Abstract:
A waterproof connector with sealing capability includes a connector housing with a plurality of conductive terminals mounted therein. The terminals are arranged around the perimeter of a circle with contact portions exposed at the radial outermost extents along the circle. The housing has a central opening around which the terminals are arranged and the terminals are each bent into a circular arc in their mounting on the housing. The housing is over molded around the terminal at intermediate portions thereof to provide a liquid proof barrier.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates generally to a watertight connector and a method of manufacturing the same. 
         [0002]    In a conventional connector, terminals made of metal rod-like members are press-fit in through holes formed in a bottom plate of a housing made of an insulating material such as a synthetic resin. In this case, a gap inevitably occurs between the inner wall surface of the through hole and the outer circumference of the terminal, and therefore, it is difficult to maintain a sealing performance between one surface side of the bottom plate from which tip portions of the terminals project to make contact with counterpart connector terminals and the other surface side of the bottom plate from which root portions of the terminals project to make contact with electrical wires or the like of a cable. 
         [0003]    For this reason, in the case of a connector requiring cleaning such as a connector used for medical devices, for instance, cleaning liquid, used for cleaning the side of the bottom plate from which the tip portions of the terminals project to contact the counterpart connector terminals, may enter the side of the bottom plate at which the terminals are to be connected to the electrical wires or the like of the cable, and it may have adverse effects such as corrosion of the connecting portions of the root portions of the terminals and the electrical wires or the like, and cracking caused by deterioration. 
         [0004]    Also, in a cable including a further linear member such as an optical fiber or the like and electrical wires integrally arranged with the further linear member, the electrical wires, in some cases, are annularly arranged around the centrally arranged further linear member so as to surround the latter. Such a cylindrical connector for connecting the annularly arranged electrical wires is proposed (refer to Japanese Patent Application Laid-Open Publication (Kokai) No. S61-237383, for instance). 
         [0005]      FIG. 19  is a cross-sectional view of such a conventional cylindrical connector. 
         [0006]    In  FIG. 19 , reference numeral  801  designates a connector terminal, and a plurality of terminals are annularly arranged so as to surround the center axis of the connector. Also, reference numeral  802  designates an elementary portion in which the terminal  801  is fitted, and the elementary portions are integrally connected to a belt-like strip  803 . The elementary portions  802  and the strip  803  are made of an elastic plastic and are integrally molded by a molding method such as injection molding or the like. In this case, the elementary portions  802  having a trapezoidal cross-section are arranged in a line and mutually coupled by the linear strip  803 . It is to be noted that each terminal  801  is embedded in each elementary portion  802 . In addition, a core portion  804  having a cylindrical or polygonal outer surface is integrally connected to one end of the strip  803 . 
         [0007]    Then, a cylinder as illustrated in the figure is formed by winding the strip  803  around the core portion  804 , with the core portion  804  being in the center. In this case, the strip  803  is arranged on the outside of the cylinder, the elementary portions  802  face the inside of the cylinder, and slanted side surfaces of the adjacent elementary portions  802  are brought into contact with each other. The thus formed cylinder is attached inside a metal or plastic bush  805  to obtain a cylindrical connector. 
       SUMMARY OF THE INVENTION 
       [0008]    However, in the above-mentioned conventional cylindrical connector, a sealing performance is not considered. Therefore, in the case where the cylindrical connector is used in applications that require cleaning, cleaning liquid that is used for cleaning the side of the cylinder from which the tip portions of the terminals  801  project to contact counterpart connector terminals, may enter the side of cylinder at which the root portions of the terminals  801  are connected to the electrical wires or the like of the cable, and it may have adverse effects such as corrosion of connecting portions of the root portions of the terminals  801  and the electrical wires or the like, or cracking caused by deterioration. 
         [0009]    It is therefore a general object of the present invention to solve the above-described conventional problems and provide a watertight connector and a method of manufacturing the same, by which opposite ends of respective terminals are separated in a watertight manner, so that penetration of liquid from one end side of the terminals into the other end side of the terminals is reliably prevented, the manufacture of the watertight connector is facilitated, and the manufacturing cost of the watertight connector is reduced, by molding at least one linear intermediate holding part by overmolding at least portions of respective terminals with a first resin, bending the intermediate holding part into a circular arc shape, and overmolding at least a portion of the circular-arc shaped intermediate holding part with a second resin. 
