Abstract:
In order to avoid cost for accommodating a shield wire in a housing while bending, and smoothly and readily accommodate within the housing while the shield electric wire is insulated, a conductive housing  1  including a rear wall  4  continuing to an annular wall  3,  and a tube wall  5  continuing to down the rear wall  4,  a method comprising the steps of: passing through a shield electric wire  2  from a lower opening  5   a  of the tube wall of the conductive housing to a front opening  3   a  of the annular wall while bending the shield electric wire; putting a shield terminal  9  movably around the shield electric wire from top of the shield electric wire; exposing a core wire  2   b  and a braid  2   a  of the shield electric wire by stripping a tip thereof; connecting an L-shaped terminal  11  to the core wire; mounting an L-shaped insulation inner housing  12  outside the L-shaped terminal; connecting the shield terminal to the braid; and accommodating a vertical part  14  of the inner housing within the conductive housing by pulling in the shield electric wire in an direction contrary to that of the shield electric wire having being passed through, so as to project a horizontal part  13  of the inner housing from the front opening.

Description:
TECHNICAL FIELD  
       [0001]    This invention relates to a method of manufacturing a connector for electromagnetic shield, including assembly process such as connecting a terminal to an electric wire while passing the electric wire through a housing. 
       BACKGROUND ART  
       [0002]    In one conventional configuration, there is described, e.g., in the PTL 1, a connector for transmitting an electric output from or to a receptacle connector, particularly in an automobile, including a divided isolating resin housing composed of a housing main body and a housing cover attachable to the housing main body, wherein a plug of the housing main body is connectable to the receptacle connector, and the electric wire is sloped relative to an area for the electric wire of the housing cover at a position fixable for the electric wire, i.e., the electric wire being bent at right angle. 
       CITATION LIST 
     Patent Literature  
       [0003]    [PTL 1] 
         [0004]    Japanese Patent Application Laid-Open Publication No. 2008-34,389 (FIG. 5) 
       SUMMARY OF INVENTION  
     Technical Problem  
       [0005]    However, with the connector in the above-mentioned conventional PTL 1, there has been drawback that when accommodating a thick shield electric wire for high voltage within an L-shaped shell conductor or component divisible from side to side, it is difficult to bend in the same shape as the shell conductive member, and there has been concern that any rattles are induced between the shell conductor and the housing cover when a lance or a lock projection is used as a lock, and thereby workability may be reduced of assembling the shell conductor and the housing cover to the housing main body, because provisionally fixing of the shell conductor to the housing cover is made by mounting the lock on a component of the receptacle side after accommodating the shield electric wire within the shell conductor and swaging a shielded conductive of the electric wire. 
         [0006]    Accordingly, an object of the invention is, in view of the above, to provide a method of manufacturing a connector that eliminates a work for accommodating the shield electric wire within the housing with the shield electric wire bent, makes a terminal connected to the shield electric wire smoothly and readily accommodated within the housing while insulated, and placed without any rattles within the housing while insulated, and further makes assembling of the connector wholly improved and readily performed. 
       Solution to Problem  
       [0007]    In order to attain the above-mentioned object, there is provided a method for manufacturing a connector having a conductive housing including a rear wall continuing to an annular wall, and a tube wall continuing to down the rear wall, the method comprising the steps of: (a) passing a shield electric wire from a lower opening of the tube wall of the conductive housing to a front opening of the annular wall while bending the shield electric wire; (b) putting a shield terminal movably around the shield electric wire from top of the shield electric wire; (c) exposing a core wire and a braid of the shield electric wire by stripping a tip thereof; (d) connecting an L-shaped terminal to the core wire; (e) mounting an L-shaped insulation inner housing outside the L-shaped terminal; (f) connecting the shield terminal to the braid; and (g) accommodating a vertical part of the inner housing within the conductive housing by pulling the shield electric wire in an direction contrary to that of the shield electric wire passed through, so as to project a horizontal part of the inner housing from the front opening. 
