Patent Publication Number: US-2021175646-A1

Title: Joint connector

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is based on and claims the benefit of priority to Korean Patent Application No. 10-2019-0160197, filed on Dec. 4, 2019, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference. 
     TECHNICAL FIELD 
     The present disclosure relates to a joint connector, and more particularly, to a joint connector capable of improving sealability between a wire connected to a female terminal and a housing. 
     BACKGROUND 
     In general, an electrical connector is used for the connection of two or more wires to carry electrical energy or to carry electrical signals or information. A pair of connectors may be joined in a male-to-female form. Such a pair of connectors may be combined to form a connector assembly. 
     A joint connector includes a bus bar having a plurality of male terminals, a plurality of female terminals electrically connected to the male terminals of the bus bar, and a housing receiving the bus bar and the plurality of female terminals. The plurality of female terminals may be electrically connected by the bus bar. For example, the joint connector distributes electrical energy input from one battery to a plurality of electrical components or performs vehicle grounding. 
     A joint connector according to the related art is provided with a seal member individually mounted on the periphery of each female terminal in order to secure sealability between each female terminal and the housing. Since the seal member is individually mounted on the periphery of each female terminal, the assembly thereof is complex, and the manufacturing cost thereof is increased. 
     In the joint connector according to the related art, a leaf spring structure is integrally formed in the female terminal. As the leaf spring structure elastically presses the male terminal, an electrical contact between the female terminal and the male terminal may be reliably maintained. However, as the joint connector is frequently checked in a vehicle manufacturing process, the female terminal and the male terminal may be repeatedly disconnected and connected. Thus, the leaf spring structure of the female terminal may be easily deformed, and this may result in high probability of contact failure between the female terminal and the male terminal. 
     In addition, it is very complex to manufacture, such as by machining, the leaf spring structure in the female terminal. It is not easy to perform inspection and dimensional measurement of the leaf spring structure of the female terminal. This makes it difficult to secure the quality of the leaf spring structure, increases the size of the female terminal, and increases the manufacturing cost. 
     The above information described in this background section is provided to assist in understanding the background of the inventive concept, and may include any technical concept which is not considered as the prior art that is already known to those having ordinary skill in the art. 
     SUMMARY 
     The present disclosure has been made to solve the above-mentioned problems occurring in the prior art while advantages achieved by the prior art are maintained intact. 
     An aspect of the present disclosure provides a joint connector capable of improving the sealability between a wire connected to a female terminal and a housing. 
     According to an aspect of the present disclosure, a joint connector may include: a bus bar having a plurality of male terminals; a plurality of female terminals electrically connected to the plurality of male terminals; a housing having a cavity receiving the bus bar and the plurality of female terminals; and a seal block having a plurality of receiving holes, and contacting the housing, wherein each receiving hole may receive an electrical wire connected to each female terminal. 
     The housing may have a first portion and a second portion. The cavity may be defined within the second portion of the housing. The first portion of the housing may have a plurality of terminal passing holes communicating with the cavity and each female terminal may pass through each terminal passing hole. 
     The plurality of receiving holes may be aligned with the plurality of terminal passing holes. 
     The joint connector may further include a first cover and a second cover facing the first cover to cover the housing. The first cover may be adjacent to the first portion of the housing, and the seal block may be interposed between the first cover and the first portion of the housing. 
     The seal block may include a plurality of outer seal lips protruding from an outer surface of the seal block toward the first cover, and a plurality of inner seal lips protruding from an inner surface of the receiving hole toward a center of the receiving hole. 
     The second cover may have a ledge extending toward the first cover, the seal block may be located within the ledge, the plurality of outer seal lips may contact the ledge, and the plurality of inner seal lips may contact the electrical wires connected to the plurality female terminals. 
     The first cover may have a plurality of insertion holes aligned with the plurality of terminal passing holes, and each female terminal may be received in the cavity through each insertion hole. 
     The bus bar may have a strip extending in a width direction of the housing, and the plurality of male terminals may extend from the strip. 