         [0010]    For solving this object, a watertight connector, according to the present invention, includes: a plurality of terminals having contact portions for contacting counterpart terminals of a counterpart connector and connection portions to be connected to other conductive members; a housing portion made of an insulating material and molded so as to integrate the terminals between the contact portions and the connection portions; the housing portion comprising a body portion having a cylindrical-surface-like outer circumferential wall surface and a cylindrical skirt portion integrally connected to the body portion at one end of the outer circumferential wall surface; and the contact portions being exposed to the outer circumference wall surface, at least free ends of the connection portions extending from the body portion in a space formed in the skirt portion. 
         [0011]    In the watertight connector according to another aspect of the present invention, the body portion has a through hole; and at least the free ends of the connection portions are arranged annularly around the through hole. 
         [0012]    In the watertight connector according to a further aspect of the present invention, the housing portion is integrally connected to the body portion and has a first fitting portion extending in a direction opposite to the skirt portion, and the through hole also extends through the first fitting portion. 
         [0013]    A method of manufacturing a watertight connector, according to the present invention, includes: steps of forming a plurality of terminals having one ends coupled to a carrier portion and arranged in a line; forming at least one intermediate holding part holding a plurality of terminals in the arranged state, by overmolding at least portions of the terminals with a first resin; bending the intermediate holding parts into a circular arc shape after removing the carrier portion; and forming a housing portion comprising a body portion having a cylindrical-surface-like outer circumferential wall surface, by overmolding at least a portion of the at least one intermediate holding part having the circular arc shape with a second resin. 
         [0014]    In the method of manufacturing a watertight connector, according to another aspect of the present invention, the intermediate holding part comprises terminal holding portions for covering at least portions of respective terminals and thin sheet-like connecting portions for connecting adjacent terminal holding portions, and the terminal holding portions and the connecting portions are alternately arranged. 
         [0015]    In the method of manufacturing a watertight connector according to a further aspect of the present invention, the terminals comprise contact portions for contacting counterpart terminals of a counterpart connector and connection portions to be connected to other conductive members, and the contact portions are exposed to one surface of the intermediate holding part and the connection portions extend from the intermediate holding part. 
         [0016]    In the method of manufacturing a watertight connector, according to a still further aspect of the present invention, the intermediate holding part is bent into a circular arc shape so that the contact portions face a side opposite to a center of curvature of the circular arc. 
         [0017]    In the method of manufacturing watertight connector, according to a still further aspect of the present invention, end portions of the or a plurality of intermediate holding parts having a circular arc shape are arranged to approach each other so as to form an annular shape and the at least a portion of the at least one intermediate holding part is overmolded with the second resin. 
         [0018]    The method of manufacturing a watertight connector, according to a still further aspect of the present invention, it further includes step of integrally connecting a cylindrical skirt portion to the body portion. 
         [0019]    According to the present invention, the watertight connector is manufactured by molding the linear intermediate holding part by overmolding at least portions of respective terminals with a first resin, bending the intermediate holding part into a circular arc shape, and overmolding at least a portion of the circular-arc shaped intermediate holding part with a second resin. Thereby, opposite end portions of respective terminals can be separated in a watertight manner, so that penetration of liquid from one end side of the terminals into the other end side of the terminals can be reliably prevented, and the manufacture of the watertight connector is facilitated, and the manufacturing cost can be reduced. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]      FIGS. 1A and 1B  are perspective views of a watertight connector according to an embodiment of the present invention; 
           [0021]      FIGS. 2A to 2C  are three side views of the watertight connector according to the embodiment of the present invention; 
           [0022]      FIG. 3  is a perspective view of the terminals according to the embodiment of the present invention; 
           [0023]      FIGS. 4A to 4C  are three side views of the terminals according to the embodiment of the present invention; 
           [0024]      FIG. 5  is a perspective view of the terminals according to the embodiment of the present invention, in the state where portions of the terminals are overmolded with the first resin; 
           [0025]      FIGS. 6A to 6C  are three side views of the terminals according to the embodiment of the present invention, in the state where portions of the terminals are overmolded with the first resin; 
