Connector having shielding shell

A connector includes: a plurality of terminals fixedly attached to an end portion of a plurality of wires and configured to be connected to the terminals of the equipment, respectively; a housing configured to retain the plurality of terminals and to be fit into the mounting hole; and a shielding shell having conductive characteristic and fixedly attached to an end portion of a cylindrical shielding member enclosing the plurality of wires collectively, and configured to be connected to the shielding casing.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a connector having shielding shell to be connected to equipment such as an inverter unit or a motor for an electric vehicle.

2. Description of the Related Art

A conventional connector used for connecting a plurality of shielded wires to equipment such as an inverter unit in an electric vehicle includes a shielding shell.

The conventional connector used for such purpose, as disclosed in JP-A-11-026093, is structured in that wire-side terminals are fixedly attached to conductors of shielded wires and retained in a housing, while a conductive connecting member is fixedly attached to a shielding layer of each shielded wire. When the connector is to be attached to equipment, the housing is plugged into a mounting hole formed in a shielding casing of the equipment, and a bracket formed in the outer circumference of the housing is fixedly connected to the outer surface of the shielding casing, and the wire-side terminals are connected to equipment-side terminals in the shielding casing. Further, the connecting member is fixed to the outer surface of the shielding casing so as to connect the shielding layer of each shielded wire to the shielding casing. Hereinafter, the conventional connector having the structure described above will be referred to as a first conventional connector.

In the first conventional connecter, however, it is necessary to repeat the process of connecting the connecting member to the shielding casing as many times as the number of shielded wires. As a solution to such a problem, a collectively-shielding structure has been considered. The collectively-shielding structure uses a non-shielded wire having no shield layer in place of each shielded wire, and uses a shielding member having a cylindrical braiding made of a metal fine line braided in a mesh like manner, in place of the shielding layer of each shielded wire. A plurality of non-shielded wires are surrounded collectively by the shielding member. According to the structure above, the step of connecting the shielding member to the shielding casing can be performed at one time. Thus, the workability is improved.

When the collectively-shielding structure is adopted, the shielding member is conductively connected to the shielding casing by: fixedly attaching the opening edge portion of the shielding member to a cylindrical shielding shell; bring a flange portion formed in the circumferential edge portion of the shielding shell into close contact to the outer surface of the shielding casing; and fixing the flange portion by bolting.

In addition, as described above, a positioning bracket projects over the outer circumference of the housing. In order to fix the bracket to the shielding casing, it is necessary to provide a notch portion in a part of the flange portion, and make the bracket project to the outside of the shielding shell through the notch portion. Therefore, the flange portion is not continuous over the whole circumference, but is disconnected in the notch portion.

As a technique for forming the shielding shell, a method using a process called deep drawing out of a metal material in a flat plate shape is adopted as follows. That is, a cylindrical portion thereof is formed gradually out of a flat plate portion, while a part of the flat plate portion is left as a flange portion. In the technique described above, the flange portion may be deformed in a curved shape in the course of working the cylindrical portion. Particularly when the flange portion has a shape that is' not continuous over the whole circumference as described previously, a curve is apt to occur and the degree of the curve becomes large.

When the flange portion is thus curved, a part of the flange portion may not come in contact with the shielding casing when the shielding shell has been attached to the shielding casing. Thus, the reliability of contact between the shielding shell and the shielding casing may be deteriorated.

Another conventional connector used for above-mentioned purpose, as disclosed in JP-A-9-161892, is structured in that a mounting hole is formed in an outer wall of a casing of the equipment, while equipment-side terminals are provided inside the casing. Wire-side fittings connected to a plurality of wires are retained in one housing, and the housing is fitted into the mounting hole. Thus, wire-side terminals are connected to the equipment-side terminals respectively. In the second conventional connector, a sealing member is provided between the inner circumference of the mounting hole and the outer circumference of the housing in order to secure waterproof inside the casing. Hereinafter, the conventional connector having the structure described above will be referred to as a second conventional connector.

In the second conventional connector, three pole terminals are disposed in a triangle, while the housing for retaining the wire-side terminals is formed to have a round outer circumference. The sealing member having an annular shape is outer-fitted to the round outer circumference of the housing.

When the terminals are disposed in a triangle as described above, it is necessary to secure a certain space in the directions of both the width and the height to dispose the terminals in the space. However, it may be considered that the equipment-side terminals are obliged to be disposed alongside due to some restriction caused by the layout of the equipment or other peripheral parts. In this case, the wire-side terminals have to be also disposed alongside. In accordance with the disposition, therefore, the housing as a whole has to be formed into a noncircular shape long from side to side, such as an elliptic shape, an oval shape or a substantially rectangular shape, and the sealing member to be attached to the outer circumference of the housing has to be also formed into a noncircular shape.

However, in the case where the outer circumference of the housing and the sealing member are formed into a noncircular shape, there is a fear that a part of the sealing member floats from the outer circumference of the housing or may be stretched excessively when the sealing member is out of circumferential position relative to the housing. Assume that the housing is fitted into the mounting hole when the sealing member is attached in such a state. In this event, the close contact state of the sealing member with the outer circumference of the housing and the inner circumference of the mounting hole (the elastic bending state of the sealing member) is not uniform in the circumferential direction. There is a fear that the reliability of the seal function deteriorates.

SUMMARY OF THE INVENTION

It is therefore an object of the invention to provide an equipment shield connecter having an improved reliability in contacting between a shielding shell and a shielding casing.

In order to achieve the object, according to one aspect of the invention, there is provided a connector to be attached to equipment in which a plurality of terminals are provided in a shielding casing and a mounting hole is formed on the shielding casing, the connector including: a plurality of terminals fixedly attached to an end portion of a plurality of wires and configured to be connected to the terminals of the equipment, respectively; a housing configured to retain the plurality of terminals and to be fit into the mounting hole; and a shielding shell having conductive characteristic and fixedly attached to an end portion of a cylindrical shielding member enclosing the plurality of wires collectively, and configured to be connected to the shielding casing.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the accompanying drawings, a description will be given in detail of preferred embodiments of the invention.