     Each male terminal may have a leaf spring structure, and the leaf spring structure may be provided at an end portion of the male terminal. 
     The leaf spring structure may include an upper spring and a lower spring facing the upper spring. 
     The female terminal may have a terminal cavity receiving the leaf spring structure of the male terminal. 
     The female terminal may be a clean body terminal. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other objects, features and advantages of the present disclosure should be more apparent from the following detailed description taken in conjunction with the accompanying drawings: 
         FIG. 1  illustrates a perspective view of a joint connector according to an embodiment of the present disclosure; 
         FIG. 2  illustrates a cross-sectional view, taken along line A-A of  FIG. 1 ; 
         FIG. 3  illustrates an exploded perspective view of a joint connector according to an embodiment of the present disclosure; 
         FIG. 4  illustrates an assembly process of a joint connector according to an embodiment of the present disclosure, in which a plurality of bus bars is received in a cavity of a housing; 
         FIG. 5  illustrates an assembly process of a joint connector according to an embodiment of the present disclosure, in which a terminal position assurance (TPA) mechanism is received in a mounting space of a housing; 
         FIG. 6  illustrates an assembly process of a joint connector according to an embodiment of the present disclosure, in which a seal block and a first cover are coupled to a housing; 
         FIG. 7  illustrates a state of a joint connector according to an embodiment of the present disclosure, in which a seal block and a first cover are coupled to a first portion of a housing; 
         FIG. 8  illustrates a perspective view, which is viewed from a direction indicated by arrow B of  FIG. 7 ; 
         FIG. 9  illustrates a cross-sectional view, taken along line C-C of  FIG. 7 ; 
         FIG. 10  illustrates an assembly process of a joint connector according to an embodiment of the present disclosure, in which a female terminal is moving toward a male terminal within a cavity of a housing; 
         FIG. 11  illustrates a state of a joint connector according to an embodiment of the present disclosure, in which locking lances engage with engaging shoulders of female terminals within a cavity of a housing; 
         FIG. 12  illustrates a perspective view of a male terminal of a joint connector according to an embodiment of the present disclosure; 
         FIG. 13  illustrates a perspective view of a female terminal of a joint connector according to an embodiment of the present disclosure; 
         FIG. 14  illustrates a cross-sectional view of disconnection of a female terminal and a male terminal in a joint connector according to an embodiment of the present disclosure; 
         FIG. 15  illustrates a cross-sectional view of connection of a female terminal and a male terminal in a joint connector according to an embodiment of the present disclosure; 
         FIG. 16  illustrates an assembly process of a joint connector according to an embodiment of the present disclosure, in which a second cover is coupled to a first cover; and 
         FIG. 17  illustrates a state of a joint connector according to an embodiment of the present disclosure, in which a first cover and a second cover are assembled. 
     
    
    
     DETAILED DESCRIPTION 
     Hereinafter, specific embodiments of the present disclosure are described in detail with reference to the accompanying drawings. In the drawings, the same reference numerals are used throughout to designate the same or equivalent elements. In addition, a detailed description of well-known techniques associated with the present disclosure has been omitted in order not to unnecessarily obscure the gist of the present disclosure. 
     Terms such as first, second, A, B, (a), and (b) may be used to describe the elements in embodiments of the present disclosure. These terms are only used to distinguish one element from another element and the intrinsic features, sequence or order, and the like of the corresponding elements are not limited by the terms. Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meanings as those generally understood by those having ordinary skill in the art to which the present disclosure belongs. Such terms as those defined in a generally used dictionary are to be interpreted as having meanings equal to the contextual meanings in the relevant field of art. Such terms are not to be interpreted as having ideal or excessively formal meanings unless clearly defined as having such in the present application. 
     Referring to  FIGS. 2 and 3 , a joint connector  10  according to an embodiment of the present disclosure may include a housing  20  having a first portion  21  and a second portion  22 . 