           [0026]      FIG. 7  is a perspective view of the terminals according to the embodiment of the present invention, in the state where the carrier portion is removed from the terminals overmolded with the first resin; 
           [0027]      FIGS. 8A to 8C  are three side views of the terminals according to the embodiment of the present invention, in the state where the carrier portion is removed from the terminals overmolded with the first resin; 
           [0028]      FIG. 9  is a first perspective view of the unit base part according to the embodiment of the present invention, in the state where the unit base part is deformed into a circular arc shape; 
           [0029]      FIG. 10  is a second perspective view of the unit base part according to the embodiment of the present invention, in the state where the unit base part is deformed into the circular arc shape; 
           [0030]      FIGS. 11A and 11B  are two side views of the unit base part according to the embodiment of the present invention, in the state where the unit base part is deformed into the circular arc shape; 
           [0031]      FIG. 12  is a perspective view of the base part formed of joined unit base parts according to the embodiment of the present invention; 
           [0032]      FIGS. 13A to 13C  are three side views of the base part formed of the joined unit base parts according to the embodiment of the present invention; 
           [0033]      FIGS. 14A and 14B  are perspective views of the counterpart connector according to the embodiment of the present invention; 
           [0034]      FIGS. 15A to 15C  are three side views of the counterpart connector according to the embodiment of the present invention; 
           [0035]      FIG. 16  is a perspective view of the counterpart connector mounted on a substrate according to the embodiment of the present invention; 
           [0036]      FIG. 17  is a perspective view of the watertight connector connected to a cable according to the embodiment of the present invention; 
           [0037]      FIG. 18  is a perspective view of the watertight connector fitted in the counterpart connector according to the embodiment of the present invention; and 
           [0038]      FIG. 19  is a cross-sectional view of the conventional cylindrical connector. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0039]    Preferred embodiment of the present invention will now be described below in detail with reference to the accompanying drawings. 
         [0040]      FIGS. 1A and 1B  are perspective views of a watertight connector according to of the present invention.  FIGS. 2A to 2C  are three side views of the watertight connector according to the embodiment of the present invention, in which  FIG. 2A  is a front view,  FIG. 2B  is a plan view, and  FIG. 2C  is a side view. 
         [0041]    In the drawings, reference numeral  1  designates the watertight connector, which includes a housing portion  11  made of an insulating material conductive, terminals  61  attached to the housing portion  11 , a first fitting portion  15  which is integrally formed with the housing portion  11 , and made of an insulating material and fitted in a counterpart connector  101 , described later. 
         [0042]    In this embodiment, representations of directions such as up, down, left, right, front, rear, and the like, used for explaining the structure and movement of each part of the watertight connector  1 , are not absolute, but relative. These representations are appropriate when each part of the watertight connector  1  is in the position shown in the figures. If the position of the watertight connector changes, however, it is assumed that these representations are to be changed according to the change of the position of the watertight connector  1 . In addition, two-color molding (multiple molding) referred to as double molding, outsert molding, insert molding, and the like, among the resin molding technologies, are referred to as overmolding. 
         [0043]    In the embodiment, the watertight connector  1  is used for medical devices, for instance, but it may be used for any purposes. The watertight connector  1  is a cylindrical connector suitable for connecting conductive wires of a cable  91 , which will be illustrated later, and which comprises a further linear member such as an optical fiber or the like and conductive wires integrally arranged with the further linear member, with the conductive wires annularly arranged around the centrally arranged further linear member so as to surround the latter, but it may be used for connecting conductive wires of any type of cable. 
         [0044]    The housing portion  11  includes a thick-plate-like and ring-shaped or annular body portion  11   b  having a through hole  13  with a circular cross-section formed in the center thereof, and a cylindrical skirt portion  11   a  extending upward and integrally connected to the upper end of the outer circumferential wall surface of the body portion  11   b.  In addition, the cylindrical first fitting portion  15  extending downward is integrally connected to the lower end of the inner circumferential wall surface of the body portion  11   b . Thereby, the housing portion  11  has, as a whole, a shape like a stepped cylinder with a large diameter portion and a small diameter portion. The housing portion  11  has the external diameter of about 30 mm, for instance, and each of the skirt portion  11   a,  the body portion  11   b,  and the first fitting portion  15  has the minimum thickness of about 0.35 mm, however, the size of each part of the watertight connector  1  may be arbitrary set. 
