Patent ID: 12212091

DETAILED DESCRIPTION TO EXECUTE THE INVENTION

Technical Problem

The connector apparatus described in Patent Document 1 is provided with a housing, giving it a large size. Also, the connector apparatus described in Patent Document 1 includes a sealant between the case and the cover that form the housing, ensuring good waterproof performance, but the number of parts is large and it tends to be complicated to manufacture.

An object of the present disclosure is to provide a connector apparatus with excellent waterproof performance. Also, an object of the present disclosure is to provide a method of manufacturing a connector apparatus for easily obtaining a connector apparatus that is compact and has excellent waterproof performance.

Effects of Present Disclosure

A connector apparatus according to the present disclosure is compact and easy to manufacture and also has excellent waterproof performance. A method of manufacturing a connector apparatus according to the present disclosure enables a connector apparatus that is compact and has excellent waterproof performance to be easily obtained.

Description of Embodiments

Firstly, embodiments of the present disclosure will be listed and described.

1. A connector apparatus according to an aspect of the present disclosure includes: a circuit board; a connector; and a mold resin portion, wherein the circuit board includes a conductor path, the connector includes a housing with a cylindrical shape and made of a resin, and a terminal projecting outward in an axial direction of the housing from inside the housing, the terminal being configured to connect to the conductor path; the mold resin portion collectively covers the circuit board, the terminal located outside the housing, and a portion of the housing, the housing and the mold resin portion include a welded portion formed by welding together constituent materials of the housing and the mold resin portion, and the welded portion is provided around an entire periphery of the housing and has a difference between a maximum width and a minimum width along a circumferential direction of the housing of 30% or less of the maximum width.

The connector apparatus of the present disclosure is provided with the welded portion provided around the entire periphery of the housing of the connector. Thus, the connector apparatus of the present disclosure has excellent adhesion between the housing and the mold resin portion around the entire periphery of the housing. This suppresses liquid such as water from entering in from gaps between the housing and the mold resin portion. By suppressing liquid from entering, liquid adhering to the conductive members, such as the circuit board and the terminal, covered by the mold resin portion can be suppressed.

In the welded portion, the difference between the maximum width and the minimum width in the circumferential direction of the housing is 30% or less of the maximum width. Thus, it can be said that the welded portion has little variation in the width in the circumferential direction of the housing. Having little variation in the width of the welded portion reduces the variation in the adhesive strength between the housing and the mold resin portion. When variation in adhesive strength is low, adhesion tends to be improved. In this manner, the connector apparatus of the present disclosure has excellent waterproof performance.

In the connector apparatus of the present disclosure, the conductive members, such as the circuit board and the terminal, are covered by the mold resin portion. Thus, the connector apparatus of the present disclosure does not need a housing to house the conductive members separately provided. Also, the connector apparatus of the present disclosure has excellent waterproof performance because of the welded portion described above, and thus a sealant does not need to be separately provided. Accordingly, with the connector apparatus of the present disclosure, the number of parts is low, the work to assemble the housing and dispose the sealant can be omitted, and manufacturability is excellent. In this manner, the connector apparatus of the present disclosure is compact and easy to manufacture.

2. For example, the connector apparatus of the present disclosure further includes four or more measurement points along the circumferential direction of the housing, wherein a ratio of the maximum width to an average width of the welded portion from the four or more measurement points is 130% or less, and a ratio of the minimum width to the average width is 70% or greater.

In this example, the width of the welded portion can be said to be uniform along the circumferential direction of the housing. When the welded portion has a uniform width, the adhesive strength between the housing and the mold resin portion tends to be uniform along the circumferential direction of the housing. Thus, this example has even better waterproof performance.

3. The connector apparatus of the present disclosure is an example wherein the housing includes a projection portion provided around an entire periphery, and the welded portion is provided on the projection portion.