     Referring to  FIGS. 2-5 , the housing  20  may have the first portion  21  and the second portion  22 . The first portion  21  may be a cube having a first height H 1 , a first width W 1 , and a first length L 1 . The second portion  22  may be a cube having a second height H 2 , a second width W 2 , and a second length L 2 . The first height H 1  of the first portion  21  may be greater than the second height H 2  of the second portion  22  and the first width W 1  of the first portion  21  may be greater than the second width W 2  of the second portion  22 . Thus, a transverse cross-sectional area of the first portion  21  may be greater than a transverse cross-sectional area of the second portion  22 . 
     Further referring to  FIG. 8 , the housing  20  may have a cavity  23  receiving a plurality of female terminals  11  and a bus bar  17  and the bus bar  17  may have a plurality of male terminals  19 . The female terminals  11  may be electrically connected to the corresponding male terminals  19  within the cavity  23 . A horizontal partition  24  and a plurality of vertical partitions  25  may be provided within the cavity  23  and the horizontal partition  24  and each of the plurality of vertical partitions  25  may partition a space that receives each female terminal  11  and each male terminal  19 . The horizontal partition  24  and a bottom of the housing  20  may have a plurality of recesses  26 , each of which receives each female terminal  11  and each male terminal  19 . Each recess  26  may have a stopper  26   a  restricting a position of the female terminal  11  and the stopper  26   a  may be stepped, i.e., extended from an end of the recess  26  downwardly. As a bottom end of the female terminal  11  is caught, i.e., stopped by the stopper  26   a , the position of the female terminal  11  may be restricted. The cavity  23  may be defined within the second portion  22 , and the second length L 2  of the second portion  22  may be greater than the first length L 1  of the first portion  21  so that the cavity  23  may have enough space. Thus, there may be enough space for electrical connections between the female terminals  11  and the male terminals  19 . 
     Referring to  FIGS. 2 and 9-11 , the housing  20  may have a plurality of locking lances  28 , and each locking lance  28  may extend obliquely from a top wall of the second portion  22  of the housing  20  and the horizontal partition  24  toward each recess  26 . The locking lance  28  may be elastically deformed. The locking lance  28  may have an engaging end  28   a  releasably engaging with an engaging shoulder  16  of the female terminal  11  and a shape of the engaging end  28   a  may correspond to that of the engaging shoulder  16 . 
     The first portion  21  of the housing  20  may have a plurality of terminal passing holes  27 , through which the plurality of female terminals  11  individually pass. The plurality of terminal passing holes  27  may communicate with the cavity  23 . In particular, the terminal passing holes  27  may be aligned with the corresponding recesses  26 . 
     Referring to  FIGS. 12-14 , each female terminal  11  may be connected to an end of an electrical wire  5  through a conductor gripper  13  and an insulator gripper  14 . The conductor gripper  13  may grip a conductor of the electrical wire  5 , and the insulator gripper  14  may grip an insulating cover of the electrical wire  5 . Each female terminal  11  may have a terminal cavity  15  receiving each male terminal  19 . The terminal cavity  15  may be defined by a top wall  15   a , a bottom wall  15   b , and two sidewalls  15   c . The terminal cavity  15  may form a clean body terminal, without a leaf spring structure, and have the smooth surface. When the female terminal  11  passes through a receiving hole  31  of a seal block  30  (further referring to  FIG. 3 ), the receiving hole  31  of the seal block  30  may not be damaged, and the possibility of deformation of the female terminal  11  may be significantly reduced. The top wall  15   a  of the female terminal  11  may have the engaging shoulder  16 , with which the locking lance  28  of the housing  20  releasably engages. Each female terminal  11  may be a clean body terminal. 
     Referring to  FIGS. 3 and 4 , the bus bar  17  may include a strip  18  and the plurality of male terminals  19  extending from the strip  18 . Each male terminal  19  may extend from the strip  18  toward each female terminal  11 , and the plurality of male terminals  19  may be electrically connected through the strip  18 . The strip  18  may extend in a width direction of the housing  20 . The plurality of male terminals  19  may be spaced apart from each other by a predetermined gap along the strip  18 . The gap between adjacent male terminals  19  may correspond to a thickness of the vertical partition  25 , and the strip  18  of the bus bar  17  may be restricted by the vertical partition  25  within the cavity  23  of the housing  20 . The vertical partition  25  may be fitted between the adjacent male terminals  19  of the bus bar  17  so that the bus bar  17  may be press-fitted into the cavity  23  of the housing  20 . 