         [0045]    In addition, the first fitting portion  15  is a portion to be fitted in the counterpart connector  101  and rib-like projecting portions  15   a  extending in the axial direction are integrally formed on the outer circumference wall surface of the first fitting portion  15 . The projecting portion  15   a , for instance, engages with a concave portion  116 , which will be described later, of the counterpart connector  101  and is used as a rotation stopper for preventing the watertight connector  1  from rotating relative to the counterpart connector  101  and vice versa, however, the projecting portion  15   a  may be used for any purpose. Further, in the illustrated embodiment, two projection portions  15   a  are formed in two positions, however, the number of the projection portions  15   a  and positions or the like for disposing the projection portions  15   a  may be arbitrary set. 
         [0046]    Further, the skirt portion  11   a  is used as a second fitting portion which is directly connected to a cable connector fitted in the cable  91  or conductors of the cable  91 . 
         [0047]    The through hole  13  also extends through the first fitting portion  15 , and if the watertight connector  1  is used for connecting conductive wires of a medical endoscope, a catheter, or the like, for example, and the further linear member such as the optical fiber, a tubular member, or the like can pass through the through hole  13 . 
         [0048]    In this embodiment, a plurality of terminals  61  are embedded in the body portion  11   b  of the housing portion  11  in a watertight manner. A tail portion  62  as a connection portion formed at one end of each terminal  61  extends upward from the upper surface of the body portion  11   b  in a space formed in the skirt portion  11   a,  and a contact portion  64  formed in the vicinity of the other end of each terminal  61  is exposed to the outer circumference wall surface of the body portion  11   b.  Each of the tail portions  62  is connected to each of a plurality of conductive wires included in the cable  91  to be connected to the watertight connector  1 . In the illustrated embodiment, the tail portions  62  are arranged on two concentric circles (two pitch circle diameters), however, the arrangement of the tail portions  62  may be arbitrary changed. For instance, the tail portions  62  may be arranged on one circle (one pitch circle diameter) or on three or more concentric circles (three or more pitch circle diameters). In addition, each of the contact portions  64  contacts and makes electrical connection to each of counterpart terminals  161  included in the counterpart connector  101  fitted with the watertight connector  1 . 
         [0049]    As described above, the tail portions  62  and the contact portions  64  are separated by the housing portion  11  in a watertight manner, since the terminals  61  are embedded in the body portion  11   b  of the housing portion  11 , there is no gap between the terminals  61  and the body portion  11   b,  and the circumference of the tail portions  62  are surrounded by the skirt portion  11   a.  Thus, the penetration of any liquid such as cleaning liquid or the like from the side of the contact portions  64  into the side of the tail portions  62  is prevented by the housing portion  11 , when cleaning the fitting side of the watertight connector  1 , that is, the side of the contact portions  64 . 
         [0050]    Next, a method of manufacturing the watertight connector  1  having the above-described structure is explained. First, a method of overmolding portions of the terminals  61  with a first resin is explained. 
         [0051]      FIG. 3  is a perspective view of the terminals according to the embodiment of the present invention.  FIGS. 4A to 4C  are three side views of the terminals according to the embodiment of the present invention, in which  FIG. 4A  is a front view,  FIG. 4B  is a plan view, and  FIG. 4C  is a side view.  FIG. 5  is a perspective view of the terminals according to the embodiment of the present invention, in the state where portions of the terminals are overmolded with the first resin.  FIGS. 6A to 6C  are three side views of the terminals according to the embodiment of the present invention, in the state where portions of the terminals are overmolded with the first resin, in which  FIG. 6A  is a front view,  FIG. 6B  is a plan view, and  FIG. 6C  is a side view.  FIG. 7  is a perspective view of the terminals according to the embodiment of the present invention, in the state where the carrier portion is removed from the terminals overmolded with the first resin.  FIGS. 8A to 8C  are three side views of the terminals according to the embodiment of the present invention, in the state where the carrier portion is removed from the terminals overmolded with the first resin, in which  FIG. 8A  is a front view,  FIG. 8B  is a plan view, and  FIG. 8C  is a side view. 