Hereinafter, a connector1according to a first embodiment of the invention will be described below with reference toFIGS. 1 through 8. Incidentally, in the following description, the direction connecting the left bottom and the right top inFIGS. 1 and 2will be defined as a horizontal (left and right) direction, and the direction connecting the left top and the right bottom in the same drawings will be defined as a front/rear direction.

The connector1in the first embodiment is to be connected to equipment10(for example, inverter unit) of an electric vehicle in upward in upward direction. The equipment10accommodates three equipment-side terminals13and an equipment main part12in a conductive shielding casing11. The equipment-side terminals13extend from the equipment main part12. Each equipment-side terminal13has a shape like a plate called a bus bar, retained in a horizontal posture and in parallel with the other equipment-side terminals13in the horizontal (left and right) direction. A bolt hole14is formed in each equipment-side terminal13so as to penetrate the equipment-side terminal13in the vertical (up and down) direction. A mounting hole15opened in a substantially elliptic shape long in the horizontal direction correspondingly to the three equipment-side terminals13is formed in a horizontal wall of the shielding casing11so as to penetrate the shielding casing11in the vertical direction. In addition, on each of the opposite, left and right sides of the mounting hole15in the shielding casing11, a temporary lock hole16and a threaded hole (not-shown) are formed to align in the horizontal (front and rear) direction.

The connector1includes wire-side terminals20, a housing30(corresponding to the retention member of the invention) and a shielding shell50. The connector1is collectively connected to terminal portions of three wires2in a lump. In each wire2, the outer circumference of a conductor is surrounded by an insulating coating. Differently from shielded wires, no shielding layer is provided in the wires2. The wire-side terminals20are connected to the terminal portions of the wires2respectively.

Each wire-side terminal20has a wire contact-cramping portion21in a closed barrel shape (the shape having a hole whose lower end surface is opened) in its lower end portion. The conductor of a wire2is received in the wire contact-cramping portion21, and fixedly and conductively attached thereto by caulking. The wire contact-cramping portion21of the wire-side terminal20is nearly columnar. The upper end portion of the wire-side terminal20is formed as a square portion22having dimensions to be circumscribed about the outer circumference of the wire contact-cramping portion21. Further, a circular portion23inscribed in the square portion22and coaxial with the wire contact-cramping portion21is formed on the upper end surface of the square portion22. In the wire-side terminal20configured thus, a threaded hole24is formed to keep its axis in the vertical (up and down) direction and to be open to the upper end surface of the circular portion23.

The housing30is made from synthetic resin, having three cavities31arranged in the horizontal (left and right) direction and penetrating the housing30in the vertical (up and down) direction. The area ranging from the upper end portion of each cavity31to the vicinity of the lower end portion thereof serves as a square receiving chamber for allowing the square portion22of the wire-side terminal20to be fitted therein without looseness. In the lower end portion of the cavity31, a rubber stopper receiving portion33having a circular shape whose diameter is larger than the square receiving portion32, and a holder receiving portion34are formed to align in the vertical (up and down) direction. In addition, in the upper end edge of the square receiving portion32(the opening edge of the cavity31in the upper end surface of the housing30), a stopper35is formed to have a circular shape to be fitted to the circular portion23of the wire-side terminal20without looseness, and to project inward to abut against the upper surface of the square portion22. Further, in the cavity31, a pair of lances36is formed to extend upward like a cantilever along the two opposite inner wall surfaces of the square receiving portion32. A detachment preventing hole37is formed in the holder receiving portion34by notching the inner wall of the holder receiving portion34.

A fitting portion38having a substantially elliptic shape to be fitted into the mounting hole15without looseness is formed in the outer circumference of the lower end portion of the housing30so as to project to the outside. When the fitting portion38is fitted into the mounting hole15, the housing30is positioned horizontally (in the horizontal (front and rear) direction and in the horizontal (left and right) direction) with respect to the shielding casing11, that is, in a direction perpendicular to the direction with which the housing30is fitted into the mounting hole15. A sealing groove39is formed in the outer circumference of the fitting portion38. A sealing ring40is attached to the sealing groove39. In the area lower than the fitting portion38in the outer circumference of the housing30, ribs41are formed to project and be located in the opposite, left and right ends (opposite ends in the direction of the major axis of the ellipse) thereof.

Further, on the lower surface of the fitting portion38, a pair of locking protrusions42(as a coupling unit of the invention) each projecting downward like a cantilever are formed on each of the left and right sides so as to extend along the opposite, front and rear surfaces of the housing30. That is, four locking protrusions42in total are formed. Each locking protrusion42has a slit43cut upward from the lower end thereof, and a pair of left and right flexible lock pieces44having the slit43lying therebetween. A protrusion44ais formed in the lower end portion of each flexible lock piece44so as to project to the outside.

A shielding shell50is a single member formed out of a metal plate material by deep drawing. The shielding shell50has a substantially elliptic cylindrical portion51substantially corresponding to the outer circumferential shape of the housing30under the fitting portion38, and a flange portion52in plate shape extending continuously all over the circumference of the cylindrical portion51so as to project horizontally from the upper edge of the cylindrical portion51to the outside.

In each of the front and rear portions of the flange portion52, a pair of left and right lock holes53(as a coupling unit of the invention) are formed to penetrate the flange portion52in the vertical (up and down) direction. In addition, in each of the opposite, left and right end portions of the flange portion52, a circular temporary lock hole54and a circular bolt hole55are formed to align in the horizontal (front and rear) direction.

In the flange portion52, a rib56is continuously formed at the circumference of the flange portion52so as to extend downward along the outer circumferential edge of the flange portion52, that is, substantially perpendicularly to the outer surface of the flange portion52. The rib56is located outside the lock holes53(oppositely to the cylindrical portion51). The flange portion52configured thus is brought into close contact with the lower surface (outer wall surface) of the shielding casing11.