     Further referring to  FIG. 12 , each male terminal  19  may have an engaging hole  19   a , to which a fastener is fastened. As the fastener is fastened to the engaging hole  19   a , the male terminal  19  may be coupled to the strip  18 . Each male terminal  19  may have a leaf spring structure  12 , and the leaf spring structure  12  may be provided at an end portion of the male terminal  19 . The leaf spring structure  12  may include an upper spring  12   a  and a lower spring  12   b  facing the upper spring  12   a . The upper spring  12   a  may be curved with its central portion protruding upwardly. The lower spring  12   b  may be curved with its central portion protruding downwardly. Referring to  FIGS. 11 and 15 , the male terminal  19  may be received in the terminal cavity  15  of the female terminal  11 , and the upper spring  12   a  and the lower spring  12   b  of the leaf spring structure  12  may be deformed within the terminal cavity  15  of the female terminal  11 . As the upper spring  12   a  and the lower spring  12   b  of the leaf spring structure  12  elastically press an inner surface of the female terminal  11 , the connection between the male terminal  19  and the female terminal  11  may be enhanced. Thus, an electrical contact between the male terminal  19  and the female terminal  11  may be reliably established. As the leaf spring structure  12  is provided at the end portion of the male terminal  19 , visual inspection and automatic dimensional measurement of the leaf spring structure  12  may be easily performed so that the quality of the leaf spring structure  12  may be reliably secured. 
     The housing  20  may have a mounting space  29  receiving a terminal position assurance (TPA) mechanism  50 . The mounting space  29  may be recessed in the second portion  22  of the housing  20 , and the mounting space  29  may be located between the first portion  21  and the second portion  22 . The mounting space  29  may communicate with the cavity  23  and the terminal passing holes  27 , and the TPA mechanism  50  may be movable within the mounting space  29  of the housing  20  in a height direction of the housing  20 . 
     The TPA mechanism  50  may have a plurality of terminal channels  51 , through which the plurality of female terminals  11  individually pass. The plurality of female terminals  11  may individually pass through the plurality of terminal channels  51  so that the TPA mechanism  50  may secure the positions of the plurality of female terminals  11 . The TPA mechanism  50  may be movable between a first position P 1  (see  FIGS. 9 and 10 ), in which the female terminal  11  is allowed to move in a longitudinal direction of the housing  20 , and a second position P 2  (see  FIG. 11 ), in which the female terminal  11  is not allowed to move in the longitudinal direction of the housing  20 . 
     Referring to  FIGS. 9 and 10 , when the TPA mechanism  50  is in the first position P 1 , the terminal channels  51  of the TPA mechanism  50  may be completely aligned with the terminal passing holes  27  of the first portion  21 . Thus, the female terminals  11  may be allowed to move through the terminal passing holes  27  of the first portion  21  and the terminal channels  51  of the TPA mechanism  50 . 
     Referring to  FIG. 11 , when the TPA mechanism  50  is in the second position P 2 , the terminal channels  51  of the TPA mechanism  50  may not be completely aligned with the terminal passing holes  27  of the first portion  21 . Thus, rear ends of the female terminals  11  may be stopped by the TPA mechanism  50  and the female terminals  11  may not be allowed to move. 
     Referring to  FIGS. 1, 2, 3, 16, and 17 , the joint connector  10  according to an embodiment of the present disclosure may include a first cover  41  and a second cover  42 , by which the housing  20  is entirely covered. The first cover  41  may be adjacent to the first portion  21  of the housing  20 , and the second cover  42  may face the first cover  41 . 