         [0008]    The above-mentioned configuration makes it possible to connect the L-shaped terminal to the shield electric wire with the shield electric wire through the conductive housing, to isolate the L-shaped terminal from outside by the inner housing, and to place smoothly and readily the L-shaped inner housing within the conductive housing by pulling out the shield electric wire toward the lower opening side and pulling in the inner housing accommodating the L-shaped terminal within the conductive housing. Preferably, the inner housing is made divisible. 
         [0009]    There is provided a method for manufacturing the connector according to the present invention recited in claim  2  characterized about the method recited in claim  1  in that the shield terminal is provided with an annular part brought into connection with the braid, and a plate extending from the annular part and including a projection with a bore, the method further comprising: (i) thread-fastening the shielded terminal to the rear wall of the conductive housing by inserting a bolt through the bore of the projection. 
         [0010]    The above-mentioned configuration makes it possible to position the annular part of the shield electric wire near the vertical part of the inner housing, to position the plate along the vertical part, to fasten the projection with the bolt near the vertical part of the inner housing, and thereby, to place, i.e., provisionally fasten the L-shaped terminal within the inner housing without any rattles while accommodated within the inner housing. It is performed by insetting a tool such as a driver from the front opening of the conductive housing to thread-fasten. 
         [0011]    There is provided a method for manufacturing the connector according to the present invention recited in claim  3  characterized about the method recited in claim  2  by further comprising: (j) placing an insulation outer housing provided with a conductive shield shell therewithin outside the horizontal part of the inner housing; and (k) bolting a flange of the conductive shield shell and a flange of the outer housing to a flange of the annular wall of the conductive housing. 
         [0012]    The above-mentioned configuration makes it possible to fasten the shield shell and the outer housing to each other along with the conductive housing at the same time. The inner housing is preferably fastened by letting its vertical flange sandwiched between the conductive housing and a flange of the outer housing or shield shell. A shell packing, if waterproof required, may be mounted between the conductive housing and the shield shell, or a housing packing between the shield shell and the outer housing. 
         [0013]    There is provided a method for manufacturing the connector according to the present invention recited in claim  4  characterized about the method recited in claim  2  by further comprising: (l) putting a wire seal around the shield electric wire before passing the shield electric wire through the conductive housing; (m) moving the wire seal along the shield electric wire after placing the outer housing outside the horizontal part of the inner housing, to put the wire seal within the tube wall of the conductive housing; and (n) holding the wire seal by a holder. 
         [0014]    The above-mentioned configuration makes it possible to adhere the wire seal to inside the tube of the conductive housing, and to hold by the holder without dropping out. Thereby, the wire seal can prevent water from infiltrating along the electric wire into the inner housing. 
       Advantageous Effects of Invention  
       [0015]    According to the invention recited in claim  1 , it is made possible readily to pass the shield electric wire alone, or nearly in the same fashion, through the conductive housing, and smoothly and readily to accommodate the L-shaped terminal and the inner housing within the conductive housing by directly assembling the L-shaped terminal and the inner housing, and pulling out the shield electric wire. Assembly workability for the connector is thereby improved. 
         [0016]    According to the invention recited in claim  2 , it is made possible to place the L-shaped terminal within the conductive housing by thread-fastening the shield terminal to the conductive housing without any rattles while insulated by the inner housing. It is thereby improved of workability for post process assembly of components such as the outer housing. 
         [0017]    According to the invention recited in claim  3 , it is made possible to fix the shield shell and the outer housing to the conductive housing in improved workability. Furthermore, it is made possible to secure the inner housing by, i.e., upon sandwiching and holding at the time the inner housing between the conductive housing and the shield shell. 
         [0018]    According to the invention recited in claim  4 , it is made possible smoothly and securely to assemble the wire seal along the shield electric wire while positioning and fixing the inner housing of the terminal side of the shield electric wire within the conductive housing and within the outer housing. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS  
         [0019]    [ FIG. 1A ] 
           [0020]      FIG. 1  is a exploded perspective view illustrating a state of passing an electric wire through a conductive housing in a first step of a method of manufacturing a connector according to the present invention. 