The welded portion is, in a representative example, formed by laser welding. With laser welding, the housing is irradiated through the mold resin portion and heat is generated at the boundary surface between the housing and the mold resin portion, with this heat welding together the constituent materials of the housing and the mold resin portion. In this example, the mold resin portion allows the laser to pass through, and the housing absorbs the laser. The housing absorbs the laser and builds up heat, and this built up heat melts the constituent material of the housing. The melting heat from the housing transfers to the mold resin portion, causing heat to build up in the mold resin portion, and this built up heat melts the mold resin portion. The melted constituent material of the housing and the melted constituent material of the mold resin portion form the welded portion.

This example is provided with the welded portion on the projection portion. In other words, in this example, the welded portion is formed by heat being generated by at laser at the projection portion. By heating being generated at the projection portion, the heat tends to be concentrated at the projection portion, making a strong welded portion easy to form. Thus, this example has even better waterproof performance.

4. The connector apparatus according to the present disclosure is an example wherein a transmittance of the mold resin portion is 40% or greater, a transmittance of the mold resin portion is a ratio (b1/a1) between an amount of light a1 and an amount of light b1×100, the amount of light a1 is an amount of light of a laser with a wavelength of 940 nm; and the amount of light b1 is an amount of light of the laser passing through a test piece of constituent material of the mold resin portion with a thickness of 2 mm.

The welded portion is formed by laser welding, as described above. Because the transmittance of the mold resin portion is 40% or greater, the laser tends to not be absorbed by the mold resin portion and easily reaches the surface of the housing. Thus, in this example, heat tends to be generated by the laser at the boundary surface between of the housing and the mold resin portion, making the welded portion easy to form.

5. The connector apparatus according to the present disclosure is an example wherein a transmittance of the housing is 10% or less, a transmittance of the housing is a ratio (b2/a2) between an amount of light a2 and an amount of light b2×100; the amount of light a2 is an amount of light of a laser with a wavelength of 940 nm; and the amount of light b2 is an amount of light of the laser passing through a test piece of constituent material of the housing with a thickness of 2 mm.

The welded portion is formed by laser welding, as described above. Because the transmittance of the housing is 10% or less, the laser tends to be absorbed by the housing. Thus, in this example, heat tends to be generated by the laser at the boundary surface between of the housing and the mold resin portion, making the welded portion easy to form.

6. The connector apparatus according to the present disclosure is an example wherein the mold resin portion contains polyamide resin or polyester.

Polyamide resin has excellent mechanical strength. Thus, the mold resin portion containing polyamide resin can easily mechanically protect the members covered by the mold resin portion. Polyester is excellent in terms of electrical insulating properties, water resistance, and the like. Thus, the mold resin portion containing polyester can easily electrically and chemically protect the members covered by the mold resin portion.

7. The connector apparatus according to the present disclosure is an example wherein the housing contains polyester.

In this example, the terminal is easily electrically and chemically protected.

8. The connector apparatus according to the present disclosure is an example wherein the mold resin portion and the housing both contain polyester.

In this example, because the mold resin portion and the housing contain the same type of resin, the solubility parameter of the mold resin portion and the housing can be brought close to one another. Thus, in this example, the conformability between the mold resin portion and the housing is good. Thus, this example has even better waterproof performance. Also, in this example, by the welded portion described below containing the same type of resin, the strength of the welded portion tends to be increased. Thus, in this example, the adhesion between the housing and the mold resin portion is further increased.

9. The connector apparatus of the present disclosure is an example wherein the mold resin portion includes a surface that comes into contact with atmosphere.

In this example, the surface of the mold resin portion is located on the outermost layer. In other words, in this example, a housing that houses the circuit board and the like is not provided. Thus, this example is easy to make compact.

10. The connector apparatus of the present disclosure is an example wherein the mold resin portion is an injection molded body.

The injection molded body can be manufactured via injection molding. Injection molding includes filling a molding mold with the constituent material of the mold resin portion while under pressure and covering the circuit board, the housing, and the like. Compared to casting, injection molding tends to completely fill up the molding mold with the constituent material of the mold resin portion. Thus, this example tends to not have gaps between the circuit board, the housing, and the like and the mold resin portion. Because gaps tend to not be formed, droplets tend to not form due to condensation of the water vapor inside the gaps. Also, because this example is manufactured via injection molding, the mold resin portion has excellent flexibility in terms of shape.

