Patent Publication Number: US-11381031-B2

Title: Connector having a terminal fixed to a housing

Description:
BACKGROUND 
     A technique disclosed by this specification relates to a connector. 
     A joint connector described in Japanese Unexamined Patent Publication No. 2013-82256 is known as an example of a conventional connector. This joint connector includes a conductive plate, a plate-like reinforcing member and a housing. 
     The conductive plate is plate-like and includes a ground terminal provided on one end side and a terminal connecting portion provided on the other end side. The reinforcing member is plate-like and includes a body-side reinforcing portion provided on one end side and a housing-side reinforcing portion provided on the other end side. 
     The housing includes a receptacle open forward, and a mating connector is fit into the receptacle. A part of the terminal connecting portion of the conductive plate and a part of the housing-side reinforcing portion of the reinforcing member are embedded in a back wall of the receptacle by insert molding. A bolt is inserted through the ground terminal of the conductive plate and the body-side reinforcing portion, and fixed to a vehicle side. 
     SUMMARY 
     However, there has been a problem that stress is applied to boundary surfaces of the conductive plate and the reinforcing member with the back wall of the receptacle and the housing is broken if vibration from the vehicle is applied to the ground terminal and a bolt fixing portion. 
     A connector disclosed in this specification is a connector with a terminal, and a housing to which the terminal is fixed, wherein the terminal includes a plate-like first connection, a holder projecting in one direction intersecting the first connection from a side edge of the first connection, and a second connection projecting in the one direction from a side edge of the first connection and facing the holder, the holder and the second connection being fixed in the housing. 
     Since the terminal is fixed at two points, i.e. at the holder and the second connection, in the housing, breakage in a boundary surface of the housing with the terminal can be prevented as compared to the case where the terminal is fixed at one point as before since a load applied to the boundary surface of the housing with the terminal is distributed to two points. 
     Further, since the terminal is fixed at two points, i.e. at the holder and the second connection in the housing, the terminal having a lower linear expansion coefficient than the housing suppresses a dimensional variation of the housing even if the housing thermally expands or contracts to cause the dimensional variation. In this way, the dimensional variation of the housing due to thermal expansion or contraction can be suppressed. 
     Further, the holder may include a first base end projecting in the one direction from the side edge of the first connection, and a holding piece projecting in the one direction from the first base end and longer in a width direction than the first base end. 
     Since the holding piece of the holder is longer in the width direction than the first base end, even if the holder fixed in the housing is going to come out from the housing, the holder is caught in the housing. In this way, the holder is prevented from coming out from the housing. 
     Further, the second connection may include a second base end projecting in the one direction from the side edge of the first connection, and a hollow cylinder projecting in the one direction from the second base end. 
     By providing the second connection with the second base end and the hollow cylinder, the second base end can be fixed in the housing, the outer surface of the hollow cylinder can be exposed from the housing and the hollow cylinder can serve as a contact portion with a mating terminal. 
     According to the connector disclosed in this specification, it is possible to prevent breakage occurring in the boundary surface between the terminal and the housing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front view of a connector of an embodiment, 
         FIG. 2  is a plan view of the connector, 
         FIG. 3  is a back view of the connector, 
         FIG. 4  is a section along A-A in  FIG. 3 , 
         FIG. 5  is a plan view of a terminal, and 
         FIG. 6  is a section of the terminal. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Embodiment 
     An embodiment is described with reference to  FIGS. 1 to 6 . 
     A connector  10  of this embodiment is a connector linking a battery of a vehicle and a PCU (Power Control Unit) and includes, as shown in  FIG. 4 , a housing  20  and two terminals  50  fixed to the housing  20  by insert molding. In the following description, a Z direction and an X direction of  FIGS. 1 and 4  are referred to as an upward direction and a rightward direction, and a Y direction of  FIGS. 2 and 3  is referred to as a forward direction. 
     As shown in  FIGS. 1, 2 and 4 , the housing  20  includes a cylindrical base portion  22  elliptical in a plan view, and a receptacle  40  open upward from the base portion  22 . An unillustrated mating connector is fit into the receptacle  40  from above. 
     A pair of first terminal fixing portions  24  project downward from side edges on both sides of the base portion  22 , and a pair of first pedestal portions  25  project toward the different terminal fixing portions  24  from lower ends of the pair of first terminal fixing portions  24 . Lower ends of the pair of first pedestal portions  25  are located below the lower ends of the pair of first terminal fixing portions  24 . Further, a second terminal fixing portion  26  projects downward from a central part of the base portion  22  and a pair of second pedestal portions  27  project toward the pair of first terminal fixing portions  24 . Lower ends of the pair of second pedestal portions  27  are located below a lower end of the second terminal fixing portion  26 . Further, a first partition wall  28  projects downward from the lower end of the second terminal fixing portion  26 . The pair of first terminal fixing portions  24  and the second terminal fixing portion  26  face each other, and spaces between facing surfaces of the pair of first terminal fixing portions  24  and the second terminal fixing portion  26  serve as accommodation spaces S 1  capable of accommodating cases  72  to be described later as shown in  FIGS. 1 and 4 . 