The housing30configured thus has a shape corresponding to the mounting hole15, that is, a substantially elliptic shape long from side to side. In the front end portion (the area in front of the flange portion52of the shielding shell50) in the outer circumference of the housing30, a circumferential sealing groove39is formed continuously all over the circumference. In addition, in the upper surface area in the outer circumference of the housing30, of the opening edge of the sealing groove39, the rear edge portion is notched backward in a rectangular shape. Thus, a pair of left and right concave regulating portions40aare formed. The positions of the pair of regulating portions40aare set to be symmetric in the horizontal (left and right) direction. In addition, the two regulating portions40aare made identical in shape and dimensions.

A sealing member40made of rubber and having a ring-like shape substantially similar to that of the housing30and that of the mounting hole15is attached to the sealing groove39configured thus. The sectional shape of the sealing member40is substantially circular. The inner circumferential portion of the sealing member40comes in elastic contact with the groove bottom surface of the sealing groove39, while the outer circumferential portion of the sealing member40comes in elastic contact with the inner circumferential surface of the mounting hole15. A pair of left and right lock portions39ato be locked in the regulating portions40aof the housing30are formed in the sealing member40. Each lock portion56has a rectangular shape to be fitted to the regulating portion52with no space therebetween, and is made to project rearward. In addition, the two lock portions39aare disposed correspondingly to the regulating portions40ain the horizontal (left and right) direction. Furthermore, the thickness (radial dimension) of each lock portion56is smaller than that of the sealing member40. In a free state (where the sealing member40is not elastically deformed), the outermost circumferential surface of the sealing member40is located outside the outer surface of each lock portion56, while the innermost circumferential surface of the sealing member40is located inside the inner surface of each lock portion56.

The connector1has rubber stoppers57, holders58and temporary lock members59as well as the aforementioned constituent parts. Each rubber stopper57has an annular shape, including lip portions in its inner and outer circumferences. The rubber stopper57is attached to the outer circumference of the wire2, and received in the rubber stopper receiving portion33of the cavity31. Each holder58has an annular shape in the same manner as the rubber stopper57. A detachment preventing protrusion58ais formed on the outer circumference of the holder58. In each temporary lock member59, a support portion59bprojects over the upper surface of a tab portion59ahaving a disc-like shape, while a pair of elastic detachment preventing pieces59cextend obliquely downward from the upper end of the support portion59b.

In installing the connector1, first the wire-side terminals20are connected to the wires2in advance respectively, and the wire-side terminals20are inserted into the cavities31from below respectively. The upper surface of the square portion22of each inserted wire-side terminal20is brought into contact with the stopper35, while the lances36are locked in the lower surface of the square portion22. Thus, each inserted wire-side terminal20is retained in the housing30in the state where the floating (detachment and attachment from and to the cavity31) of the wire-side terminal20in vertical direction is being limited. In addition, the rubber stopper57and the holder58are outer-fitted to each wire W in advance. After the wire-side terminal20is received in the cavity31, the rubber stopper57is displaced upward and fitted into the rubber stopper receiving portion33of the cavity31. Thus, sealing is secured between the outer circumference of the wire2and the inner circumference of the rubber stopper receiving portion33by the rubber stopper57. After that, the holder58is displaced upward so as to be fitted into the holder receiving portion34and brought into contact with the lower surface of the rubber stopper57. Thus, the detachment preventing protrusion58aof the holder58is locked in the detachment preventing hole37of the housing30so that downward detachment of the holder58is limited, and hence the rubber stopper57received in the cavity31is prevented from dropping off downwardly.

On the other hand, the three wires2are inserted into a cylindrical shielding member (bracket shield)60is formed by a braiding made of a metal fine line braided in a meshed manner. A terminal portion of the shielding member60enclosing the three wires2collectively is connected to the shielding shell50. For the connection, the terminal portion of the shielding member60is put over the cylindrical portion51of the shielding shell50, and a substantially elliptic caulking ring61is fitted to the outer circumference of the terminal portion. Then, the caulking ring61is caulked. Thus, as a result of the caulking, the terminal portion of the shielding member60is clamped and fixed between the cylindrical portion51and the caulking ring61. In such a manner, conductive connection is secured between the shielding member60and the shielding shell50.

The shielding shell50is accommodated in the housing30from below. The locking protrusions42of the housing30are engaged with the lock holes53of the shielding shell50. Thus, both the housing30and the shielding shell50are integrated. In the course of the incorporation, the elastic lock pieces44of the locking protrusions42enter the lock holes53while bending inward elastically, and the ribs41of the housing30abut against the upper-surface-side opening edge portion of the cylindrical portion51. As soon as such a regular state of incorporation is established, the elastic lock pieces44exert their own elastic restoring force so that their claw pieces44aare locked in the opening edges on the lower sides of the lock holes53respectively. By the abutment of the ribs41and the fitting between the locking protrusions42and the lock holes53, the housing30and the shielding shell50are accommodated in the state their floating in any direction of the vertical (up and down) direction, the horizontal (left and right) direction and the horizontal (front and rear) direction is limited.

In addition, the temporary lock members59are attached to the temporary lock holes54of the shielding shell50from below respectively. Thus, the support portions59band the elastic detachment preventing pieces59care made to project above the flange portion52in advance. The downward detachment of the attached temporary lock members59is limited due to the elastic detachment preventing pieces59ccaught in the opening edge portions of the temporary lock holes54.

The connector1accommodated thus is attached by inserting the housing30into the mounting hole15of the shielding casing11from below and bringing the flange portion52of the shielding shell50into close contact with the lower wall of the shielding casing11. Between the inner circumferential surface of the mounting hole15and the outer circumference of the housing30fitted into the mounting hole15, waterproof is secured by the sealing ring40of the housing30.

Assume that when the sealing member40is attached to the sealing groove39, there is a circumferential misalignment of the sealing member40with respect to the sealing groove39because the sealing groove39and the sealing member40have noncircular shapes, that is, substantially elliptic shapes long from side to side. In such a case, there is a fear that there occurs such a problem that a part of the sealing member40may float from the sealing groove39. In this embodiment, however, the regulating portions40aare formed in the sealing groove39so as to sink in the direction crossing the circumferential direction, while the lock portions39aare formed in the sealing member40so as to project in the direction crossing the circumferential direction. When the regulating portions40aand the lock portions39aare fitted to each other, the sealing member40can be positioned circumferentially relatively to the sealing groove39. Accordingly, in the state where the housing30is not fitted into the mounting hole15, there occurs no problem that the sealing member40may float partially from the sealing groove39, or may be stretched partially. Thus, the sealing member40is attached properly to the sealing groove39(housing30).