     The first cover  41  may have a plurality of insertion holes  47  aligned with the terminal passing holes  27  of the first portion  21  of the housing  20 . The female terminal  11  may be inserted into the insertion hole  47  and be received in the recess  26  of the cavity  23 . The first cover  41  may include a plurality of latch arms  43 . Each latch arm  43  may extend from the first cover  41  toward the housing  20 , and the latch arm  43  may have a first latch hook  45 . The first portion  21  of the housing  20  may have a plurality of first slots  21   a , and the seal block  30  may have a plurality of second slot  30   a . The plurality of first slots  21   a  may be aligned with the plurality of second slots  30   a  respectively. The latch arms  43  may be inserted into the first slots  21   a  and the second slots  30   a  respectively. The first latch hook  45  of each latch arm  43  may be snap-fitted to a back surface  21   b  of the first portion  21  so that the first cover  41  may be coupled to the housing  20 . 
     The second cover  42  may receive the housing  20  and the seal block  30 . The second cover  42  may have a ledge  44  extending toward the first cover  41 , and the ledge  44  may have a plurality of second latch hooks  46  protruding from an outer surface of the ledge  44  toward the first cover  41 . The first cover  41  may have a plurality of third slots  41   a . The second latch hooks  46  may be snap-fitted into the third slots  41   a  of the first cover  41  so that the second cover  42  may be coupled to the first cover  41 . 
     Referring to  FIG. 2 , the second cover  42  may have a plurality of support projections  48  holding the bus bar  17 . As each support projection  48  holds the bus bar  17 , the bus bar  17  may be stably supported in the cavity  23  of the housing  20 . 
     The joint connector  10  according to an embodiment of the present disclosure may include the seal block  30  tightly contacting or tightly attached to the housing  20 . The seal block  30  may be interposed between the first cover  41  and the first portion  21  of the housing  20 . For example, the seal block  30  may have a vertical cross section corresponding to that of the first portion  21  of the housing  20 . 
     The seal block  30  may be made of a material having elasticity and sealability, such as rubber. Referring to  FIG. 2 , the seal block  30  may have the plurality of receiving holes  31 , each of which receives the electrical wire  5  connected to the female terminal  11 . The receiving holes  31  may be aligned with the terminal passing holes  27  of the first portion  21  respectively, so that the female terminals  11  may pass through the receiving holes  31  and be located within the recesses  26 . 
     Referring to  FIGS. 2 and 3 , the seal block  30  may include a plurality of outer seal lips  33  protruding from an outer surface of the seal block  30  toward the first cover  41 , and a plurality of inner seal lips  32  protruding from an inner surface of each receiving hole  31  toward the center of the receiving hole  31 . Each outer seal lip  33  may be continuously formed along an outer peripheral edge of the seal block  30 . When the outer seal lip  33  contacts the ledge  44  of the second cover  42 , it may be deformed to seal an inner surface of the ledge  44 . Each inner seal lip  32  may be continuously formed along an inner peripheral edge of the receiving hole  31 . When the inner seal lip  32  contacts an outer surface of the electrical wire  5 , it may be deformed to seal the outer surface of the electrical wire  5 . 
     The seal block  30  may be located within the ledge  44  of the second cover  42 , and the ledge  44  of the second cover  42  may be interposed between a flange of the first cover  41  and the outer seal lips  33  of the seal block  30 . When the female terminal  11  is electrically connected to the male terminal  19  within the cavity  23  of the housing  20 , the inner seal lips  32  of the seal block  30  may tightly contact the outer surface of the electrical wire  5  connected to the female terminal  11 , and the inner seal lips  32  may be deformed with respect to the outer surface of each electrical wire  5 . Thus, the plurality of electrical wires  5  may be connected to the housing  20  in a sealing manner by one seal block  30 . When the second cover  42  is coupled to the first cover  41 , the plurality of outer seal lips  33  may tightly contact the ledge  44  of the second cover  42 , and the outer seal lips  33  may be deformed with respect to the ledge  44 . Thus, the sealability between the first cover  41  and the second cover  42  may be secured. 
     An assembly process of the joint connector  10  according to an embodiment of the present disclosure is described below. 