11. The connector apparatus according to the present disclosure is an example wherein the circuit board and the connector form a control unit.

Because this example has excellent waterproof performance between the housing and the mold resin portion, it can be used for an extended period of time. Thus, this example is suitable to be used as a control unit. Also, because this example is compact, it is suitable to be used as a control unit.

12. A method of manufacturing a connector apparatus according to an aspect of the present disclosure includes: preparing an assembled article including a circuit board and a connector; forming an integrated article by covering a portion of the assembled article with a mold resin portion; and irradiating the integrated article with a laser, wherein the circuit board includes a conductor path, the connector includes a housing with a cylindrical shape and made of a resin, and a terminal projecting outward in an axial direction of the housing from inside the housing, the terminal being configured to connect to the conductor path, in the forming the integrated article, the circuit board, the terminal located outside the housing, and a portion of the housing are collectively covered by the mold resin portion, and in the irradiating with the laser, an entire periphery of the housing is irradiated with a laser all at once through the mold resin portion, and constituent materials of the housing and the mold resin portion are welded together.

In the method of manufacturing a connector apparatus according to the present disclosure, the entire periphery of the housing of the connector is irradiated all at once. Hereinafter, this method of laser irradiation is referred to as all at once irradiation. Example of laser irradiation other than all at once irradiation include laser irradiation while scanning around the circumferential direction of the housing. Hereinafter, this method of laser irradiation is referred to as scanning irradiation.

Laser welding generates heat at the boundary surface between the housing and the mold resin portion. In the case of at all once irradiation, the heat generated at the boundary surface tends to be substantially uniform across all sections. Thus, in the case of all at once irradiation, regarding the welded portion formed by welding together the constituent materials of the housing and the mold resin portion, the welded portion can be formed with a small amount of variation in the width. Specifically, a welded portion with a difference between the maximum width and the minimum width in the circumferential direction of the housing of 30% or less can be formed around the entire periphery of the housing. In the case of scanning irradiation, because the heat generated at the boundary surface described above transfers in the scanning direction, the heat tends to be non-uniform. In the case of scanning irradiation, a welded portion tends to be formed that is formed as the scanning proceeds, with the width increasing as the scanning proceeds.

In the case of collective irradiation, a plurality of emitting ports of the laser are arranged in a line along the circumferential direction of the housing and laser is simultaneously emitting from the plurality of emitting ports of the laser, for example. The emitting ports of the laser are arranged so that the laser spots are in line and evenly spaced along the circumferential surface of the housing. Thus, in the case of all at once irradiation, the laser irradiation apparatus is easily made compact. On the other hand, in the case of scanning irradiation, a laser emitting port need to be made scan along the circumferential direction of the housing. Thus, in the case of scanning irradiation, a mechanism for making the laser emitting port scan is required, increasing the size of the apparatus.

In this manner, the method of manufacturing a connector apparatus of the present disclosure using all at once irradiation and easily obtains a connector apparatus provided with a welded portion.

13. The method of manufacturing a connector apparatus according to the present disclosure is an example wherein the irradiating with the laser is performed with the mold resin portion pressed against the housing side.

By the mold resin portion being pressed against the housing side, gaps tend to not form between the housing and the mold resin portion. By emitting the laser with essentially no gaps between the housing and the mold resin portion, the constituent material of the housing and the mold resin portion easily weld together, which tends to improve the adhesion between the housing and the mold resin portion.

Description of Embodiments

Embodiments of the present disclosure will be described in detail below with reference to the drawings. Components with the same name are given the same reference numeral.