In addition, the elastic detachment preventing pieces59cof the temporary lock members59are made to penetrate the temporary lock holes16of the shielding casing11, and locked in their opening edges. Due to the locking between the temporary lock members59and the temporary lock holes16, the shielding shell50and the housing30, that is, the connector1is kept temporarily locked in the shielding casing11. After that, bolts (not shown) are inserted into the bolt holes55of the shielding shell50from below, and screwed down to the threaded holes of the shielding casing11. Thus, the shielding shell50is conductively fixed to the shielding casing11, and hence the connector1is attached to the equipment10in the state where the floating of the connector1is limited.

In this attached state, the upper end surface of each wire-side terminal20received in the housing30is opposed to the lower surface of the corresponding equipment-side terminal13so as to be in contact therewith or at a slight distance therefrom, and further the bolt hole14of each equipment-side terminal13aligns with the threaded hole24of the corresponding wire-side terminal20. A bolt62is inserted into the bolt hole14, and screwed down to the threaded hole24. Thus, the wire-side terminals20are connected to the corresponding equipment-side terminals13, respectively, conductively and in the state where the floating of the wire-side terminals20is limited.

In the first embodiment, as described above, the wire-side terminals20are collectively retained by the housing30, and the housing30is fitted into the mounting hole15. Accordingly, the housing30can be positioned relatively to the shielding casing11without providing any bracket in the outer circumference of the housing30. Since the bracket can be omitted thus, the flange portion52can be formed continuously all over the circumference of the shielding shell50so that the flange portion52can be prevented from being curved and deformed when the shielding shell50is formed.

In addition, the rib56is formed to rise substantially perpendicularly to the outer surface of the flange portion52. Accordingly, the rib56also exerts a function of increasing the strength of the flange portion52having a plate-like shape. In addition, the rib56is formed continuously all over the circumference. Accordingly, the effect of increasing the strength is enhanced. Since the strength of the flange portion52is enhanced thus, the flange portion52is prevented from being curved and deformed. Thus, the reliability of contact of the flange portion52with the shielding casing11is improved.

In addition, the locking protrusions42of the housing30are locked in the lock holes53of the shielding shell50so that the housing30is integrally coupled with the shielding shell50. Accordingly, the process of attaching the housing30to the mounting hole15and the work of attaching the shielding shell50to the shielding casing11can be carried out by one action. Thus, the workability is improved.

Since the front end portions (lower end portions) of the locking protrusions42penetrate the flange portion52and project on the outer surface side (lower surface side) thereof, there is a fear that the locking protrusions42may be broken or deformed due to interference of foreign matters. In the first embodiment, however, the rib56extending on the lower surface side (outer surface side) where the lower end portions of the locking protrusions42project is formed at the outer circumferential edge of the flange portion52(that is, outside the locking protrusions42). Accordingly, the rib56acts as a protecting member. Thus, foreign matters are prevented from interfering with the locking protrusions42. In addition, since the lower end edge of the rib56extends down below the lower ends of the locking protrusions42, the effect of preventing foreign matters from interfering with the locking protrusions42is enhanced.

In addition, in the state where the shielding shell50and the housing30accommodated in the shielding casing11are coupled with each other, the shielding shell50and the housing30are temporarily locked in the shielding casing11by the temporary lock members59. Accordingly, it is not necessary to press the shielding shell50and the housing30onto the shielding casing11by hand during the work of fixing the shielding shell50to the shielding casing11. Thus, the workability is improved.

In the first embodiment, as described above, the three wire-side terminals20are collectively retained by the housing30, and the housing30is fitted into the mounting hole15of the shielding casing11. Accordingly, the number of man-hours can be reduced in comparison with a structure in which a plurality of wire-side terminals are attached to mounting holes individually. In addition, not shielded wires each having a shield function but non-shielded type wires2are used, and the wires2are surrounded by a cylindrical shielding member in a lump, while the shielding shell50is fixedly attached to the terminal of the shielding member so as to be connected to the shielding casing11. Accordingly, the number of man-hours can be reduced in comparison with a structure in which shielded wires are connected to a shielding casing individually.

In addition, the locking protrusions42of the housing30are locked in the lock holes53of the shielding shell50so that the housing30is integrally coupled with the shielding shell50. Accordingly, the process of attaching the housing30to the mounting hole15and the work of attaching the shielding shell50to the shielding casing11can be carried out by one action. Thus, the workability is further improved.

The locking protrusions42project on the outer surface side (lower surface side) of the flange portion52. Therefore, the locking protrusions42may be broken or deformed due to interference of foreign matters. However, in the embodiment, a rib56bent on the lower surface side (outer surface side) of the flange portion52, that is, on the side where the locking protrusions42project is formed at the circumferential edge of the flange portion52. In addition, the lower end edge of the rib56extends downward under the lower ends of the locking protrusions42. Accordingly, by means of the rib56, foreign matters can be surely prevented from interfering with the locking protrusions42. Further, the rib56is formed to rise from the outer surface of the flange portion52at substantially right angles. Accordingly, the rib56also exerts a function of increasing the strength of the flange portion52having a plate-like shape.

In addition, in the state where the shielding shell50and the housing30incorporated in the shielding casing11are coupled with each other, the shielding shell50and the housing30are temporarily locked in the shielding casing11by the temporary lock members59. Accordingly, it is not necessary to press the shielding shell50and the housing30onto the shielding casing11by hand during the work of fixing the shielding shell50to the shielding casing11. Thus, the workability is improved.

The gap between the outer circumference of the fixed housing30and the inner circumference of the mounting hole15is sealed liquid-tightly by the sealing member40. Here, since the sealing member40is circumferentially positioned properly with respect to the housing30by the fitting between the regulating portions40aand the lock portions39a, the sealing member40is elastically deformed uniformly all over the circumference, and hence circumferentially uniform sealing performance can be obtained. Thus, the shielded wires20are attached to the equipment10.

