Patent Publication Number: US-6991496-B2

Title: Electrical connector

Description:
CROSS REFERENCE TO RELATED APPLICATION 
   This application is based on Japanese Patent Application No. 2003-167870 filed on Jun. 12, 2003, the contents of which are incorporated herein by reference. 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to an electrical connector. Specifically, the electrical connector is connected to electrical wiring, which is connected to an electrical control unit (ECU), and has a circuit board for controlling a motor-driven actuator. 
   2. Description of Related Art 
   A connector having a circuit board for controlling an actuator for driving a door of a vehicle air conditioner is disclosed in JP-A-H11-275801. The connector has a housing, a circuit board, a wire connection, and an actuator connection. The circuit board is disposed within the housing, and a control circuit is mounted on the circuit board. The wire connection is connected to electrical wiring, which is connected to an ECU. The actuator connection is connected to a motor-driven actuator. 
   In such a connector, the control circuit produces a control signal in response to an input signal from the ECU via the electrical wiring. The control circuit sends the control signal to the motor-driven actuator to control the actuator. 
   The inventors considered an actuator control system by using the connectors. In the actuator control system, the connectors having the circuit boards are connected in parallel to the electrical wiring extending from the ECU. The connectors are connected to respective actuators. The ECU communicates with the each circuit board of the connector via the electrical wiring. The actuator control system controls a plurality of actuators by using a time division multiple communication. 
   In such an actuator control system, if one of the circuit boards in the connectors is broken down, all of the connectors and the electrical wiring can be integrally changed to new ones. However, this increases the cost. 
   Instead, as shown in  FIG. 14A-14C , only the connector  90   b  having the broken circuit board may be cut to remove it, and a new connector  90   d  may be electrically connected between connectors  90   a ,  90   c  through the electrical wiring W/H. However, it is difficult to connect the new connector because of the required processes, such as swage process, soldering process, and isolating process. 
   SUMMARY OF THE INVENTION 
   An object of the present invention is to provide an electrical connector that can be easily repaired. 
   According to one aspect of the present invention, the electrical connector has a housing, a circuit board, a harness terminal, and an actuator terminal. The circuit board is detachably housed in the housing. The harness terminal connects a wiring harness to the circuit board. The actuator terminal connects an actuator to the circuit board. 
   Since the circuit board is detachably housed in the housing, the circuit board can be easily changed without changing the entire structure of the wiring harness and the electrical connector. Therefore, it is easy to repair the circuit board with low cost. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description made with reference to the accompanying drawings. In the drawings: 
       FIG. 1  is a schematic diagram showing an air conditioner for a vehicle according to a first embodiment of the present invention; 
       FIG. 2  is a block diagram showing a control system of the air conditioner according to the first embodiment; 
       FIG. 3  is a schematic diagram showing an actuator according to the first embodiment; 
       FIG. 4  shows a schematic perspective view of a connector according to the first embodiment; 
       FIG. 5  shows another schematic perspective view of the connector according to the first embodiment; 
       FIG. 6A  is a schematic top view of another connector according to a second embodiment of the present invention; 
       FIG. 6B  is a schematic side view of the connector according to the second embodiment; 
       FIG. 7  is a schematic side view of the connector according to the second embodiment; 
       FIG. 8  is a schematic top view of another connector according to a third embodiment of the present invention; 
       FIG. 9A  is a schematic side view of the connector according to the third embodiment;. 
       FIG. 9B  is a schematic side view of an internal structure of the connector according to the third embodiment; 
       FIG. 9C  is a schematic side view of the connector according to the third embodiment; 
       FIG. 10  is a schematic top view of another connector according to a fourth embodiment of the present invention; 
       FIG. 11A  is a schematic side view of the connector according to the fourth embodiment; 
       FIG. 11B  is a schematic side view of an internal structure of the connector according to the fourth embodiment; 
       FIG. 11C  is a schematic side view of the connector according to the fourth embodiment; 
       FIG. 12  is a schematic top view of another connector according to a fifth embodiment of the present invention; 
       FIG. 13A  is a schematic side view of the connector according to the fifth embodiment; 
       FIG. 13B  is a schematic side view of an internal structure of the connector according to the fifth embodiment; 
       FIG. 13C  is a schematic side view of the connector according to the fifth embodiment; and 
       FIGS. 14A–14C  show a connector according to a related art. 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   The preferred embodiments of the present invention will be explained with reference to the accompanying drawings. In the drawing, the same numerals are used for the same components and devices. 
