Patent Publication Number: US-7901219-B2

Title: Connecting structure for accessory device and cable, waterproofing structure for accessory device, and mounting structure for accessory device

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to auxiliary machineries composed of electrical components, such as sensors, that are installed in automobiles and the like. More specifically, the present invention relates to a connecting structure for a auxiliary machinery and a cable and a waterproofing structure for the auxiliary machinery in which the space required for mounting the auxiliary machinery and for connecting the auxiliary machinery to the cable in a wire harness interconnecting auxiliary machineries can be made smaller, and the number of component parts can be reduced. The present invention further relates to a mounting structure for the auxiliary machinery in which the size of the space required for mounting the auxiliary machinery to a member in which the auxiliary machinery is mounted (hereinafter called “receiving member”) can be reduced. 
     Priority is claimed on Japanese Patent Applications Nos. 2002-287407 and 2002-287408, filed Sep. 30, 2003, the content of which is incorporated herein by reference. 
     2. Description of the Related Art 
     As shown in  FIGS. 11 and 12 , it has been the conventional practice to electrically connect an auxiliary machinery  100 , such as a sensor to be installed in an automobile or the like, by attaching a connector  111 , which houses a connection terminal that is connected to a cable  112  in a wire harness, to a connector engaging member  102  in housing  101 , which houses a sensor board  109  and the like. Since a high degree of water resistance may be required of this type of auxiliary machinery  100  depending on where it is to be installed, a complete waterproofing process is performed on auxiliary machinery  100  by, for example, filling the inside of housing  101  with a sealer  108  such as silicon grease in order to seal (waterproof) sensor board  109  and connector engaging member  102 , and then covering this filled area with a cover  107 . Naturally, a waterproofing process using a sealer or the like is also carried out to the areas of connection between connector  111  and connector engaging member  102 . An auxiliary machinery  100  with this type of design is usually firmly mounted to its site of attachment, i.e., receiving member  120 , on a panel, etc., using a fastening member  121  such as a clip (see Japanese Patent Applications, First Publication Nos. 5-346461, 2002-184514, and 2002-231375, for example). 
     However, in the above-described auxiliary machinery  100 , a connector  111  is required in order to connect housing  101  and cable  112 . For this reason, it is necessary to ensure that there is adequate space to permit connection in the direction indicated by arrow h 1  in  FIG. 11 . In addition, about the same amount of space is needed in order to dispose auxiliary machinery  100 . Further, when waterproofing this type of auxiliary machinery  100 , other parts, such as silicon grease  108  or cover  107 , are separately required to complete the process, so that the number of components increases. 
     In addition, because auxiliary machinery  100  is mounted to receiving member  120  via fastening member  121 , a space for inserting and withdrawing fastening member  121  into/out of housing  101  is required in the direction indicated by arrow h 2  in  FIG. 11 . For this reason, the overall space required to dispose auxiliary machinery  100  increases. 
     SUMMARY OF THE INVENTION 
     The present invention was conceived in view of the above-described circumstances and has as its objective the provision a connecting structure and a waterproofing structure for an auxiliary machinery and a cable, in which it is possible to reduce the space required for connecting the auxiliary machinery and the cable and the space required for mounting the auxiliary machinery to a receiving member, and to decrease the number of parts required for waterproofing. 
     It is a further objective of the present invention to provide a mounting structure for the auxiliary machinery in which the amount of the space required for disposing the auxiliary machinery to the receiving member can be reduced. 
     The connecting structure for auxiliary machinery and cable according to the present invention is a structure for connecting a cable in which a plurality of conductors are surrounded by an insulating covering and arrayed in a flat configuration and an auxiliary machinery that attaches directly to this cable; and characterized in that the auxiliary machinery is provided with a housing being equipped with a board on which electronic components are mounted and to which a specific circuitry pattern has been formed, a connection terminal that is connected to the circuitry pattern on the board and to at least one conductor among the conductors of the cable, and a molded part for sealing the connections between the connection terminal of the housing and the conductors of the cable; and the cable is disposed so as to extend along the outside of the auxiliary machinery. 