Although the outer circumferential shape of the housing30, the inner circumferential shape of the mounting hole15and the sealing member40are substantially elliptic, that is, noncircular in this embodiment as described above, the waterproof function using the sealing member40can be exerted surely because the sealing member40is positioned circumferentially with respect to the housing30due to the fitting between the lock portions39aformed in the sealing member40and the regulating portions40aformed in the housing30, and because the circumferential floating of the sealing member40with respect to the housing30is limited.

In addition, the sealing member40is attached to the outer circumference of the housing30while the fitting between the regulating portions40aand the lock portions39ais carried out in the state where they are exposed to the outer surface of the housing30. Thus, the locking state between the regulating portions40aand the lock portions39acan be confirmed visually before the housing30is fitted into the mounting hole15.

Hereinafter, a connector100according to a second embodiment of the invention will be described with reference toFIGS. 9 through 11.

The connector100in the second embodiment is used for connecting a shielded wire harness101to equipment110such as an inverter unit or a motor in an electric vehicle.

The equipment110accommodates an equipment main part112and three equipment-side terminals113in a conductive shielding casing111. The equipment-side terminals113extend from the equipment body112. Each equipment-side terminal113has a shape like a plate bent into a substantially L-shape, called a bus bar. A bolt hole114is formed in the horizontal portion of each equipment-side terminal113so as to penetrate the equipment-side terminal113in the vertical (up and down) direction. Three circular mounting holes115are formed in a side wall of the shielding casing111so as to align in the horizontal (left and right) direction correspondingly to the equipment-side terminals13respectively.

The wire harness101is constituted by a plurality of wires120, a shielding member135and a corrugated tube136.

Each wire120is different from shielded wires in that the outer circumference of a conductor121is surrounded by an insulating coating122, but no shielding layer is provided in the wire120. A wire-side terminal125is connected to the terminal portion of each wire120.

The shielding member135is formed by a cylindrical braiding made of a metal thin wire braided in a meshed manner. The shielding member135collectively encloses the three wires120. The shielding member135can expand and contract in radial and in lengthwise direction due to the flexibility of the metal thin wire.

The corrugated tube136is made from synthetic resin, having a cylindrical shape comprised of a large number of bellows lined up. Thus, the corrugated tube136can be deformed elastically desirably. The three wires120are inserted into the corrugated tube136in a lump. The inner diameter of the corrugated tube136is set to be a required minimum that can substantially keep the three wires120bundled in a triangle. Incidentally, in the corrugated tube136, an expanding slot (not shown) is formed in the length direction of the corrugated tube136so as to extend all over the length thereof. Normally the corrugated tube136keeps the cylindrical shape in which the expanding slot is closed due to the elastic restoring force of the corrugated tube136itself.

The connector100includes wire-side terminals125, sheath pieces130(corresponding to the housing of the invention), a shielding shell140, and a cover150.

The approximately first half part of each wire-side terminal125is formed as an equipment connecting portion126which has a shape like a flat plate long in the horizontal (front and rear) direction and in which a bolt hole127is formed. The approximately second half part of the wire-side terminal125is formed as a wire connecting portion128having a shape of a so-called open barrel shape. The conductor121of the wire120is conductively connected to the wire connecting portion128by cramp contact.

Each sheath piece130is molded out of resin integrally with the corresponding wire-side terminal125so as to surround the rear end portion of the equipment connecting portion126and the whole of the wire connecting portion128of the wire-side terminal125, and the front end portion of the insulating coating122. The equipment connecting portion126of the wire-side terminal125projects from the front end surface of the sheath piece130. On the other hand, the portion of the wire120covered with the insulating coating122is led out from the rear end surface of the sheath piece130. The outer circumference of the rear end portion of the sheath piece130is formed into a circular portion coaxial with the wire120. A sealing ring132is attached to a sealing groove131in the outer circumferential surface of the circular portion. The sheath pieces130configured thus are fitted into the mounting hole115so as to be positioned relatively to the shielding casing111in the vertical (up and down) and horizontal (left and right) directions perpendicular to the fitting direction.

The shielding shell140is a single part formed out of a metal plate material by deep drawing. The shielding shell140has a substantially elliptic cylindrical portion141long from side to side as a whole, a plate-like flange portion142projecting from the front end edge of the cylindrical portion141to the outside all over the circumference thereof, and a pair of flange portions143extending obliquely upward and outward from the opposite, left and right end portions of the flange portion142respectively so as to be flush with each other. The front surfaces of the flange portion142and the flange portions143are brought into surface contact with the outer wall surface of the shielding casing111. Bolt holes144corresponding to threaded holes (not shown) of the shielding casing111are formed in the flange portions143.

A rib145is formed continuously all over the circumference of the shielding shell140so as to follow the outer circumferential edges of the flange portion142and the flange portions143and to extend rearward substantially perpendicularly to the circumference of the shielding shell140.

The cover150is made of rubber, having a cylindrical shape as a whole. The front end portion of the cover150is formed as a large-diameter portion151having a substantially elliptic shape similar to the cylindrical portion141of the shielding shell140. The rear end portion of the cover150is formed as a small-diameter portion152having a circular shape in the same manner as the corrugated tube136. The large-diameter portion151and the small-diameter portion152are connected through a tapered portion153expanding gradually to be longer from side to side and to have a larger size in the vertical (up and down) direction at a position closer to the front. A large-diameter-side fitting portion154comprised of a protrusion bar extending circumferentially is formed on the inner circumference of the large-diameter portion151. A small-diameter-side fitting portion155having a plurality of circumferential irregularities formed continuously in the axial direction is formed in the inner circumference of the small-diameter portion152. In addition, in the right side surface portion of the cover150, a slit156cut to be long and narrow is formed to range from the rear end (opening edge of the small-diameter portion152) of the cover150to the large-diameter portion151through the tapered portion153. The front end of the slit156does not reach the front end of the cover150, but is located substantially in the middle of the large-diameter portion151in the front/rear direction. A circular hole157having a larger diameter than the width of the slit156is formed in the front end portion of the slit156.