Connector Apparatus

A connector apparatus1of this embodiment is provided with a circuit board2and a connector3as illustrated inFIGS.1and2. The circuit board2is provided with a conductor path20. The connector3is provided with a housing31and a terminal32. The housing31is made of resin and has a cylindrical shape. The terminal32projects outward from the housing31in the axial direction and connects to the conductor path20. The connector apparatus1of this embodiment is advantageous in that it is provided with the mold resin portion4that collectively covers the circuit board2, the terminal32located outside of the housing31, and a portion of the housing31. Also, the connector apparatus1of this embodiment is advantageous in that it is provided with a welded portion5provided around the entire periphery of the housing31. The welded portion5is, in a representative example, formed by laser welding. The welded portion5is configured by welding together constituent material of the housing31and the mold resin portion4using heat from a laser. The configurations will be described in detail below. In the drawings, the welded portion5is indicated by cross hatching.

Circuit Board

The circuit board2is a plate-like member on which electronic components (not illustrated) such as a semiconductor relay, the connector3, and the like are mounted. A printed circuit board may be used as the circuit board2. The circuit board2is provided with the conductor path20. The conductor path20refers to a section of a conductive member forming the electric circuit of the circuit board2that is exposed from the surface. The conductor path20, for example, includes a conductive pattern21of the circuit board2, a terminal (not illustrated) of an electronic component mounted on the circuit board2, and a solder22connecting the terminal of the electronic component, the terminal32of the connector3, and the conductive pattern21. The circuit board2is embedded in the mold resin portion4described below.

Connector

The connector3is a connection member to which a counterpart connector (not illustrated) is connected. The counterpart connector is connected to an in-vehicle electrical component or the like via a wire harness. The connector3is mounted on the circuit board2. The connector3is provided with the housing31and the terminal32. The connector3is further provided with an attachment portion33and a fixing member34(FIG.2). The connector3is disposed with a gap between it and the extended surface of the circuit board2. The connector3illustrated inFIGS.1and2is disposed above the circuit board2.

Housing

The housing31is a tube-shaped member into which the counterpart connector fits. The housing31is a closed-bottom cylinder that is open on the side where the counterpart connector fits into and closed on the side opposite the open side. The terminal32, described below, extends through the closed surface. In other words, the terminal32runs from inside the housing31to outside the housing31, through the closed surface. Hereinafter, the closed surface may also be referred to the closed end surface. The terminal32located outside of the housing31projects from the closed end surface. The closed end surface of the housing31and the area nearby are embedded in the mold resin portion4described below around the entire periphery.

In the present example, the cross-sectional shape of the housing31is a stadium. The cross-section of the housing31is a cross-section taken along a direction orthogonal to the axial direction of the housing31. A stadium shape refers to a shape with two arc portions joined at both ends of a pair of parallel linear portions of the same length.

Transmittance

The housing31preferably has low transmittance. The transmittance of the housing31is a percentage (b2/a2)×100, where a2 is the amount of light of laser with a wavelength of 940 nm and b2 is the amount of light of the laser having passed through a test piece of the constituent material of the housing31with a thickness of 2 mm. The housing31with low transmittance easily absorbs the laser. In other words, the housing31with low transmittance is easily melted by the laser. Thus, the welded portion5described below is easy to form. The transmittance of the housing31is preferably 10% or less, for example. The housing31with a transmittance of 10% or less easily absorbs the laser and is easily melted, making the welded portion5easy to form. The transmittance of the housing31is more preferably 7% or less, and particularly preferably 5% or less. The color of the housing31is preferably an opaque black, gray, or similar color. These colors easily absorb the laser.

Material

The housing31preferably contains polyester, for example. Polyester is excellent in terms of electrical insulating properties, water resistance, and the like. Thus, the housing31containing polyester can mechanically, electrically, and chemically protect the terminal32and the like inside the housing31. A representative example of polyester includes polybutylene terephthalate (PBT). The housing31also preferably further contains a coloring agent. An example of a coloring agent is an agent that lowers the transmittance of the housing31. Carbon black is an example of a coloring agent. By adding carbon black, the color of the housing31can easily be made black.