         [0052]    First, a conductive metal plate is subjected to punching and bending to form the terminals  61  as illustrated in  FIGS. 3 to 4C . The terminals  61  are coupled to a carrier portion  66  which is used for transportation or the like and will be removed in a following step, and a plurality of terminals  61  are integrally formed with each other. As illustrated in  FIGS. 3 to 4C , each terminal  61  includes an elongated belt-like linear body portion  63  which is embedded in the housing portion  11 , the contact portion  64  having the shape of a baseball home plate and perpendicularly connected to the upper end of the body portion  63 , and the elongated belt-like linear tail portion  62  perpendicularly connected to the lower end of the body portion  63 , and the terminal  61  has, as a whole, a substantially cranked side shape. Further, the tail portion  62  of each terminal  61  is coupled to the broad belt-like linear carrier portion  66  via an elongated belt-like connecting portion  67 . Reference numeral  67   a  designates a boundary line indicating a boundary between the tail portion  62  and the connecting portion  67 , and the cutting will be performed along the boundary line  67   a  when the carrier portion  66  will be removed in the following step. 
         [0053]    In the embodiment shown in  FIGS. 3 to 4C , the terminals  61  with longer body portions  63  and the terminals  61  with shorter body portions  63  are alternatively arranged so that the tail portions  62  can be arranged on two concentric circles as described above, in which the tail portions  62  of the terminals  61  with the longer body portions  63  form the inner circle in  FIG. 2B  and the tail portions  62  of the terminals  61  with the shorter body portions  63  form the outer circle in  FIG. 2B . For instance, when the tail portions  62  cooperate to form a single circle, all of the body portions  63  are formed to be equal in length, and when the tail portions  62  form three concentric circles, the body portions  61  are formed to have three different levels of length. 
         [0054]    Subsequently, portions of the terminals  61  are overmolded with the first resin by a molding method such as injection molding, cast molding, or the like, so as to form a harmonica part  16  as an intermediate holding part, as illustrated in  FIGS. 5 to 6C . In this case, at least portions of the contact portions  64 , the body portions  63 , and the tail portions  62  are set in a primary metal mold (not shown) and the melted first resin is filled in the primary metal mold so as to form the harmonica part  16  integrated with portions of the terminals  61 . For instance, the first resin may be a PPS (Poly Phenylene Sulfide) resin, but any type of resin may be used as long as the resin can be used in the molding methods such as injection molding, cast molding, or the like, and has appropriate flexibility. 
         [0055]    The harmonica part  16  includes core portions  16   a  as terminal holding portions for covering at least portions of the contact portions  64 , the body portions  63 , and the tail portions  62 , and thin sheet-like connecting portions  16   b  for connecting adjacent core portions  16   a.  With this structure, the harmonica portion  16  as a whole is a linear member as illustrated in  FIG. 6A , and has a concertina shape or a shape suggestive of successive openings of a harmonica as seen from the front. In addition, a first cut-away portion  16   c  and a second cut-away portion  16   d  are formed in the core portion  16   a,  having such a shape that corners of the upper surface are cut-away at substantially right angle. 
         [0056]    The plate-like contact portion  64  is almost entirely embedded in the core portion  16   a,  except for the upper surface of the contact portion  64  exposed to the upper surface of the core portion  16   a.  In addition, the body portion  63  is almost entirely embedded in the core portion  16   a,  except for a portion of the surface of the body portion  63  exposed to one surface of the first cut-away portion  16   c . Further, a portion of the tail portion  62  near the body portion  63  is embedded in the core portion  16   a,  but a portion of the tail portion  62  near the connecting portion  67  extends outwards from the core portion  16   a.    
         [0057]    Subsequently, the connecting portion  67  is cut off from the tail portion  62  along the boundary line  67   a  to remove the carrier portion  66  and the connecting portions  67 . Thereby, a unit base part  17   a  as illustrated in  FIGS. 7 to 8C  can be obtained. The unit base part  17   a  comprises the harmonica part  16  and the terminals  61  having portions embedded in the core portions  16   a  of the harmonica part  16 . 
         [0058]    Next, a method of manufacturing the watertight connector  1 , by overmolding at least a portion of the harmonica part  16  with the second resin. 