   [First Embodiment] 
     FIG. 1  shows a schematic diagram of an air conditioner  1  for a vehicle according to a first embodiment of the present invention. In the first embodiment, an electrical connector for an actuator is applied to the air conditioner  1 . 
   The air conditioner  1  has an air conditioner casing  2  as an air passage. An inside air suction port  3 , an outside air suction port  4 , and an inside/outside air switching door  5  are disposed upstream of the air conditioner casing  2 . The inside air suction port  3  sucks the inside air. The outside air suction port  4  sucks the outside air. The inside/outside air switching door  5  selectively opens and closes the inside air suction port  3  and the outside air suction port  4 . 
   A filter (not shown) and an air blower  7  are disposed downstream of the inside/outside air switching door  5 . The filter removes dust in the air. The air blower  7  sucks the air through the inside and outside air suction ports  3 ,  4 . Then, the air blower  7  blows the sucked air to each air blow port  14 ,  15 ,  17 . 
   An evaporator  9  is disposed downstream of the air blower  7 . The evaporator  9  cools the air blowing into a vehicle compartment. All of the air blown by the air blower  7  passes through the evaporator  9 . A heater core  10  is disposed downstream of the evaporator  9 . The heater core  10  heats the air blowing into the vehicle compartment. The heater core  10  uses coolant of an engine  11  as a heat source. 
   The air conditioner casing  2  has a bypass passage  12 . The airflow can bypass the heater core  10  through the bypass passage  12 . An air mix door  13  is disposed upstream of the heater core  10 . The air mix door  13  adjusts an airflow ratio between the quantity of the airflow flowing through the heater core  10  and the quantity of the airflow flowing through the bypass passage  12  to control the temperature of the air flowing into the vehicle compartment. 
   A face blowout port  14 , a foot blowout port  15 , and a defroster blowout port  17  are disposed at the most downstream of the air conditioner casing  2 . The face blowout port  14  blows conditioned air toward an upper body of a passenger in the vehicle compartment. The foot blowout port  15  blows the conditioned air toward a lower body of the passenger. The defroster blowout port  17  blows the conditioned air toward an inner surface of a windshield  16  of the vehicle. Blowout mode switching doors  18 ,  19 ,  20  are rotatably installed upstream of the face blowout port  14 , the foot blowout port  15 , and the defroster blowout port  17 , respectively. 
   The blowout mode switching doors  18 ,  19 ,  20 , the air mix door  13 , and the inside/outside air switching door  5  are opened and closed by respective motor-driven actuator  21 , such as a servomotor Mo. 
     FIG. 2  shows a block diagram of a control system of the air conditioner. As shown in  FIG. 2 , the actuators  21  are connected to respective electrical connectors  23 . An ECU  22  has a communication unit  22   a  and an ECU connector  24 . The actuators  21  are electrically connected to the communication unit  22   a  of the ECU  22  in series via the ECU connector  24 , wiring harnesses W/H, and the electrical connectors  23  for the actuators  21 . Each actuator  21  is controlled by the ECU  22 . 
   As shown in  FIG. 3 , the actuator  21  has the servomotor Mo, a reduction gear T, and an output gear G 4 . The reduction gear T has a plurality of gears G 1 , G 2 , G 3 . The output gear G 4  has a printed board  21   a . The printed board  21   a  has an arc shaped conductive portion and an arc shaped nonconductive portion. The printed board  21   a  is integrally rotated with the output gear G 4 . The actuator  21  also has a casing  21   b . The casing  21   b  has a plate contact  21   c . The plate contact  21   c  slidably contacts the printed board  21   a . The plate contact  21   c  and the printed board  21   a  constitute a potentiometer, which detects a rotational angle of the output gear G 4 . 
   The casing  21   b  also has male connectors  21   d . The male connectors  21   d  electrically connect to the plate contact  21   c  and the servomotor Mo. The detected signal for the rotational angle of the output gear G 4  and supply current for driving the servomotor Mo are sent and received via the male connectors  21   d.    
   The electrical connection between ECU  22  and each actuator  21  will be explained with reference to  FIGS. 4 ,  5 .  FIGS. 4 ,  5  show schematic diagrams of the electrical connector  23 . The electrical connector  23  is connected to an actuator side of the wiring harness W/H, which connects between the ECU  22  and the actuator  21 . 