     As shown in  FIG. 4 , an inner tube portion  30  projects upward from the base portion  22 . As shown in  FIG. 2 , the inner tube portion  30  is in the form of a tube elliptical in a plan view and disposed inside the receptacle  40 . The upper end position of the inner tube portion  30  is located below that of the receptacle  40  as shown in  FIG. 4 . 
     As shown in  FIG. 4 , a pair of first projecting portions  32  project upward from the base portion  22 . The pair of first projecting portions  32  are in the form of bars and disposed at a predetermined distance from each other in the inner tube portion  30 . Tip parts  34  having round tips are provided to project upward on upper end parts of the first projecting portions  32 . An outer diameter of a lower end of the tip part  34  is larger than that of the first projecting portion  32 , and the first projecting portion  32  and the tip part  34  are coaxially disposed. 
     As shown in  FIG. 4 , a second partition wall  36  projects upward from an upper end part of the base portion  22 , and disposed between the pair of first projecting portions  32 . The second partition wall  36  functions as an insulation wall for insulating between the pair of terminals  50  to be described later. The positions of front end parts of the first projecting portions  32  and the second partition wall  36  are located below an upper end opening edge of the inner tube portion  30 . 
     Grooves are provided respectively on upper and lower sides of the outer peripheral surface of the receptacle  40 , wherein the upper groove serves as a first groove portion  42  and the lower groove serves as a second groove portion  44 . A first rubber ring  88  is fit in the first groove portion  42 , and a second rubber ring  90  is fit in the second groove portion  44 . 
     As shown in  FIGS. 1 to 4 , a plate-like second projecting portion  46  projects leftward from the outer peripheral surface of the receptacle  40 . As shown in  FIG. 4 , the second projecting portion  46  is provided between the first and second groove portions  42 ,  44 . A fastening hole  48  is open in the second projecting portion  46 , and a hollow cylindrical first collar  86  is mounted in the fastening hole  48 . Although not shown, a bolt is inserted through the first collar  86  and fixed to a mating member. 
     As shown in  FIG. 5 , the terminal  50  is formed by press-working and bending a thin copper plate and includes a first connecting portion  52  (first connector), a holding portion  56  (holder) and a second connecting portion  62  (second connector) to be connected to a mating terminal. 
     The first connecting portion  52  is in the form of a rectangular plate and a fastening hole  54  to which a bolt can be fastened is open in the first connecting portion  52 . As shown in  FIG. 4 , the first connecting portion  52  is in contact with the lower surfaces of the pair of first pedestal portions  25  and the lower surfaces of the second pedestal portions  27 . 
     As shown in  FIGS. 4, 5 and 6 , the holding portion  56  includes a plate-like first base end portion  58  (first base end) projecting upward from a side edge of the first connecting portion  52  and a plate-like holding piece  60  projecting upward from the first base end portion  58 . The holding portion  56  of the terminal  50  is embedded in the first terminal fixing portion  24  of the housing  20  as shown in  FIG. 4 . Here, a boundary of the housing  20  with the holding portion  56  serves as a boundary surface S 2 . 
     A length in a width direction of the holding piece  60  is longer than that of the first base end portion  58  as shown in  FIG. 5 , whereby the terminal  50  is prevented from coming out from the first terminal fixing portion  24 . 
     As shown in  FIGS. 4 and 5 , the second connecting portion  62  projects upward from a side edge of the first connecting portion  52  and includes a second base end portion  64  (second base end) located at a position facing the holding portion  56  and a hollow cylindrical portion  66  (hollow cylinder) projecting upward from the second base end portion  64 . Here, an outer diameter of the hollow cylindrical portion  66  is about 3 mm. Further, a plate thickness of the terminal  50  is so set that resin can be filled into the hollow cylindrical portion  66  during insert molding while an outer diameter criterion of the hollow cylindrical portion  66  is satisfied. 
     As shown in  FIG. 4 , the hollow cylindrical portion  66  is provided with a positioning portion  68  cut and raised from the hollow cylindrical portion  66  toward the second partition wall  36  of the housing  20 . The positioning portion  68  is used to position a mold during insert molding. 
     As shown in  FIG. 4 , the second connecting portion  62  is embedded in the housing  20  from the second base end portion  64  to an upper end part of the positioning portion  68 . Here, a boundary of the housing  20  with the second connecting portion  62  serves as a boundary surface S 3 , which is located between the lower and upper ends of the second pedestal portion  27 . Since the terminal  50  is fixed to the housing  20  at two points, i.e. at the holding portion  56  and the second connecting portion  62 , via the boundary surfaces S 2  and S 3  in this way, the terminal  50  having a lower linear expansion coefficient than the housing  20  suppresses a dimensional variation of the housing  20  even if the housing  20  thermally expands or contracts to cause the dimensional variation. In this way, the dimensional variation of the housing  20  due to thermal expansion or contraction can be suppressed. 