Terminal

The terminal32electrically connects the counterpart connector and the circuit board2. The terminal32runs from inside the housing31to outside the housing31, through the closed end surface of the housing31. The portion of the terminal32located inside the housing31is disposed aligned with the axial direction of the housing31. The end of the terminal32located inside the housing31is electrically connected to the counterpart connector. The portion of the terminal32located outside the housing31is bent to extend toward the circuit board2. The terminal32of the present example is made of a metal wire bent at essentially a right angle. The other end of the terminal32located outside the housing31is electrically connected to the conductive pattern21of the circuit board2. The solder22is used to electrically connect this end of the terminal32and the conductive pattern21. The terminal32may be a press-fit terminal. In this case, the terminal32is electrically connected to the conductive pattern21via pressure. Thus, in a case in which the terminal32is a press-fit terminal, the solder22can be omitted. The other end of the terminal32extends through the circuit board2. The terminal32located outside the housing31is embedded in the mold resin portion4.

Attachment Portion

The attachment portion33is integrally formed with the housing31. In the present example, the attachment portion33is integrally formed as a portion of the housing31. The attachment portion33bends in an L-shape from the closed end surface of the housing31extending toward the circuit board2. The attachment portion33of the present example is made of a cylindrical rod member bent at essentially a right angle. In the present example, two attachment portions33are provided on either side of the terminal32. A threaded hole is provided in the end surface of the attachment portion33. The fixing member34described below is attached to the threaded hole. By sandwiching the circuit board2between the end surface of the attachment portion33and the fixing member34, the circuit board2and the housing31are fixed together. The attachment portion33is embedded in the mold resin portion4.

Fixing Member

The fixing member34fixes the housing31to the circuit board2. As the fixing member34, for example, a screw may be used. The fixing member34of the present example is a screw made of resin. In the present example, two fixing members34extend through insertion holes (not illustrated) provided in the circuit board2and are attached to the attachment portions33. By attaching the fixing members34to the attachment portions33, the housing31is fixed to the circuit board2. A portion of the fixing member34is exposed from the surface of the circuit board2. The fixing member34is embedded in the mold resin portion4.

Mold Resin Portion

The mold resin portion4mechanically, electrically, and chemically protects the conductive members, such as the circuit board2and the terminal32, from the external environment. The mold resin portion4collectively covers the circuit board2, the terminal32located outside of the housing31, and a portion of the housing31. In the present example, the mold resin portion4collectively covers the circuit board2and a large portion of the connector3. A large portion of the connector3refers to the region excluding the end portion of the housing31on the open side where the counterpart connector is fit into.

The mold resin portion4includes a surface that comes into contact with the atmosphere. Coming into contact with the atmosphere means being exposed without the connector apparatus1being covered by a case or the like, and this refers to the outermost surface of the connector apparatus1. In the present example, the surface of the mold resin portion4comes into contact with the atmosphere all over. In other words, the connector apparatus1is caseless. This gives the connector apparatus1a compact size.

Transmittance

The mold resin portion4preferably has a high transmittance. The transmittance of the mold resin portion4is a percentage (b1/a1)×100, where a1 is the amount of light of laser with a wavelength of 940 nm and b1 is the amount of light of the laser having passed through a test piece of the constituent material of the mold resin portion4with a thickness of 2 mm. The mold resin portion4with a high transmittance tends to not absorb the laser, allowing the laser to easily reach the housing31. Thus, the welded portion5described below is easy to form. The transmittance of the mold resin portion4is preferably 40% or greater, for example. The mold resin portion4with a transmittance of 40% or greater tends to allow the laser to pass through, making the welded portion5easy to form. The transmittance of the mold resin portion4is more preferably 45% or greater, and particularly preferably 50% or greater. The color of the mold resin portion4is preferably colorless and transparent, white and transparent, and opaque white, or the like. These colors tend to allow the laser to pass through.