   As shown in  FIGS. 4 ,  5 , the connector  23  has a connector housing  23   a . The connector housing  23   a  is made of resin, and has a rectangular shape. The connector housing  23   a  has a hole  233 . The connector housing  23   a  houses a circuit board  230 , first terminals  231 , and second terminals  232 . 
   The circuit board  230  is disposed in the hole  233 . An integrated circuit (IC)  23   b  is mounted on the circuit board  230 . A motor driving circuit and a communication circuit are integrated in the IC  23   b . That is, they are packed in one chip. The motor driving circuit produces a control signal to control the actuator  21  (the motor Mo). The communication circuit communicates different signals with the motor driving circuit and the ECU  22 . The different signals include a signal for controlling the motor driving circuit in response to an input signal from the ECU  22 . The different signals also include other signals that are produced from the potentiometer and the motor driving circuit. The motor driving circuit and the communication circuit constitute a control circuit of the present invention. 
   The first terminals  231  and the second terminals  232  are provided on the bottom of the hole  233 . The first terminals  231  are made of phosphor bronze or any other acceptable material. The first terminals  231  are integrally formed with respective harness terminals  23   d . Each first terminal  231  has a curved shape (a bent shape). The first terminals  231  contact respective first electrodes (not shown) provided on the underside of the circuit board  230 . 
   The second terminals  232  are made of phosphor bronze or any other acceptable material. The second terminals  232  are integrally formed with respective contact terminals  240 . Each second terminal  232  has a curved shape (a bent shape). The second terminals  232  contact respective second electrodes (not shown) provided on the underside of the circuit board  230 . 
   The connector housing  23   a  has a lid  250 . The hole  233  can be opened and closed by the lid  250 . Protrusions  251  are provided on the underside of the lid  250 . The protrusions  251  push the circuit board  230  against the first and second terminals  231 ,  232  when the lid  250  is closed. Accordingly, they improve contact performance between the circuit board  230  and the terminals  231 ,  232 . 
   The connector housing  23   a  has openings  23   c , which the male connectors  21   d  of the actuator  21  are plugged into. The contact terminals  240  are provided in respective openings  23   c . The contact terminals  240  are electrically connected to the respective second terminals  232 . The contact terminals  240  contact the male connectors  21   d  of the actuator  21  when the male connectors  21   d  are plugged into the openings  23   c.    
   The connector housing  23   a  also has the harness terminals  23   d . The harness terminals  23   d  are provided so that the harness terminals  23   d  protrude from the connector housing  23   a . The harness terminals  23   d  are electrically connected to the respective wiring harnesses W/H. The harness terminal  23   d  has V-shape notch  23   e  on its top end. The wiring harness W/H is electrically connected to the harness terminal  23   d  so that the wiring harness W/H is embedded in the V-shape notch  23   e  in a condition that the wiring harness W/H is held between the connector housing  23   a  and a cover  23   f.    
   In detail, when the wiring harness W/H is inserted in the V-shape notch  23   e , insulation coating of the wiring harness W/H is cut by the V-shape notch  23   e . Thus, a core wire within the insulation coating of the wiring harness W/H is electrically conducted to the harness terminal  23   d.    
   As shown in  FIG. 5 , the cover  23   f  has a C-shape at its cross section, and has joint openings  270 . Joint protrusions  260  of the connector housing  23   a  are inserted into the joint openings  270  so that the cover  23   f  is held onto the connector housing  23   a.    
   The harness terminals  23   d  have three terminals. One of the harness terminals  23   d  is used as a power line. Another terminal is used as a ground line. The other terminal is used as a command line (data communication line) for the control signal. The control signal is sent and received based on a certain protocol. 
   Next, a method for assembling the electrical connector  23  will be explained. The male connectors  21   d  of the actuator  21  are inserted into the openings  23   c  of the electrical connectors  23 . The male connectors  21   d  contact the respective contact terminals  240 . Accordingly, the male connectors  21   d  electrically connected to the respective second terminals  232  via the respective contact terminals  240 . 
   The cover  23   f  is pressed to the connector housing  23   a  in a condition that the wiring harnesses W/H are inserted in the respective V-shape notches  23   e . At that time, the cover  23   f  is elastically deformed in an arrow direction Y (shown in  FIG. 5 ) so that the cover  23   f  is broadened by the connector housing  23   a . Then, the joint protrusions  260  are inserted into the joint openings  270 . Thus, the cover  23   f  is held onto the connector housing  23   a.    