     First, the plurality of bus bars  17  may be mounted in the cavity  23  of the housing  20 . Referring to  FIG. 4 , two bus bars  17  may be press-fitted into the cavity  23  of the housing  20 . The upper bus bar  17  may be press-fitted to the top of the horizontal partition  24 , and the lower bus bar  17  may be press-fitted to the bottom of the second portion  22  of the housing  20 . As illustrated in  FIGS. 9 and 10 , the male terminals  19  of each bus bar  17  may be located in the recesses  26  of the housing  20 . 
     Then, as illustrated in  FIG. 5 , the TPA mechanism  50  may be received in the mounting space  29  of the housing  20 . Here, as illustrated in  FIGS. 9 and 10 , the TPA mechanism  50  may be in the first position P 1 , in which the female terminals  11  are allowed to move in the longitudinal direction of the housing  20 . 
     When the TPA mechanism  50  is in the first position P 1 , as illustrated in  FIG. 6 , the latch arms  43  of the first cover  41  may be inserted into the first slots  21   a  of the first portion  21  of the housing  20  and the second slots  30   a  of the seal block  30 . As illustrated in  FIGS. 7-9 , the first latch hooks  45  of the latch arms  43  may be coupled to the back surface  21   b  of the first portion  21  of the housing  20 , and the first cover  41  and the seal block  30  may be coupled to the first portion  21  of the housing  20 . 
     Thereafter, as illustrated in  FIG. 10 , the female terminals  11  may move toward the male terminals  19  located in the recesses  26  of the housing  20 . As illustrated in  FIG. 11 , when the female terminals  11  move to a position in which they are connected to the male terminals  19 , the engaging ends  28   a  of the locking lances  28  may engage with the engaging shoulders  16  of the female terminals  11 . When the engaging ends  28   a  of the locking lances  28  engage with the engaging shoulders  16  of the female terminals  11 , the leaf spring structures  12  of the male terminals  19  may be elastically coupled to the terminal cavities  15  of the female terminals  11 . The TPA mechanism  50  may move to the second position P 2  so that the positions of the female terminals  11  may be secured. 
     Then, the second cover  42  may move toward the first cover  41  as illustrated in  FIG. 16 , and the second latch hooks  46  of the second cover  42  may be snap-fitted into the third slots  41   a  of the first cover  41  as illustrated in  FIG. 17 . 
     As set forth above, according to embodiments of the present disclosure, the sealability between the wires  5  connected to the female terminals  11  and the housing  20  may be improved by the seal block  30  having the plurality of receiving holes  31 . In particular, compared to the related art, the joint connector  10  according to the embodiments of the present disclosure may achieve the sealability between the wires  5  connected to the female terminals  11  and the housing  20  using one seal block  30  so that the watertightness of the joint connector may be significantly improved. In particular, a gap between the electrical wires may be significantly reduced so that the size of the joint connector may be reduced, and the electrical wires may become thinner. 
     According to the embodiments of the present disclosure, the leaf spring structure  12  may be provided at the male terminal  19 . Thus, there is no concern about the deformation of the leaf spring structure  12  and the female terminal  11 , and the electrical contact between the male terminal  19  and the female terminal  11  may be reliably maintained. 
     According to the embodiments of the present disclosure, the male terminal  19  may have the leaf spring structure  12 , and the leaf spring structure  12  of the male terminal  19  may be elastically deformed within the terminal cavity  15  of the female terminal  11 . Thus, the connection between the male terminal  19  and the female terminal  11  may be enhanced, and the electrical contact between the female terminal  11  and the male terminal  19  may be reliably maintained within the housing  20 . In particular, as the leaf spring structure  12  is provided at the end portion of the male terminal  19 , the visual inspection and automatic dimensional measurement of the leaf spring structure may be easily performed. Thus, the quality of the leaf spring structure may be reliably secured. 
     Hereinabove, although the present disclosure has been described with reference to the specific embodiments and the accompanying drawings, the present disclosure is not limited thereto. The present disclosure may be variously modified and altered by those having ordinary skill in the art to which the present disclosure pertains without departing from the spirit and scope of the present disclosure claimed in the following claims.