         [0059]      FIG. 9  is a first perspective view of the unit base part according to the embodiment of the present invention, in the state where the unit base part is deformed into a circular arc shape.  FIG. 10  is a second perspective view of the unit base part according to the embodiment of the present invention, in the state where the unit base part is deformed into the circular arc shape.  FIGS. 11A and 11B  are two side views of the unit base part according to the embodiment of the present invention, in the state where the unit base part is deformed into the circular arc shape, in which  FIG. 11A  is a front view and  FIG. 11B  is a rear view.  FIG. 12  is a perspective view of the base part formed of joined unit base parts according to the embodiment of the present invention.  FIGS. 13A to 13C  are three side views of the base part formed of the joined unit base parts according to the embodiment of the present invention, in which  FIG. 13A  is a front view,  FIG. 13B  is a plan view, and  FIG. 13C  is a side view. 
         [0060]    First, the harmonica portion  16  is deformed by bending it into the circular arc shape, as illustrated in  FIGS. 9 to 11B . In this case, when seen from the front, as illustrated in  FIG. 11A , the harmonica portion  16  is deformed so that the line connecting the connecting portions  16   b  forms a circular arc, the top surface of the core portion  16   a,  that is, the surface to which the contact portion  64  is exposed, faces outward, and the lower surface of the core portion  16   a  faces inward. In other words, the arrangement is such that the contact portions  64  face the side opposite to the center of curvature of the arc. The harmonica part  16  includes core portions  16   a  and the thin plate-like connecting portions  16   b  for connecting adjacent core portions  16   a,  and the core portions  16   a  and the connecting portions  16   b  are alternately arranged, so it is possible to form the line connecting the connection portions  16   b  into a circular arc shape, by bending the connection portions  16   b.  It is to be noted that the curvature of the circular arc formed by the line connecting the connection portions  16   b  can be appropriately set. 
         [0061]    Subsequently, a ring-shaped or annular base part  17  as illustrated in  FIGS. 12 to 13C  can be obtained by using a plurality of unit base parts  17   a  having the circular arc shape. In this case, end portions of the harmonica parts  16  are joined or approached each other. The base part  17  is a ring-shaped or annular member having an outer circumferential surface on which a plurality of contact portions  64  are arranged in a line, and includes a plurality of tail portions  62  extending from one of the surfaces perpendicular to the axial direction of the ring or loop and in the axial direction. Here, in the illustrated embodiment, the tail portions  62  are so arranged to form two concentric circles. 
         [0062]    In this case, the number of the unit base parts  17   a  required for forming one base part  17  varies according to the length of the unit base parts  17   a  and the curvature of the circular arc formed by the line connecting the connecting portions  16   b.  For instance, if the length of the unit base parts  17   a  is shorter, the number of the unit base parts  17   a  required for forming one base part  17  increases even when the curvature is constant. In addition, even if the length of the unit base parts  17   a  is constant, for instance, the number of the unit base parts  17   a  required for forming one base part  17  decreases when the curvature is small. It is to be noted that when the length of the unit base parts  17   a  is sufficiently long, as illustrated in  FIGS. 12 to 13C , the base part  17  can be obtained by joining opposite ends of one unit base part  17   a  or bringing them in close proximity to each other. 
         [0063]    Subsequently, at least the housing portion  11  of the watertight connector  1 , as illustrated in  FIGS. 1 and 2 , is formed, by overmolding at least portions of the harmonica parts  16  included in the base part  17  with the second resin by molding the method such as injection molding, cast molding, or the like. In this case, the base part  17  is set in a secondary mold (not shown) and the melted second resin is filled therein to form the body portion  11   b  of the housing portion  11  which is integrated with at least portions of the harmonica parts  16 . 
         [0064]    Incidentally, when the watertight connector  1  is used for medical devices, for instance, it is preferable that the second resin be a resin which is highly resistant to chemicals and is verified that the resin has no adverse effect on the human body, such as Radel® polyphenylsulfon, or the like, however, the second resin may be other resins. By this, the second resin is filled in a space formed between the adjacent core portions  16   a  of the harmonica parts  16 , and in the first cut-away portion  16   c  and the second cut-away portion  16   d,  and the like, to obtain the thick-plate, ring-shaped or annular body portion  11   b.    