   At the same time, the insulation coating of the wiring harnesses W/H are cut by the V-shape notches  23   e , so that the core wire within the insulation coating of the wiring harnesses W/H are electrically connected to the harness terminals  23   d . Accordingly, the wiring harnesses W/H are electrically connected to the respective first terminals  231  via the respective V-shape notch  23   e  and the respective harness terminals  23   d.    
   After that, the lid  250  is opened by an operator. The circuit board  230  is disposed on the first and second terminals  231 ,  232  in the hole  233 . Then, the lid  250  is closed, so that the circuit board  230  is pushed by the protrusions  251 . The first and second terminals  231 ,  232  are elastically deformed, and the circuit board  230  is electrically connected to the first and second terminals  231 ,  232  at the first and second electrodes provided on the underside of the circuit board  230 . 
   If the circuit board  230  is broken down, the lid  250  is opened and the circuit board  230  is removed from the hole  233  by the operator. Then, a new circuit board  230  is provided on the terminals  231 ,  232  instead of the broken circuit board  230 , and the lid  250  is closed. At that time, as described above, the first and second terminals  231 ,  232  are elastically deformed, and the circuit board  230  is electrically connected to the first and second terminals  231 ,  232  at the first and second electrodes. 
   Since the circuit board  230  is detachable in the connector housing  23   a  as described above, it is easy to change the circuit board  230  independently even if the circuit board  230  is broken down. This reduces a cost of the change, and it is easy to repair the electrical connector  23 . 
   [Second Embodiment] 
   In the first embodiment, the circuit board  230  is disposed on the first and second terminals  231 ,  232  in the hole  233  of the connector housing  23   a  so that the circuit board  230  is electrically connected to the terminals  231 ,  232 . Instead, as shown in  FIGS. 6A ,  6 B, the second embodiment uses different first terminals  2311  and different second terminals  2321 . 
   An electrical connector  235  has a connector housing  23   a   1 . The connector housing  23   a   1  has a through-hole  2331 . The first terminals  2311  and the second terminals  2321  are provided in the through-hole  2331 . The first terminals  2311  are disposed on an inner wall of the through-hole  2331 , and are connected to the respective harness terminals  23   d . The second terminals  2321  are disposed on an opposite wall of the through-hole  2331 , and are connected to the respective contact terminals  240 . The terminals  2311 ,  2321  are elastically and independently deformed, so that the circuit board  230  is inserted between the first terminals  2311  and the second terminals  2321 . Electrodes of the circuit board  230  electrically contact the terminals  2311 ,  2321  at sides of the circuit board  230 . 
   As shown in  FIG. 7 , if the circuit board  230  is broken down, the circuit board  230  can be independently changed in the second embodiment as in the first embodiment. This reduces a cost of the change, and it is easy to repair the electrical connector  235 . 
   [Third Embodiment] 
   In the first and second embodiments, the circuit board  230  is removed from the hole  233  and the through-hole  2331 , and the new circuit board  230  is disposed. Instead, as shown in  FIGS. 8 ,  9 A– 9 C, the circuit board  230  is removed by disassembling a dividable connector housing  23   a   2  in the third embodiment. 
   In the third embodiment, as shown in  FIG. 8 , an electrical connector  236  has the dividable connector housing  23   a   2 . The connector housing  23   a   2  has a first housing  300   a  and a second housing  300   b . The connector housing  23   a   2  can be disassembled into the housings  300   a ,  300   b.    
   The first housing  300   a  has joints  310  on both of its sides. The joints  310  protrude toward the second housing  300   b  beyond a dividing surface  400  of the housings  300   a ,  300   b . The joints  310  have edge portions  3101 . The edge portions  3101  are wider than openings  321  of protrusions  320 . 
   The second housing  300   b  has the protrusions  320  on both of its sides. The protrusions  320  have respective openings  321 . The joints  310  are inserted into the openings  321 , so that the housings  300   a ,  300   b  are connected to each other. 
   As shown in  FIGS. 9A ,  9 B, first terminals  2312  are provided in the first housing  300   a . The first terminals  2312  are elastically deformed, and the circuit board  230  is held on its side by the first terminals  2312 . The first terminals  2312  are electrically connected to the electrodes of the circuit board  230 . 