The connector100and the wire harness101are connected in the following manner.

First, each wire-side terminal125is cramped with the terminal of the corresponding wire120, and the wire-side terminal125and the sheath piece130are integrated by mold forming. In addition, the three wires120are inserted into the shielding member135in advance. The terminal portions of the wires120and the wire-side terminals125are led out to the outside of the shielding member135so as to spread in the horizontal (left and right) direction not to interfere with each other. In addition, a major part of the wires120except their terminal portions are bundled in a triangle. In this state, the corrugated tube136is attached to the outer circumference of the shielding member135. The corrugated tube136is set to have an inner diameter small enough to internally touch a triangle formed by bundling the three wires120, practically. Thus, a major part of the wires120except their terminal portions are retained to be bundled in a triangle. Thus, the diameter of the shielding member135is reduced to prevent the meshes of the braiding from opening, while the shielding member135follows the inner circumference of the corrugated tube136.

The terminal portion of the shielding member135is exposed to the outside from the terminal portion of the corrugated tube136. As described previously, the three wire-side terminals125are led out from the terminal of the corrugated tube136so as to spread in the horizontal (left and right) direction. In accordance with this arrangement, the terminal portion of the shielding member135is also largely spread in the horizontal (left and right) direction while the size in the vertical (up and down) direction is also increased. Thus, an increased-diameter portion135ais formed.

The increased-diameter portion135ain the terminal portion of the shielding member135is connected to the shielding shell140. For the connection, the increased-diameter portion135ais put over the cylindrical portion141of the shielding shell140from behind, and a caulking ring137having a substantially elliptic shape is fitted to the outer circumference of the cylindrical portion141. The caulking ring137is caulked. As a result of this caulking, the terminal portion of the increased-diameter portion135ais fixedly put between the cylindrical portion141and the caulking ring137so that the shielding member135and the shielding shell140are connected conductively. In addition, as a result of the caulking, a caulking groove138extending circumferentially is formed in the outer circumference of the caulking ring137.

After the caulking, the cover150is attached to surround the increased-diameter portion135aof the shielding member135. For the attachment of the cover150, the cover150is elastically deformed to open the slit156so that the opening portion of the small-diameter portion152is expanded temporarily. In that state, the cover150is put, from the front, over the three wire-side terminals125, the terminal portions of the three wires120, the shielding shell140, the increased-diameter portion135aof the shielding member135and the terminal portion of the corrugated tube136in that order.

When the cover150passes through the flange portion142and the flange portions143of the shielding shell140, the cover150is restored to its initial shape so as to close the slit156. The large-diameter side fitting portion154of the cover150is fitted into the caulking groove138, while the small-diameter side fitting portion155is fitted to the irregular portion in the outer circumference of the terminal portion of the corrugated tube136. As a result of the fitting of the two fitting portions154and155, the cover150is integrated with the shielding shell140and the corrugated tube136. In this state, the large-diameter portion151of the cover150encloses the caulking portion between the cylindrical portion141of the shielding shell140and the increased-diameter portion135aof the shielding member135, the tapered portion153encloses the approximately second half portion of the increased-diameter portion135a, and the small-diameter portion152encloses the terminal portion of the corrugated tube136. In addition, the increased-diameter portion135aof the shielding member135follows the inner circumference of the cover150practically.

Incidentally, the front end edge of the large-diameter portion151of the cover150is located on the inner circumferential side with respect to the rib145of the shielding shell140. Accordingly, there is no fear that foreign matters interfere the front end portion of the cover150externally.

Finally, in order to prevent the cover150from being detached from the corrugated tube136, an adhesive tape (not shown) is wound spirally over the range from the outer circumference of the small-diameter portion152of the cover150to the outer circumference of the corrugated tube136. It is desired that the adhesive tape is wound to cover all the length of the slit156. In addition, it is desired that the adhesive tape is also wound to cover all the length of the corrugated tube136so as to close the expanding slot.

Thus, the connection between the connector100and the wire harness101is completed. After that, the sheath pieces130are fitted into the mounting holes115of the shielding casing111respectively. The fitted sheath pieces130are positioned relatively to the shielding casing111. Incidentally, in each mounting hole115, sealing is secured between the inner circumference of the mounting hole115and the outer circumference of the sheath piece130by the sealing ring132. In addition, the equipment connecting portion126of the wire-side terminal125penetrating the mounting hole115is put on the upper surface of the equipment-side terminal113lying ahead in the shielding casing111, so that the bolt holes114and127of both the equipment-side terminal113and equipment connecting portion126are aligned. Then, a nut117is screwed down and fastened to a bolt116passed through both the bolt holes114and127. Thus, both the terminals113and125are fixed in the state where their swinging is limited, while they are connected conductively.

When the terminals113and125have been connected with each other, the shielding shell140is attached to the shielding casing111. For the attachment, the bolt holes144of the shielding shell140are aligned with the threaded holes of the shielding casing111, and bolts (not shown) inserted into the bolt holes144are screwed down and fastened to the threaded holes. Thus, the shielding shell140is fixed to the shielding casing111, and connected thereto conductively. In such a manner, the shielding member135is connected to the shielding casing111through the shielding shell140, and the attachment of the connector100to the equipment110is completed.

In the second embodiment, as described above, the wire-side terminals125are retained by the sheath pieces130, and the sheath pieces130are fitted into the mounting holes115. Accordingly, the sheath pieces130can be positioned relatively to the shielding casing111without providing any bracket in the outer circumferences of the sheath pieces130. Since the bracket can be omitted thus, the flange portion142and the flange portions143can be formed continuously all over the circumference of the shielding shell140so that the flange portion142and the flange portions143can be prevented from being curved and deformed when the shielding shell140is formed.

In addition, the rib145is formed to rise substantially perpendicularly to the outer surfaces of the flange portion142and the flange portions143. Accordingly, the rib145also exerts a function of increasing the strength of the flange portion142and the flange portions143each having a plate-like shape. In addition, the rib145is formed continuously all over the circumference. Accordingly, the effect of increasing the strength is enhanced. Since the strength of the flange portion142and the flange portions143is enhanced thus, the flange portion142and the flange portions143are prevented from being curved and deformed. Thus, the reliability of contact of the flange portion142and the flange portions143with the shielding casing111is improved.