         [0065]    In addition, since the annular base part  17  is set in the secondary mold, the terminals  61  may be accurately set in the secondary mold in the annularly arranged state. 
         [0066]    Generally, it is easy to accurately set the terminals  61  linearly arranged in the mold, however, it is difficult to accurately set the annularly arranged terminals  61  in the mold. That is, as illustrated in  FIGS. 3 to 4C , the terminals  61  are formed by subjecting a metal plate to punching and bending, and are coupled to the linear carrier portion  66 , so a plurality of terminals  61  are integrally formed. For this reason, with the use of the carrier portion  66 , it is relatively easy to accurately place the terminals  61  in a linear cavity of a primary mold with the terminals  61  maintained in the linearly arranged state so that predetermined distances from respective portions of the terminals  61  to respective portions of the cavity surface are ensured. On the contrary, it is extremely difficult to place the terminals  61  in a circular cavity of a secondary mold with the terminals  61  maintained in the annularly arranged state so that predetermined distances from respective portions of the terminals  61  to respective portions of the cavity surface are ensured. 
         [0067]    However, in this embodiment, since the base part  17  obtained by overmolding portions of the terminals  61  with the first resin is set in the secondary mold, it is possible to ensure predetermined distances from respective portions of the terminals  61  to respective portions of the cavity surface, by bringing portions of the resin overmolding the terminals  61 , that is, for instance, surfaces of respective portions of the core portions  16   a,  into contact with respective portions of the cavity surface. Therefore, it becomes easy to accurately set the terminals  61  in the circular cavity of the secondary mold so that predetermined distances from respective portions of the terminals  61  to respective portions of the cavity surface are ensured even when the terminals  61  are annularly arranged. 
         [0068]    Subsequently, the first fitting portion  15  and the skirt portion  11   a  are integrally connected to the body portion  11   b,  by a molding method such as double molding, or the like. It is to be noted that the first fitting portion  15  and the skirt portion  11   a  can be sequentially connected to the body portion  11   b  in a separate molding step or can be connected to the body portion  11   b  at the same time in the same molding step. Further, the first fitting portion  15  and/or the skirt portion  11   a  can be molded integrally with the body portion  11   b  when forming the body portion  11   b  by overmolding the base portion  17  with the second resin. Thereby, the watertight connector  1  as illustrated in  FIGS. 1 to 2C  can be obtained. 
         [0069]    Next, an example of use of the watertight connector  1  is explained. 
         [0070]      FIGS. 14A and 14B  are perspective views of the counterpart connector according to the embodiment of the present invention.  FIGS. 15A to 15C  are three side views of the counterpart connector according to the embodiment of the present invention, in which  FIG. 15A  is a bottom view,  FIG. 15B  is a side view, and  FIG. 15C  is a plan view.  FIG. 16  is a perspective view of the counterpart connector mounted on a substrate according to the embodiment of the present invention.  FIG. 17  is a perspective view of the watertight connector connected to a cable according to the embodiment of the present invention.  FIG. 18  is a perspective view of the watertight connector fitted in the counterpart connector according to the embodiment of the present invention. 
         [0071]    As illustrated in  FIGS. 14A to 16 , the counterpart connector  101  has an approximately cylindrical shape, and has a counterpart housing portion  111  made of an insulating material such as a synthetic resin and the counterpart terminals  161  made of a conductive material such as metal and provided in the counterpart housing portion  111 . The counterpart housing portion  111  includes a ring-shaped or annular body portion  111   b  made of a thick plate having a through hole  113  having a circular cross-section formed in the center thereof, and a cylindrical skit portion  111   a  extending upward is integrally coupled to the upper end of the outer circumferential wall surface of the body portion  111   b.    
         [0072]    When the watertight connector  1  is fitted in the counterpart connector  101 , it is inserted in the skirt portion  111   a.  In addition, the first fitting portion  15  of the watertight connector  1  is inserted in the through hole  113 , and the relative rotation between the watertight connector  1  and the counterpart connector  101  is prevented, by the engagement of the projection portions  15   a  of the first fitting portion  15  with the concave portions  116  formed in the through hole  113 . 