     The waterproofing structure for auxiliary machinery according to the present invention is a structure for waterproofing an auxiliary machinery that is directly connected to a cable in which a plurality of conductors are surrounded by an insulating covering and arrayed in a flat configuration; and characterized in that the auxiliary machinery is provided with a housing being equipped with a board on which electronic components are mounted and to which a specific circuitry pattern has been formed, a connection terminal that is connected to the circuitry pattern on the board and to at least one conductor among the conductors of the cable, and a molded part for sealing the connections between the connection terminal of the housing and the conductors of the cable. 
     In the present invention, the cable can be directly connected to the auxiliary machinery without using a connector, and is disposed so as to extend along the outside of the auxiliary machinery. As a result, it is possible to decrease the space needed for connecting the auxiliary machinery with the cable, as well as to reduce the space required for disposing the auxiliary machinery to a receiving member. In addition, in the present invention, a molded part is used to seal the connection portion between the connection terminals of the housing of the auxiliary machinery and the conductors of the cable. As a result, waterproofing components such as silicon grease or covers that were required in the conventional art are not needed in the present invention, making it possible to reduce the number of parts. 
     Note that it is also acceptable to directly couple the auxiliary machinery to the end of the cable, by directing the end of the cable toward the proximal end portion of the housing of the auxiliary machinery and connecting the conductors near the end of the cable to the proximal end portion of the connecting terminal along a direction that is perpendicular to the axes of the conductors; in this arrangement, the cable is installed so as to lie along the outside of the housing extending over a specific distance from the proximal end to the distal end of the housing, and such that the axes of the conductors bend in a direction perpendicular to the side of the housing. By disposing the cable in this way, it is possible to effectively prevent an increase in the space required for connecting and disposing the auxiliary machinery. 
     The mounting structure for auxiliary machinery according to the present invention is a structure for mounting an auxiliary machinery that is directly coupled to a cable in which a plurality of conductors are surrounded by an insulating covering and arrayed in a flat configuration to a receiving member, characterized in that: the receiving member is provided with a mounting hole for mounting the auxiliary machinery; and the auxiliary machinery is provided with a housing in which a distal end thereof can engage in the mounting hole and being equipped with a board on which electronic components are mounted and to which a specific circuitry pattern has been formed, a connection terminal which connects with the circuitry pattern on the board and with at least one of the conductors of the cable, a retainer that attaches to the distal end of the housing and the outer periphery of which engages in the mounting hole of the receiving member, and a molded part that seals the connecting portion between the connection terminal of the housing and the conductors of the cable; and wherein, the auxiliary machinery is mounted to the receiving member by attaching the retainer in the mounting hole from one side of the receiving member, and attaching the housing of the auxiliary machinery to the retainer from the other side of the receiving member. 
     In the present invention, the auxiliary machinery is mounted to the receiving member by attaching the retainer in the mounting hole from one side of the receiving member and attaching the housing to the retainer which has attached to the receiving member from the other side of the receiving member. As a result, it is not necessary to provide space at the auxiliary machinery housing mounting side of the receiving member, for inserting or withdrawing fastening members such as the clips that have been employed in the conventional art. Thus, the overall space needed to dispose the auxiliary machinery can be reduced. 
     Note that it is preferable that the retainer is provided with a collar for interlocking with the periphery of the mounting hole from the side opposed to the side in which the housing is attached, a projecting part for interlocking with the periphery of the mounting hole from the side in which the housing is attached, and an interlocking projection that interlocks with the housing. 
     Alternatively, it is preferable that the retainer is provided with a collar for interlocking with the periphery of the mounting hole from the side opposed to the side in which the housing is attached and an interlocking projection that interlocks with the housing. In this case, the auxiliary machinery be mounted and firmly fixed to the receiving member in a state such that the peripheries of either open side of the mounting hole are held between the collar of the retainer and the distal end of the housing after it has been mounted in the retainer. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a disassembled diagonal perspective view of an auxiliary machinery, omitting a portion thereof, in which the connecting structure for auxiliary machinery and cable and the water proofing structure according to an embodiment of the present invention are employed. 