In addition, the shielding member135is surrounded by the cover150to be thereby protected. In the edge portion of the cover150on the side of the shielding shell140, the opening edge thereof follows the outer surface of the flange portion142. Thus, in the second embodiment, there is a slight gap between the opening edge of the cover150and the outer surface of the flange portion142. For that reason, there is a fear that foreign matters may enter the gap so as to turn up the opening edge of the cover150toward the outside. In the second embodiment, however, the rib145extending and bent toward the outer surfaces of the flange portion142and the flange portions143is formed at the outer circumferential edges of the flange portion142and the flange portions143. Thus, since the rib145is located outside the opening edge of the cover150, foreign matters are prevented from interfering with the opening edge of the cover150by the rib145. In such a manner, the cover150is prevented from turning up.

In addition, the extending end edge of the rib145extends at the rear of the opening edge of the cover150so that the inner circumferential surface of the rib145is opposed to the outer circumference of the opening edge portion of the cover150. That is, the rib145encloses the opening edge portion of the cover150and all the circumference of the gap between the opening edge of the cover150and the outer surface of the flange portion142. Thus, foreign matters can be surely prevented from interfering with the opening edge portion of the cover150.

In addition, in the wire harness101, the shielding member135made of a braided wire is surrounded by the corrugated tube136, and an end portion of the shielding member135is made to project from the corrugated tube136so that the diameter thereof is increased. The increased-diameter portion135aof the shielding member135is covered with the cover150. Thus, the increased-diameter portion135ais protected surely.

In addition, the cover150is made of elastically deformable rubber. Accordingly, the cover150does not have to be detached from the increased-diameter portion135a, for example, when the shielding shell140and the increased-diameter portion135aof the shielding member135are moved temporarily toward the corrugated tube136in order to insert the wire-side terminals125into the mounting holes115of the shielding casing111.

Further, the cover150made of rubber makes it possible to flexibly deal with the case where the wires120and the increased-diameter portion135aare bent with a small radius of curvature between the shielding shell140and the corrugated tube136.

In addition, the cover150has the large-diameter portion151corresponding to the shielding shell140and the small-diameter portion152corresponding to the corrugated tube136. Since the slit156cut from the opening end of the cover150on the side of the small-diameter portion152is formed in the cover150, the small-diameter portion152of the cover150does not have to be expanded forcibly against the elastic force when the shielding shell140and the increased-diameter portion135aof the shielding member135are passed through the cover150after the shielding shell140is fixedly attached to the increased-diameter portion135a. Thus, the workability is improved.

In addition, the large-diameter-side fitting portion154and the small-diameter-side fitting portion155are formed in the cover150, and the fitting portions154and155are fitted into the caulking groove138and the irregular portion of the outer circumference of the corrugated tube136respectively. Thus, the cover150is prevented from being detached from the corrugated tube136and the shielding shell140.

The invention is not limited to the embodiments explained in the description and the drawings. For example, the following embodiments are also included in the technical scope of the invention, and further various modifications other than the following embodiments can be made without departing from the gist of the invention.

(1) Although a flange portion serving as means for attaching a shielding shell to a shielding casing is formed integrally with the shielding shell in the embodiments, the attachment means to the shielding casing may be provided as an exclusive part separated from the shielding shell.

(2) Although wire-side terminals are accommodated in a housing molded in advance in the embodiments, the wire-side terminals and the housing may be integrated by insert molding or mold forming according to the invention.

(3) Although a temporary locking unit for the shielding casing is provided in the shielding shell in the embodiments, the temporary locking unit may be provided in the housing according to the invention.

(4) Although the embodiments describe the case where the equipment is an inverter unit of an electric vehicle, the invention is also applicable to the case where the equipment is another unit (for example, a motor provided on wheels) other than the inverter unit of an electric vehicle.

(5) Although the first embodiment describes the case where three wire-side terminals are retained in one housing in a lump, the number of wire-side terminals to be retained in one housing may be two or not smaller than four according to the invention.

(6) Although the first embodiment describes the case where a waterproof sealing ring is provided, the invention is also applicable to a non-waterproof connector having shielding shell having no sealing ring.

(7) Although a housing and a shielding shell are integrated by locking protrusions and lock holes in the first embodiment, according to the invention the housing and the shielding shell do not have to be integrated, but the work of fitting the housing into a mounting hole and the work of incorporating the shielding shell into a shielding casing are carried out in different steps respectively.

(8) Although the sealing member is attached to the outer circumference of the housing in the first embodiment, the sealing member may be attached to the inner circumference of the mounting hole according to the invention. In this case, the regulating portions for locking the lock portions of the sealing member therein are formed in the mounting hole.

(9) Although the outer circumferential shape of the housing and the inner circumferential shape of the mounting hole are made substantially elliptic in the first embodiment, they may be set to be not the elliptic shape but another shape such as an oval shape, or a substantially rectangular shape having arc-shaped corners according to the invention.

(10) Although the locking state between the regulating portions and the lock portions can be observed visually in the first embodiment, according to the invention the lock portions may be provided on the inner circumferential side of the sealing member so that the locking state cannot be confirmed visually. In this case, the lock structure using irregularities between the regulating portions and the lock portions is hidden inside the sealing member. Thus, the appearance is improved.

(11) Although the regulating portions are made concave while the lock portions are made convex in the first embodiment, according to the invention the regulating portions may be made convex while the lock portions are made concave. Alternatively, a convex regulating portion and a concave regulating portion may be provided while a concave lock portion and a convex lock portion are provided.

(12) Although the regulating portions are disposed only on the upper surface side of the housing in the first embodiment, according to the invention the regulating portions may be formed only on the lower surface side of the housing, or may be formed on both the upper and lower surfaces of the housing.

(13) Although two regulating portions are provided in the first embodiment, according to the invention the number of regulating portions may be one or not smaller than three.

(14) Although the regulating portions are disposed symmetrically in the horizontal (left and right) direction in the first embodiment, two regulating portions may be disposed asymmetrically in the horizontal (left and right) direction according to the invention.