           [0021]      FIG. 1B  is a perspective view illustrating a state after passing the electric wire through the conductive housing. 
           [0022]      FIG. 2  is a perspective view illustrating a state in which such a shield terminal is put around the electric wire in a second step. 
           [0023]      FIG. 3  is a perspective view illustrating a state in which an L-shaped terminal is connected to the electric wire in a third step. 
           [0024]      FIG. 4  is a perspective view illustrating a state in which an L-shaped terminal is connected to an inner housing in a forth step. 
           [0025]      FIG. 5  is an exploded perspective view illustrating one configuration of the inner housing. 
           [0026]      FIG. 6  is an exploded perspective view illustrating an inner housing assembly thereof. 
           [0027]      FIG. 7  is a perspective view illustrating a state in which the shield terminal is connected to a braid of the electric wire in a fifth step. 
           [0028]      FIG. 8  is a perspective view, which is partially cross-sectioned, illustrating a state in which the inner housing assembly is incorporated within the conductive housing in a sixth step. 
           [0029]      FIG. 9  is a perspective view, which part is partially cross-sectioned, illustrating a state in which the inner housing assembly is fixed to the conductive housing in a seventh step. 
           [0030]      FIG. 10  is an exploded perspective view illustrating a state in which such the outer housing assembly is mounted on the conductive housing in an eighth step. 
           [0031]      FIG. 11  is an exploded perspective view illustrating one configuration of the outer housing assembly. 
           [0032]      FIG. 12  is a perspective view illustrating a state in which a wire seal is mounted on the conductive housing in a ninth step. 
           [0033]      FIG. 13A  is an exploded perspective view illustrating a state in which a rear holder is mounted on the conductive housing in a tenth step. 
           [0034]      FIG. 13B  is a perspective view illustrating a state after the rear holder is mounted. 
           [0035]      FIG. 14  is a perspective view illustrating a state in which a lever is mounted on the outer housing in a eleventh step. 
       
    
    
     DESCRIPTION OF EMBODIMENTS  
       [0036]      FIGS. 1 to 14  show one embodiment of a method for manufacturing or assembling a connector according to the present invention. 
         [0037]    According to the method for manufacturing or assembling the connector, a shield electric wire  2  is, as shown in  FIGS. 1A and 1B , first each passed through a metal or aluminum conductive housing  1 . The conductive housing  1  is as shown in  FIG. 1A , provided with a front annular wall (flange wall)  3 , a bulge wall (rear wall)  4  bulging toward and continuing to, back the annular wall integrally (see  FIG. 1B ), a plurality of tube walls  5  (herein, e.g., three pieces) parallel to each other formed integrally down the bulge wall  4 , and a small flange (flange part)  6  projecting vertically the annular wall  3 . A vertical through bore  5   a  in the tube wall  5  communicates with a front opening  3   a  of the annual wall  3  through a space  4   a  ( FIG. 1B ) in the bulge wall  4 . 
         [0038]    The shield electric wire  2  is conventional one, each provided with an isolating outer cover, a conductive metal braid or shield part inside the outer cover, a isolating inner layer inside the braid, a conductive core wire inside the inner layer, outside the outer cover of which a synthetic rubber wire seal  7  is preliminarily passed trough. 
         [0039]    The electric wire  2  is as shown in  FIG. 2B , each inserted from a lower opening (substituted by reference sign  5   a ) of the tube wall  5  of the conductive housing, to be passed trough front opening  3   a  of the annular wall  3  through the inner space  4   a  of the bulge wall  4 . The electric wire  2  is each smoothly bent in an arc fashion, and smoothly in contact with a slope  4   b  of a guide wall  4  from the inner space  4   a  of the bulge  4  to the front opening  3   a  of the annular wall  3 . The slope  4   b  of the bulge  4  is slantwise opposed to an upper opening (not shown) of the tube wall  5 . The electric wire is angled within 90-degree (e.g., 45-degree or less). The wire seal  7  is, without engagement with the tube wall  5 , positioned down the tube wall  5 . 