         FIG. 2  is a diagonal perspective view for showing a cross-section through the cable connected to the auxiliary machinery. 
         FIG. 3A  is a perspective view for explaining the connecting structure for auxiliary machinery and cable according to an embodiment of the present invention, with a portion of the auxiliary machinery omitted from the figure. 
         FIG. 3B  is a perspective view for explaining the connecting structure for auxiliary machinery and cable according to an embodiment of the present invention, with a portion of the auxiliary machinery omitted from the figure. 
         FIG. 4A  is a perspective view for explaining the waterproofing structure for auxiliary machinery according to an embodiment of the present invention. 
         FIG. 4B  is a perspective view for explaining the waterproofing structure for auxiliary machinery according to an embodiment of the present invention. 
         FIG. 5  is a schematic partial cross-section for explaining the auxiliary machinery mounted in a receiving member. 
         FIG. 6  is a disassembled diagonal perspective for explaining the mounting structure for the auxiliary machinery according to an embodiment of the present invention. 
         FIG. 7  is a cross-sectional view along the line A-A′ in  FIG. 6  for explaining the mounting structure for mounting the auxiliary machinery to the receiving member. 
         FIG. 8  is a cross-sectional view along the line B-B′ in  FIG. 6  for explaining the mounting structure for mounting the auxiliary machinery to the receiving member. 
         FIG. 9A  is a perspective view for explaining the connecting structure for auxiliary machinery and cable according to another embodiment of the present invention, omitting a portion of the structure. 
         FIG. 9B  is a perspective view for explaining the waterproofing structure for auxiliary machinery according to another embodiment of the present invention. 
         FIG. 10  is a cross-sectional view of the mounting structure for auxiliary machinery according to another embodiment of the present invention. 
         FIG. 11  is a side view for explaining a conventional mounting structure for auxiliary machinery, showing a cross-section through one portion thereof. 
         FIG. 12  is a disassembled side view for simply explaining a conventional waterproofing structure for auxiliary machinery, showing a cross-section through one portion thereof. 
     
    
    
     PREFERRED EMBODIMENTS OF THE INVENTION 
     Preferred embodiments of the present invention will now be explained with reference to the accompanying figures. 
       FIG. 1  is a disassembled diagonal perspective view of an auxiliary machinery, omitting a portion thereof, in which the connecting structure for auxiliary machinery and cable and the waterproofing structure according to an embodiment of the present invention are employed.  FIG. 2  is a diagonal perspective view for showing a cross-section through the cable that is connected to this same auxiliary machinery.  FIGS. 3A and 3B  are perspective views for explaining the connecting structure for auxiliary machinery and cable according to an embodiment of the present invention, a portion of the auxiliary machinery being omitted from the figures.  FIGS. 4A and 4B  are perspective views for explaining the waterproofing structure for auxiliary machinery according to an embodiment of the present invention. 
     As shown in  FIG. 1 , sensor  1 , which is the auxiliary machinery employed in this example, is provided with a housing  11  consisting of a resin molded product, for example, a board  12  that is housed within housing  11 , a sensor component  13  that is mounted on board  12 , a connection terminal  14  that is connected to board  12 , a retainer  20  which mounts on the distal end of housing  11 , and a molded part (omitted from this figure) that is formed at the proximal end of housing  11  and will be explained below later. A retainer engaging member  15  for engaging retainer  20  is formed at the distal end of housing  11 , and an exposed connecting portion  18  is formed at the proximal end of housing  11 . Exposed connecting portion  18  provides exposed a board side connecting portion  16  for connecting the board  12  and connection terminal  14 , and a terminal side connecting portion  17  for connecting the connection terminal  14  and conductor  4  being positioned opposite side of board side connecting portion  16  with connection terminal  14  intervening therebetween. An interlocking piece  19  is formed to part of housing  11  so that when retainer  20  is completely engaged in retainer engaging member  15 , this interlocking piece  19  interlocks with an interlocking projection  21  that is formed to retainer  20 , thereby stopping retainer  20  in housing  11  and holding it fast there (note that this interlocking projection  21  and interlocking piece  19  comprise the retainer interlocking mechanism). 