(15) Although the two regulating portions are made identical in shape and dimensions in the first embodiment, two or more regulating portions may be made different in shape and dimensions according to the invention.

(16) Although wire-side terminals are retained in sheath pieces individually and respectively in the second embodiment, according to the invention a plurality of wire-side terminals may be retained in one sheath piece collectively.

(17) Although the sheath pieces retaining the wire-side terminals and the shielding shell are attached to the shielding casing in the state where they are separated from each other in the second embodiment, according to the invention the sheath pieces and the shielding shell may be attached to the shielding casing in the state where they have been coupled by a lock portion or the like.

(18) Although a slit is provided in a cover in the second embodiment, according to the invention the cover may be provided with no slit.

(19) Although the cover is made of rubber easy to be elastically deformed in the second embodiment, according to the invention the cover may be made of synthetic resin difficult to be elastically deformed. In this case, when the cover is formed into two half split parts, the incorporating work becomes easy.

(20) Although an end portion of the cover is outer-fitted to the corrugated tube in the second embodiment, according to the invention the end portion of the cover does not have to be fitted to the end portion of the corrugated tube.

(21) Although the end portion of the cover is fitted to the shielding shell in the second embodiment, according to the invention the end portion of the cover does not have to be fitted to the shielding shell.

(22) Although the cover is formed so that the slit does not reach the opening edge on the large-diameter portion side but the large-diameter portion is formed into a cylindrical shape continuous all over the circumference in the second embodiment, according to the invention the slit may be formed in a range from the opening edge on the small-diameter portion side to the opening edge on the large-diameter portion side. Also in this case, the cover retains its cylindrical shape due to its elastic restoring force. In addition, when an adhesive tape is wound around the outer circumference of the cover, the cover can be prevented from being expanded and deformed.

(23) Although a tapered portion whose diameter varies gradually is provided between the large-diameter portion and the small-diameter portion of the cover in the second embodiment, according to the invention such a tapered portion does not have to be provided, but the large-diameter portion and the small-diameter portion may be formed continuously to have a diameter varying stepwise.

(24) Although a slight gap is formed between the opening edge of the cover and the outer surface of the flange portion of the shielding shell in the second embodiment, according to the invention the opening edge of the cover may abut against the outer surface of the flange portion with no gap therebetween.

According to the invention, the wire-side terminals are retained by a housing collectively, and the housing is fitted into a mounting hole. Accordingly, the housing can be positioned relatively to a shielding casing without any bracket provided in the outer circumference of the housing. Since the bracket can be omitted thus, the flange portion of the shielding shell can be formed to be continuous all over the circumference. Thus, the flange portion is prevented from being curved and deformed when the shielding shell is formed. Further, since a rib is formed at the circumferential edge of the flange portion, the flange portion is prevented from being curved and deformed by the rib. Thus, since the flange portion is surely prevented from being curved and deformed in such a manner, the reliability of contact of the flange portion with the shielding casing is improved. Further, due to the rib formed in the flange portion, foreign matters can be prevented from interfering with any member located on the outer circumferential side of the flange portion.

The housing and the shielding shell can be coupled integrally by the lock portion. Accordingly, the work of fitting the housing into the mounting hole and the work of attaching the shielding shell to the shielding casing can be attained by one action. Thus, the workability is improved. In addition, since the rib bent on the outer surface side is provided in the flange portion, foreign matters can be prevented from interfering with any projecting portion of the locking protrusion even if the locking protrusion projects on the outer surface side of the flange portion.

An end portion of the shielding member is covered and protected by a cover. In addition, the opening edge of the cover follows the outer surface of the flange portion. Since the rib bent on the outer surface side is formed in the flange portion, foreign matters are prevented from interfering with the opening edge of the cover by the rib. Thus, the cover is prevented from turning up.

A plurality of wire-side terminals are retained by a housing collectively, and the housing is fitted into a mounting hole. Accordingly, the number of man-hours can be reduced in comparison with a structure in which a plurality of wire-side terminals are attached to mounting holes individually. In addition, not shielded wires each having a shield function but non-shielded type wires are used, and the wires are surrounded by a cylindrical shielding member in a lump, while a shielding shell is fixedly attached to the terminal of the shielding member so as to be attached to a shielding casing. Accordingly, the number of man-hours can be reduced in comparison with a structure in which shielded wires are connected to a shielding casing individually.

The housing and the shielding shell can be coupled integrally with each other by coupling units. Accordingly, the work of attaching the housing to the mounting hole and the work of attaching the shielding shell to the shielding casing can be carried out by one action. Thus, the workability is further improved.

A locking protrusion projects on the outer surface side of a flange portion. Therefore, there is a fear that the locking protrusion may be broken or deformed due to interference of foreign matters. According to the invention, however, a protective wall bent on the outer surface side, that is, on the side where the locking protrusion projects is formed at the circumferential edge of the flange portion. Thus, foreign matters can be prevented from interfering with the locking protrusion by the protective wall. In addition, the protective wall is formed to rise from the outer surface of the flange portion. Accordingly, the strength of the flange portion having a plate-like shape can be increased.

The shielding shell and the housing accommodated in the shielding casing as they have been coupled with each other are temporarily locked in the shielding casing by a temporary locking unit. Accordingly, it is not necessary to press the shielding shell and the housing onto the shielding casing by hand during the work of fixing the shielding shell to the shielding casing. Thus, the workability is improved.

Even when the outer circumferential shape of the housing, the inner circumferential shape of the mounting hole and the sealing member have a noncircular shape such as an elliptic shape, circumferential floating of the sealing member is regulated by locking between the lock portion and the regulating portion, so that the sealing member is positioned circumferentially. Due to this positioning, the sealing member is positioned relatively to the outer circumference of the housing or the inner circumference of the mounting hole. Thus, the waterproof function using the sealing member is attained surely.

The regulating portion is formed to be exposed on the outer surface of the housing, while the sealing member is attached to the outer circumference of the housing. Accordingly, the locking state between the regulating portion and the lock portion can be confirmed visually before the housing is fitted into the mounting hole.