         [0073]    Further, the counterpart terminals  161  are arranged in the inner surface of the skirt portion  111   a  and counterpart contact portions  163  of the counterpart terminals  161  project inward. Further, the counterpart terminals  161  and the terminals  61  are electrically connected to each other, by the contact of the counterpart contact portions  163  with the contact portions  64  of the watertight connector  1 . 
         [0074]    In addition, tail portions  162  of the counterpart terminals  161  project from the body portion  111   b.  The tail portions  162  are connected to connection pads, through holes, or the like arranged in the surface of a substrate  191  such as a printed circuit board or the like by a connection means such as soldering. Thereby, the counterpart connector  101  is mounted on the substrate  191 . It is to be noted that the counterpart connector  101  may be mounted on an electric equipment such as a medical device or the like, an electronics device, or the like, instead of the substrate  191 . 
         [0075]    On the other hand, as illustrated in  FIG. 17 , the watertight connector  1  is coupled to the end of the cable  91 . The cable  91  comprises a further linear member such as an optical fiber or the like and conductive wires as other conductive members integrated with the further linear member, with the conductive wires annularly arranged around the centrally arranged further linear member so as to surround the circumference thereof, but any type of cable may be used as the cable  91 . Further, the conductive wires are connected to the tail portions  62  of the terminals  61 . 
         [0076]    With this structure, as illustrated in  FIG. 18 , the conductive wires of the cable  91  are connected to wirings (not shown) of the substrate  191  via the terminals  61  and the counterpart terminals  161  when the watertight connector  1  is fitted in the counterpart connector  101  mounted on the substrate  191 . 
         [0077]    As described above, in this embodiment, the harmonica part  16  is molded by overmolding at least a portion of each terminal  61  with the first resin, the unit base part  17   a  comprising the harmonica part  16  and the terminals  61  is bent into a circular arc shape to form the annular base part  17 , the base part  17  is set in the mold, and at least a portion of the base part  17  is overmolded with the second resin, so that at least the body portion  11   b  of the housing portion  11  of the watertight connector  1  is molded. 
         [0078]    Thereby, a gap between the contact portion  64  and the tail portion  62  of each terminal  61  can be separated in a watertight manner, and the penetration of liquid from the side of the contact portion  64  to the side of the tail portion  62  can be surely prevented, and thus it is possible to obtain the watertight connector  1  the manufacture of which is facilitated and the manufacturing cost of which is reduced. 
         [0079]    Further, since the terminals  61  are set in the primary mold in the linearly arranged state when the unit base part  17   a  is formed, it is possible to easily and accurately position the terminals  61  and to overmold the terminals  61  with the first resin, and since the annular base part  17  obtained by deforming the unit base part  17   a  into a circular arc shape is set in the secondary mold when the body portion  11   b  is formed, it is possible to easily and accurately position the terminals  61  and to overmold the terminals  61  in the annularly arranged state with the second resin. 
         [0080]    In addition, since the body portion  11   b  is molded by further overmolding at least a portion of the harmonica part  16 , which is formed by overmolding at least portions of the terminals  61  with the first resin, with the second resin, the contact portions  64  and the tail portions  62  of the terminals  61  can be surely separated in a watertight manner by the body portion  11   b.  That is, if there is a gap between the harmonica part  16  formed by molding with the first resin and the terminals  61 , since the further overmolding is performed with the second resin, the gap will be filled with the second resin and the gap is surely closed off. In addition, even when cracks occur in the connection portions  16   b  or the like, or when gaps occur between the terminals  61  and the core portions  16   a,  the second resin, similarly, will be further applied for overmolding, and the cracks or gaps will be surely closed off by filling the second resin. 
         [0081]    Further, when a relatively expensive resin such as Radel® polyphenylsulfon or the like is used, the usage thereof can be suppressed by using the relatively expensive resin for only as the second resin, thereby the cost of the resin can be suppressed. 
         [0082]    Further, in this embodiment, the explanation is made as to the case of molding the body portion  11   b  of the housing portion  11  by double molding, however, the body portion  11   b  can be molded by overmolding three or more times. 
         [0083]    The present invention is not limited to the above-described embodiment, and may be changed in various ways based on the gist of the present invention, and these changes are not eliminated from the scope of the present invention.