Material

The mold resin portion4preferably contains polyamide resin or polyester, for example. Polyamide resin has excellent mechanical strength. Thus, the mold resin portion4containing polyamide resin can easily mechanically protect the members covered by the mold resin portion4. Polyester is excellent in terms of electrical insulating properties, water resistance, and the like. Thus, the mold resin portion4containing polyester can easily electrically and chemically protect the members covered by the mold resin portion4.

The housing31and the mold resin portion4preferably contain the same type of resin. Particularly, the housing31and the mold resin portion4are preferably made of the exact same resin. By configuring the housing31and the mold resin portion4to contain the same type of resin, the solubility parameter of the housing31and the mold resin portion4can be brought close to one another. Accordingly, good conformability between the housing31and the mold resin portion4can be achieved. Also, by the welded portion5described below containing the same type of resin, the strength of the welded portion5tends to be increased. Thus, the adhesion between the housing31and the mold resin portion4is further increased. For example, in a case in which the housing31contains polyester, the mold resin portion4preferably contains polyester.

The mold resin portion4is preferably an injection molded body. An injection molded body can be manufactured via injection molding. Injection molding includes filling a molding mold with the constituent material of the mold resin portion4while under pressure and covering the circuit board2, the housing31, and the like. Compared to casting, injection molding tends to completely fill up the molding mold with the constituent material of the mold resin portion4. Thus, compared to a casting molded body, an injection molded body tends to not have gaps between the circuit board2, the housing31, and the like and the mold resin portion4. Because gaps tend to not be formed, droplets tend to not form due to condensation of the water vapor inside the gaps. Also, an injection molded body has excellent flexibility in terms of the shape of the mold resin portion4. In the present example, the mold resin portion4is configured as a quadrangular prism.

The constituent material of the mold resin portion4preferably has a melting point ranging from 180° C. to 200° C. By the constituent material having a melting point of 180° C. or greater, deformation due to the mold resin portion4melting when the connector apparatus1is used can be prevented. Also, by the constituent material having a melting point of 200° C. or less, the molding temperature for the injection molding can be set to 200° C. or less, and at this molding temperature, the solder22and the like can be prevented from melting.

The mold resin portion4is an injection molded body and thus is provided with a trace portion40of a gate. The trace portion40is a section corresponding to a gate for filling the cavity of the mold with the constituent material of the mold resin portion4when molding the mold resin portion4. An attachment portion including a portion corresponding to the gate is formed on the mold resin portion4manufactured by injection molding. When the attachment portion is removed, the trace portion40of the gate is formed on the mold resin portion4. The attachment portion, in addition to including a portion corresponding to a gate, may include a portion corresponding to a spray and may further include a portion corresponding to a runner. The attachment portion is removed by snapping off the attachment portion, for example. Because the terminal32and the like are disposed at or near the housing31, the gate using for injection molding is preferably set at a position distanced from the housing31. Accordingly, the trace portion40is preferably provided on the mold resin portion4on the opposite side to the housing31.

Welded Portion

As illustrated inFIG.3, the welded portion5is formed by welding together the constituent material of the housing31and the mold resin portion4. Welding refers to welding that satisfies at least one of: mixing constituent materials together, melting constituent materials together, using shear force to cause material failure not interfacial failure, or roughening the surface of the connector3. Interfacial failure refers to a failure at the interface between the housing31and the mold resin portion4. This means separation along the interface between the housing31and the mold resin portion4. Accordingly, the constituent material of one member, either the housing31or the mold resin portion4, does not adhere to that of the other member. Material failure refers to a failure inside one member, either the housing31or the mold resin portion4. This means that both members separate with the constituent material of one member being adhered at the surface of the other member that faces the one member. The welded portion5increases the adhesion between the housing31and the mold resin portion4.

The welded portion5is provided around the entire periphery of the housing31. Thus, liquid such as water entering in from the space between the housing31and the mold resin portion4can be suppressed. Accordingly, liquid adhering to the conductive members, such as the circuit board2and the terminal32, can be suppressed.