         [0040]    A conductive metal shield sleeve  8  and a conductive metal shield terminal  9  is, as shown in  FIG. 2 , then sequentially put around each the electric wire  2  (or passing each electric wire through the conductive metal shield sleeve  8  and the conductive metal shield terminal  9 ), to make a tip (an end) of the electric wire  2  stripped, exposing the braid  2   a  and the core wire  2   b.  The shield sleeve  8  and the shield terminal  9  are arranged movable along the outer cover of the electric wire  2 . 
         [0041]    The shield sleeve  8  is formed annular, and has a downside flange  8   a  and an upside main body (substituted by reference sign  8 ). The shield terminal  9  is composed of a annular part  9   a,  an elongated plate  9   c  projecting and extending upwardly from an upside flange  9   b  of the annular part  9   a,  a projection  9   d  with a bore  9   e  orthogonal to and at a tip of the plate  9   c.    
         [0042]    Then, as shown in  FIG. 3 , the L-shaped terminal  11  is each crimped to connect to the core wire  2   b  of the electric wire  2 . The terminal  11  is crimped using such a manual terminal crimping tool (not shown). The L-shaped terminal  11  is composed of an upside parallel male electric contact  11   a,  a downside vertical electric connection part  11   b  (a crimping connection part), and an L-shaped bent plate  11   c  connecting the contact  11   a  and the connection part  11   b.    
         [0043]    Then, as shown in  FIG. 4 , outside the L-shaped terminal an isolating resin inner housing  12  is each mounted. The inner housing  12  is divided into side to side, to accommodate the L-shaped terminal  11  (in  FIG. 3 ), followed by coupling to each other to lock. 
         [0044]    The inner housing  12  is as shown in  FIG. 5  formed in L-shape divisible side to side, of which divided housings  12   a,    12   b  each have an upside parallel divided tube  13  in cross-sectionally semicircle shape, a downside vertical divided tube  14  in cross-sectionally rectangle shape, a terminal housing  15  (a slit space) in the divided tubes  13 ,  14 , a parallel mating male terminal inserting bore (slit)  17  disposed at a front wall  16  of the parallel divided tube  13 , a vertical flange  18  projected at a rear end of the parallel divided tube  13 , a block  19  formed backward a flange  18  of the right side divided tube  12 , and lock part such as a lock frame  20  and a lock stop  21 . 
         [0045]    The block  19  is provided a slit  19   a  brought into positioning and coupling to the conductive housing  1 . The inner housing  12  is allowed to be vertically divisible. The divided housing may in this case each be made integral in parallel. A pair of parallel divided tubes  13  is incorporated into the parallel tube (parallel part)  13 , a pair of vertical divided tube  14  the vertical tube (vertical part)  14 . 
         [0046]    Then, as shown in  FIGS. 6 ,  7 , the shield sleeve  8  and the shield terminal  9  are upwardly moved along the electric wire  2 , the braid  2   a  of the electric wire  2  is downwardly turned down to overlap on the shield sleeve  8 , and the shield terminal  9  is swaged over the overlapping portion of the braid  2   a  to connect. The upwardly extended plate  9   c  of the shield terminal  9  is positioned parallel to the electric wire  2 , adjacent to the vertical tube  13  of the inner housing  12 . 
         [0047]    Pulling downward the electric wire  2  (a direction contrary to that of inserting the electric wire  2  as shown in  FIG. 1 ) from a state as shown in  FIG. 7  allows an inner housing assembly  12 ′ shown in  FIG. 8  to be accommodated in the conductive housing  1 . The inner housing assembly  12 ′ is composed of the inner housing  12  and the L-shaped terminal  11 . The electric wire  2  is, from a state as shown in  FIG. 7 , smoothly contacted with inside the tube  5  of the conductive housing  1  or inner circumference of the annular wall  3 . The inner housing assembly  12 ′ is smoothly pulled in from the vertical tube  14  into the conductive housing  1 . 
