a cantilever shape has been described, this configuration is not an essential configuration. For example, in an embodiment, a locking protrusion passing portion49may be formed and the opening edge portion of the receiving space44aof the joint connector housing42may function as the locking receiving portion45. In this case, a configuration is conceivable in which a through hole that is the same as the above-described second through hole48in which the locking protrusion39is received is formed inward of the opening edge portion and adjacent to the opening edge portion.

Also, although an embodiment in which the plurality of stacked connectors12are connected to one joint connector40was described, this configuration is not an essential configuration. A configuration may be adopted in which one stacked connector12is connected to one joint connector. Also, a configuration in which a plurality of the stacked connectors12are connected to one joint connector40, a configuration in which a plurality of the stacked connectors12are connected to one side of one joint connector40, or a configuration in which a plurality of the stacked connectors12are connected to both sides of one joint connector40may be adopted.

Note that configurations described in the above-described embodiments and variations can be combined as appropriate as long as no contradiction arises therein.

Although this invention has been described in detail above, the above description is illustrative in all aspects, and this invention is not limited thereto. It will be understood that numerous modifications not illustrated here can be envisioned without departing from the scope of this invention.

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