     Retainer  20  is provided with an engaging hole  22  in which retainer engaging member  15  of housing  11  engages, a collar  23  which interlocks with the periphery of a mounting hole that is formed in a panel, i.e., the receiving member here that will be explained further below, from the side opposite to the side of attachment of housing  11 , and an interlocking claw  24  which interlocks with the periphery of the mounting hole on the side of attachment of housing  11  for mounting and fixing in place retainer  20  in the panel. 
     As shown in  FIG. 2 , cable  2  is a flat cable wherein rod-shaped conductors  4   a ,  4   b ,  4   c ,  4   d  and  4   e  comprising single or stranded wire formed from Cu or Al, for example, are covered by an insulating covering  5  consisting of an insulating resin such as polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyimide (PI), polyolefin (PO), or the like, and the insulating coverings  5  are joined to each other by a bridging member  5   a  consisting of the same insulating resin as that of insulating covering  5 . Note that it is also acceptable for flat cable  2  to be a flexible flat cable having a structure wherein rectangular column shaped conductors are covered with an insulating covering  5  that is formed to be flat by means of a laminator or extrusion. Flat cable  2  may also be a so-called wire harness in which a plurality of conductors  4  are bundled into the form of a harness. 
     Cable  2  is disposed so as to extend along the outside of sensor  1  and is connected to housing  11  of sensor  1  as shown in  FIGS. 3A and 3B  for example. In other words, cable  2  is connected to housing  11  at terminal side connecting portion  17 , by directing one end  2   a  of cable  2  toward the proximal side of housing  11 , and connecting the conductors  4  (i.e.,  4   a ,  4   c , and  4   e  here) near cable end  2   a  to pressure welded parts  14   a  which are positioned on the tip end of connection terminal  14  along a direction that is perpendicular to the axes of the conductors  4 . Regarding connection terminal  14 , note that it is a pressure welded terminal in which the tips of these pressure welded parts  14   a  are divided into two parts, with conductors  4  being held between these divided parts and weld-connected. The cable  2  connected to housing  11  in this way is installed to lie along the side of housing  11 , extending a specific range from the proximal side to the distal side of housing  11 , and in an arrangement such that the axial direction of each of conductors  4   a ˜ 4   e  is curved so as to extend along the direction of their connection to pressure welded parts  14   a  in connection terminal  14 , i.e., cable  2  is bent in a direction that is perpendicular to the side of housing  11 . 
     In this way, cable  2  can be connected to sensor  1  by directly connecting to housing  11 , without employing a connector or the like. As a result, as shown in  FIG. 5 , when sensor  1  is mounted in mounting hole  96  in panel  97 , the space  98  needed for connecting sensor  1  and cable  2  can be greatly reduced, and the space  99  needed to dispose sensor  1  can be made smaller as well. 
     The tip parts  14   b  of connection terminal  14  pass through board  12  and are connected to a circuit (not shown) on board  12  by soldering for example, at board side connecting portion  16  which is positioned opposite side of terminal side connecting portion  17  with connection terminal  14  interposed therebetween. 
     In housing, the area of connection between board  12  and connection terminal  14  and the area of connection between conductor  4  and connection terminal  14  are exposed at exposed connecting portion  18  which is consisting of board side connecting portion  16  and terminal side connecting portion  17 . Since waterproofing treatment is not carried out on exposed connecting portion  18 , this could prove problematic depending on where sensor  1  is installed. Therefore, as shown in  FIG. 4 , a molded part  9  ( 9   a ,  9   b ) is formed to the proximal side of housing  11  for sealing board side connecting portion  16  and terminal side connecting portion  17  by encompassing exposed connecting portion  18  in a unitary manner with housing  11 . 