         [0048]    The block  19  back the inner housing  12  is as shown in  FIG. 8  contacted with a wall face  21  in the bulge  4  of the inner housing  1 , leading to prevention of further pulling in. The vertical tube  14  of the inner housing  12  is accommodated in the bulge  4  and the tube wall  5 , making the parallel tube  13  project from the front opening  3   a  of the annular wall  3 . The reference sign  11  in  FIG. 8  indicates the L-shaped terminal. The shield terminal  9  is accommodated in the tube wall  5 . 
         [0049]    Then, as shown in  FIG. 9 , by inserting a bolt  22  from the opening  3   a  of the annular wall  3  into the  9   e  in the projection  9   d  at upper end of the plate  9   c  of the shield terminal ( FIG. 7 ), and installing into a threaded bore in the bulge (rear wall)  4  of the conductive housing  1 , the shield terminal  9  is fixed to the conductive housing  1 . The above operation makes it easy to fix the inner housing assembly  12 ′ integral with the shield terminal  9  to the conductive housing  1 . The threaded bore is formed inside the parallel tube  23  in the bulge  4 . 
         [0050]    While the projection  9   d  of the shield terminal  9  of leftmost the electric wire  2  in the  FIG. 3  is located left, turning around as shown in  FIG. 4 , i.e., rotating 180-degree the annular part  9   a  allows both the shield terminals  9  to be fixed with one bolt  22  shown in  FIG. 9  to the conductive housing  1  upon overlapping the projection  9   d  of the shield terminal  9  of leftmost the electric wire  2  with that of center the electric wire  2 . Since the projection  9   d  is located widthwise center the plate  9   c,  the shield terminal  9  is allowed to use in reverse. 
         [0051]    The slit  19   a  back the block  19  of the inner housing  12  is as shown in  FIG. 9  positioned to engage with the parallel rib  24  in the bulge  4  of the conductive housing  1 . The vertical flange  18  of the inner housing  12  is pressed down by a flange of the outer housing to be described hereinafter. The conductive housing  1  and the inner housing  12 ′ compose the conductive housing assembly  1 ′. 
         [0052]    Then, as shown in  FIG. 10 , an oblong circumference slit  25  front the annular wall  3  of the conductive housing  1  is packed with a shell packing  26 , from above which an isolating resin outer housing  27  (also referred to as a front housing) and a assembly or outer housing assembly  27 ′ composed of a conductive metal shield shell  28  and a housing packing  29  are assembled to the conductive housing  1 , to be thread fastened with a bolt  30 . 
         [0053]    The shield shell  28  is, as shown in  FIG. 11 , composed of an oblong parallel tube  31 , and a vertical flange  32  back the tube  31 , which the flange  32  includes an annular projection  33  bulging backward and a small outward flange  34  with a bore. The outer housing  27  is composed of an oblong parallel main body  35  and a vertical flange  36  back the main body  25 , both sides of the main body  35  are cut away in a slit shape, and backward the slit  36  an axis  37  is projected. The flange  36  includes a small flange  38  with a bore. Backward the flange  36  an annular projection  39  adapted to engage with the circumference slit  33   a  of the shield shell  28  is disposed. 
         [0054]    The housing packing  29  has a lock projection  29   a  engaging with the bore  40  of the flange  32  of the shield shell  28 , and mounted outside the tube  31 . The annular projection  33  of the shield shell  28  is positioned to be pressed into the circumference slit  25  of the conductive housing  1  ( FIG. 10 ) along with the shell packing  26  (outside or inside of the shell packing  26 ). The flange  36  of the outer housing  27  and the flange  32  of the shield shell  28 , overlapping front and rear to each other, press backward the flange  18  shown in  FIG. 10  of the inner housing  12  in the conductive housing  1 , to sandwich and fix between a wall of the bulge wall  4  and themselves. 