     As shown in  FIG. 4 , a part of the hollow cylindrical portion  66  above the upper end part of the positioning portion  68  is exposed to outside, and the first projecting portion  32  of the housing  20  is located inside the hollow cylindrical portion  66 . The hollow cylindrical portion  66  serves as a route for resin when the tip part  34  is formed. Further, an upper end of the hollow cylindrical portion  66  is in contact with a lower end of the tip part  34  of the housing  20 . By the contact of the hollow cylindrical portion  66  with the mating terminal, the terminal  50  is electrically connected to the mating terminal. Since the tip part  34  of the housing  20  is provided on the upper end part of the hollow cylindrical portion  66 , the contact of a user&#39;s finger or the like with the hollow cylindrical portion  66  is prevented when the finger or the like intrudes into the receptacle  40 . 
     As shown in  FIGS. 1 and 4 , the case  72  is in the form of a box with an open lower wall, and a fixing hole  74  is open in an upper wall. A second collar  76  is accommodated in the fixing hole  74 . Further, a nut  78  is accommodated between the second collar  76  and the terminal  50 . An unillustrated bolt is inserted into the fastening hole  54  of the first connecting portion  52  of the terminal  50  and threadably engaged with the nut  78 . The second collar  76  serves as an escaping hole for the bolt. As shown in  FIG. 4 , the lower surfaces of both side walls of the cases  72  can be in contact with the upper surfaces of the pair of first pedestal portions  25  and the upper surfaces of the pair of second pedestal portions  27 , and downward displacements of the cases  72  accommodated in the accommodation spaces S 1  of the housing  20  are restricted. 
     Next, functions of this embodiment are described. 
     The connector  10  is connected to the mating connector, and unillustrated mating round terminals are fixed to the first connecting portions  52  of the terminals  50  by the bolts. If vibration is applied to the connector  10  from the vehicle thereafter, a phase difference is generated between the vibration of the terminals  50  fixed to the mating round terminals and the vibration of the housing  20  connected to the mating connector, whereby a load is applied to the boundary surfaces S 2  and S 3 . However, since each terminal  50  is fixed to the housing  20  at two positions via the boundary surfaces S 2 , S 3 , the load applied to the housing  20  is distributed to two points as compared to the case where a terminal is fixed to a housing at one point as before. Thus, the breakage of the housing  20  in the boundary surfaces S 2 , S 3  between the terminal  50  and the housing  20  can be prevented. Further, by fixing the terminal  50  to the housing  20  at two points, the terminal  50  is integrated with the housing  20  and the terminal  50  is less likely to be broken by vibration as compared to the case where the terminal  50  is fixed at one point. Therefore, the breakage of the terminal  50  can be prevented even if the plate thickness of the terminal  50  is such a small thickness that the diameter of the hollow cylindrical portion  66  is about 3 mm and resin can pass into the hollow cylindrical portion  66 . 
     As described above, according to this embodiment, since the terminal  50  is fixed at two points, i.e. at the holding portion  56  and the second connecting portion  62 , in the housing  20 , a load applied to the boundary surfaces S 2 , S 3  of the housing  20  with the terminal  50  can be distributed to two points as compared to the case where a terminal is fixed at one point in a housing as before. Thus, breakage in the boundary surfaces S 2 , S 3  of the housing  20  with the terminal  50  can be prevented. 
     Further, since the terminal  50  is fixed at two position, i.e. at the holding portion  56  and the second connecting portion  62 , in the housing  20 , even if the housing  20  thermally expands or contracts to cause a dimensional variation, the terminal  50  having a lower linear expansion coefficient than the housing  20  suppresses the dimensional variation of the housing  20 . In this way, the dimensional variation of the housing  20  due to thermal expansion or contraction can be suppressed. 
     Further, since the holding piece  60  of the holding portion  56  is longer in the width direction than the first base end portion  58 , even if the holding portion  56  fixed in the housing  20  is going to come out from the housing  20 , the holding piece  60  is caught in the housing. In this way, the holding portion  56  is prevented from coming out from the housing  20 . 
     By providing the second connecting portion  62  with the second base end portion  64  and the hollow cylindrical portion  66 , the second base end portion  64  can be fixed in the housing  20 , the outer surface of the hollow cylindrical portion  66  can be exposed from the housing  20  and the hollow cylindrical portion  66  can serve as a contact portion with the mating terminal. 
     Other Embodiments 
     The technique disclosed by this specification is not limited to the above described and illustrated embodiment. For example, the following various modes are also included. 
     (1) Although the first connecting portion  52  is in the form of a rectangular plate in the above embodiment, the shape of the first connecting portion  52  does not matter and may be in the form of a circular plate. 
     (2) Although the holding portion  56  and the second connecting portion  62  are embedded in the housing  20  and the terminal is fixed at two points in the housing  20  in the above embodiment, other holding portion(s) may be added to the terminal and the terminal may be fixed at three or more points in the housing  20 . 
     (3) Although two terminals  50  are provided in the above embodiment, one, three or more terminals may be provided.