   Second terminals  2322  are provided in the second housing  300   b . The second terminals  2322  are inserted into the circuit board  230  to be fixed to the circuit board  230 . The second terminals  2322  are electrically connected to the electrodes of the circuit board  230 . 
   As shown in  FIG. 9C , if the circuit board  230  is broken down, the connector housing  23   a   2  is disassembled. At that time, the second housing  300   b , the second terminals  2322 , and the circuit board  230  are integrally divided from the first housing  300   a . The combined part, which has the second housing  300   b , the second terminals  2322 , and the circuit board  230 , is changed to a new combined part in order to change the circuit board  230 . Instead, the second terminals  2322  and the circuit board  230  may be changed to new parts by further disassembling from the second housing  300   b.    
   [Fourth Embodiment] 
   In the third embodiment, the circuit board  230  is held on its side by the first terminals  2312  in the first housing  300   a , and the first terminals  2312  are electrically connected to the electrodes of the circuit board  230 . Instead, as shown in  FIGS. 10 ,  11 A– 11 C, different first terminals  2313  are electrically connected to the electrodes of the circuit board  230  via a relay board  410 . 
   In the fourth embodiment, an electrical connector  237  has a dividable connector housing  23   a   3 . The connector housing  23   a   3  has another first housing  300   a   1  and another second housing  300   b   1 . The connector housing  23   a   3  can be disassembled into the housings  300   a   1 ,  300   b   1 . The first terminals  2313  are provided in the first housing  300   a   1 . 
   The relay board  410  is made of conductive metal. The first terminals  2313  are inserted through the relay board  410 , and the relay board  410  is fixed to the first terminals  2313 . The relay board  410  is electrically connected to electrodes provided on the surface of the circuit board  230  at the backside of the relay board  410 . Thus, the first terminals  2313  are electrically connected to the circuit board  230  via the relay board  410 . 
   As shown in  FIG. 11C , if the circuit board  230  is broken down, the connector housing  23   a   3  is disassembled. At that time, the second housing  300   b   1 , the second terminals  2322 , and the circuit board  230  are integrally divided from the first housing  300   a   1  as in the third embodiment. The circuit board  230  is changed to a new circuit board  230  by changing the combined part, which has the second housing  300   b   1 , the second terminals  2322 , and the circuit board  230 . 
   [Fifth Embodiment] 
   In the third and fourth embodiments, the second housings  300   b ,  300   b   1 , the second terminals  2322 , and the circuit boards  230  are integrally divided from the first housings  300   a ,  300   a   1 . Instead, as shown in  FIGS. 12 ,  13 A– 13 C, the circuit board  230  can be independently changed by disassembling a dividable connector housing  23   a   4  in the fifth embodiment. 
   In the fifth embodiment, an electrical connector  238  has the dividable connector housing  23   a   4 . The connector housing  23   a   4  has a first housing  300   a   2  and a second housing  300   b   2 . The connector housing  23   a   4  can be disassembled into the housings  300   a   2 ,  300   b   2 . 
   As shown in  FIGS. 13A ,  13 B, the first terminals  2312  are provided in the first housing  300   a   2 , and second terminals  2323  are provided in the second housing  300   b   2 . Each of the first and second terminals  2312 ,  2323  has a curved shape (a bent shape) so that the first and second terminals  2312 ,  2323  are elastically and independently deformed and the circuit board  230  is electrically held between the first terminals  2312  and the second terminals  2323 . Therefore, if the circuit board  230  is broken down, the circuit board  230  is independently changed by disassembling the connector housing  23   a   4 . 
   [Another Embodiment] 
   The present invention should not be limited to the embodiments discussed above and shown in the figures, but may be implemented in various ways without departing from the spirit of the invention. 
   For example, in the foregoing embodiments, the wiring harnesses W/H are inserted in the V-shape notches  23   e , so that the core wires within the insulation coating of the wiring harnesses W/H are electrically connected to the harness terminals  23   d . Instead, the core wires can be electrically connected to the harness terminals  23   d  by other methods, such as soldering, pressure welding, and pressing. 
   In the foregoing embodiments, the electrical connector for the actuator is applied to the vehicle air conditioner. Instead, the electrical connector can be applied to other control systems for other actuators using other networks.