         [0055]    Overlapping the small flanges  38 ,  34  of the outer housing  27  and the shield shell  28 , respectively, as shown in  FIG. 10 , the bolt  30  is inserted into the small flanges  38   a,    34   a,  and is thread fastened to the thread bore  6   a  of the small flange  6  of the conductive housing  1 , letting the outer housing assembly  27 ′ to be fixed to the conductive housing  1  as shown in  FIG. 12 . 
         [0056]    The parallel tube  13  of the inner housing  12 , as shown in  FIG. 12 , is inserted into the tube  31  of the shield shell  28  along its inside, and is positioned within inside space of the outer housing  27 . Then, the wire seal  7  is moved as shown in  FIG. 12 , upward along the electric wire  2  such that its outside lip  7   a  is inserted into the vertical tube wall  5  of the conductive housing  1  in close contact therewith. The inside lip of the wire seal  7  is in close contact with the outer cover of the electric wire  2 . 
         [0057]    Then, a pair of front and rear divided holders  42   a,    42   b,  as shown in  FIGS. 13A ,  13 B, is assembled outside a synthetic resin short (or long) corrugated tube  41  attached to the electric wire  2 , and a circumference projection strip  43  in each of the divided holders  42   a,    42   b  is engaged with a circumference slit  41   a  of the corrugated tube  41  while each of the divided holders  42   a ,  42   b,  is locked in each other with a projection  44  and a lock means such a lock frame  45 , to be assembled as a rear holder or holder  42 . A rear holder assembly  42 ′ composed of the rear holder  42   a  and the corrugated tube  41  is pulled up along the electric wire  2 , and an upward lock frame  46  of the rear holder  42  is engaged with a projection downside the tube wall  5  of the conductive housing  1 , shown in  FIG. 10 . The rear holder  42  is adapted to prevent the shield seal  7 , shown in  FIG. 12 , from dropping out. 
         [0058]    Then, nearly U-shaped lever  48  for low-insertion-force engagement is as shown in  FIG. 14  assembled to the axis  37  of the outer housing  27 , completing a connector  50 , i.e., shield waterproof connector. The lever  48  is provided with a cam bore  49  adapted to engage with a driven projection (not shown) of a mating connector entering into the slit  36  of the outer housing. 
         [0059]    Note that while in the above-mentioned embodiment the shield sleeve  8  has been utilized, it may be made possible that the annular wall  9   a  of the shield terminal  9   a,  avoiding the shield sleeve  8 , is directly swaged and connected to the braid  2  of the electric wire  2 . “The shield terminal” in claim  1  includes the one with or without a shield sleeve  8 . 
         [0060]    Further, note that while in the above-mentioned embodiment the shell packing  29 , the housing packing  26 , and the cable seal  7  have been utilized, it may be made possible to avoid these shield member if no need of waterproof. And in the above-mentioned embodiment the lever  48  for connector engagement has been mounted, it is made possible to avoid the lever  48  when manually connecting the connector  50  to the mating connector without the lever. 
       INDUSTRIAL APPLICABILITY  
       [0061]    The method for manufacturing the connector according to the present invention may be utilized for readily assembling the electromagnetic shield connector. 
       REFERENCE SIGNS LIST  
       [0000]    
       
           1  conductive housing 
           2  shield electric wire 
           2   a  braid 
           2   b  core wire 
           3  annular wall 
           3   a  front opening 
           4  bulge wall (rear wall) 
           5  tube wall 
           5   a  lower opening 
           6  small flange (flange part) 
           7  wire seal 
           9  shield terminal 
           9   a  annular part 
           9   c  plate 
           9   d  projection 
           9   e  bore 
           11  L-shaped terminal 
           12  inner housing 
           13  parallel tube (parallel part) 
           14  vertical tube (vertical part) 
           22  bolt 
           27  outer housing 
           28  shield shell 
           32 ,  36  flange 
           42  rear holder (holder) 
           50  connector