     This molded part  9  ( 9   a ,  9   b ) is formed by filling a mold with a molding resin such as a hot melt resin and then hardening it. Molded part  9  is formed in a unitary manner to conform to the shape of exposed connecting portion  18  on housing  11 . By forming molded parts  9   a ,  9   b  to housing  11  in this way, it is possible to carry out a waterproofing treatment to exposed connecting portion  18 , which consists of board side connecting portion  16  and terminal side connecting portion  17 , without requiring silicon grease, covers, etc., as was the case in the conventional art. Moreover, the connection between pressure welded parts  14   a  of connection terminal  14  and conductor  4  of cable  2  at terminal side connecting portion  17  can be strongly maintained. As a result, the number of parts required for waterproofing sensor  1  can be reduced. 
     Note that each of the molded parts  9   a ,  9   b  in the molded part  9  in this example were formed separately. However, as shown in  FIG. 5 , it is also acceptable to mold the entire proximal side of housing  11 , and form molded part  9  such that it seals exposed connecting portion  18  of housing  11 . 
     The sensor  1  having this type of structure is mounted to a panel  97  as shown specifically in  FIGS. 6 through 8 . In this case, first, as shown in  FIG. 6 , housing  11  and retainer  20  are disposed to either side of panel  97  so that retainer engaging member  15  on housing  11  and the retainer  20  side that attaches to housing  11  (i.e., the side opposite where collar  23  is formed) face one other with mounting hole  96  in panel  97  interposed therebetween. Next, as shown in  FIGS. 7 and 8 , interlocking claw  24  (not shown in the figures) is passed through mounting hole  96  in panel  97 , and attaching retainer  20  to panel  97  on the side opposite where housing  11  attaches. Retainer  20  interlocks and is held in place in panel  97  in this case because the periphery of mounting hole  96  in panel  97  is held between the collar  23  and interlocking claw  24  of retainer  20 . Next, by engaging retainer engaging part  15  of housing  11  in engaging hole  22  of retainer  20 , interlocking projection  21  of retainer  20  and interlocking piece  19  of housing  11  interlock, so that housing  11  interlocks and is held fast in retainer  20 . As a result, sensor  1  can be mounted and firmly held in place in panel  97  with surety and ease. 
     Note that, as described above, exposed connecting portion  18 , consisting of board side connecting portion  16  and terminal side connecting portion  17 , on the proximal side of housing  11  are completely sealed by molded parts  9   a ,  9   b  ( 9   a  is omitted from the figure). As a result, moisture has no effect on board  12  or connection terminal  14 . In addition, since cable  2  lies along the side of housing  11  in sensor  1  and extending a specific range from the proximal end to the distal end of the housing, and bends so as to extend along the direction of its connection to connection terminal  14 , and this cable  2  is further installed so as to extend along surface  97   a  of panel  97 , the space needed for disposing sensor  1  on panel  97  can be reduced. 
     In addition, sensor  1  is mounted and fixed in place on panel  97  by mounting retainer  20  in mounting hole  96  formed in panel  97 , from the opposite side of attachment of housing  11 , thereby mounting and fixing in place housing  11  in retainer  20 . Therefore, it is not necessary to provide a space for inserting or withdrawing a fastening member such as the clips conventionally employed, to the housing  11  attachment side of panel  97 . As a result, the space needed for disposing sensor  1  can be made smaller. 
     Note that it is also acceptable to connect cable  2  to terminal side connector  17  by connecting each of conductors  4   a  through  4   e  to pressure welded parts  14   a  of connection terminals  14  at intermediate areas thereof, as shown in  FIG. 9 . When forming molded part  9  ( 9   a ,  9   b ) with this type of connection arrangement, sensor  1  has the form as shown in  FIG. 9B . 
     In addition to interlocking and fixing retainer  20  in mounting hole  96  using collar  23  and interlocking claw  24 , it is also acceptable to employ other methods for mounting sensor  1  in panel  97 . Namely, as shown in  FIG. 10 , it is also acceptable to mount and fix in place sensor  1  to panel  97  by holding the periphery of both openings of mounting hole  96  in panel  97  between collar  23  of retainer  20  and an end piece  11   a  that is formed to housing  11 .