In the welded portion5, the difference between the maximum width and the minimum width in the circumferential direction of the housing31is 30% or less of the maximum width. Thus, it can be said that the welded portion5has little variation in the width in the circumferential direction of the housing31. Having little variation in the width of the welded portion5reduces the variation in the adhesive strength between the housing31and the mold resin portion4. The ratio of the difference to the maximum width of the welded portion5in the circumferential direction of the housing31may be referred to as the width ratio. The width ratio of the welded portion5is obtained by separating the housing31and the mold resin portion4and exposing the welded portion5and measuring the width of the welded portion5along the circumferential direction of the housing31. The housing31and the mold resin portion4can be separated using an appropriate tool such as pliers to separate the mold resin portion4from the housing31, for example. The width ratio of the welded portion5is more preferably 20% or less, and particularly preferably 10% or less.

The welded portion5is preferably measured using a plurality of, specifically four or more, measurement points along the circumferential direction of the housing31, with the ratio of the maximum width to the average width of the welded portion5from the plurality of measurement points being 130% or less, and the ratio of the minimum width to the average width being 70% or greater. The ratio of the maximum width to the average width of the welded portion5is referred to as the maximum width ratio. The ratio of the minimum width to the average width of the welded portion5is referred to as the minimum width ratio. When the maximum width ratio is 130% or less and the minimum width ratio is 70% or greater, the width of the welded portion5can be said to be uniform along the circumferential direction of the housing31. When the welded portion5has a uniform width, the adhesive strength between the housing31and the mold resin portion4tends to be uniform along the circumferential direction of the housing31. The maximum width ratio of the welded portion5is more preferably 120% or less, and particularly preferably 110% or less. The minimum width ratio of the welded portion5is more preferably 80% or greater and particularly preferably 90% or greater. The welded portion5preferably has a maximum width ratio of 120% or less and a minimum width ratio of 80% or greater. Particularly, the welded portion5preferably has a maximum width ratio of 110% or less and a minimum width ratio of 90% or greater. Note that the maximum width ratio of the welded portion5may be 105% or less, and the minimum width ratio may be 95% or greater.

Application

The connector apparatus1of this embodiment can be suitably used in an engine control unit of a vehicle, a module of an electric brake system of a vehicle, and the like. An example of an engine control unit includes a fuel injection engine control unit (FI-ECU), for example. Examples of an electric brake system module include an electro mechanical brake (EMB) and an electronic parking break (EPB) module.

Method of Manufacturing a Connector Apparatus

The method of manufacturing a connector apparatus according to this embodiment includes a process of preparing an assembled article, a process of forming an integrated article, and a process of irradiating using a laser. The method of manufacturing of a connector apparatus will be described in detail below with reference toFIGS.4to6.

Process of Preparing an Assembled Article

In the process of preparing an assembled article, as illustrated inFIG.4, an assembled article100in which the circuit board2and the connector3described above are connected together is prepared. In the assembled article100, the conductive pattern21of the circuit board2and the terminal32of the connector3are electrically connected by the solder22. Also, in the assembled article100, the attachment portions33of the connector3are fixed to the circuit board2via the fixing members34(FIG.2). In the present example, the cross-sectional shape of the housing31of the connector3is a stadium.

Process of Forming an Integrated Article

In the process of forming an integrated article, as illustrated inFIG.5, an integrated article200is manufactured by covering a portion of the assembled article100with the mold resin portion4. Specifically, in the process of forming an integrated article, the mold resin portion4collectively covers the circuit board2, the terminal32located outside of the housing31of the connector3, and a portion of the housing31. In other words, in the process of forming an integrated article, the mold resin portion4covers a large portion of the assembled article100excluding the opening of the housing31of the connector3where the counterpart connector is fit into. In the present example, the mold resin portion4is configured as a quadrangular prism. Accordingly, the mold resin portion4surrounds the housing31with four sides.

Process of Irradiating Using a Laser

In the process of irradiating using a laser, the housing31is collectively irradiated with a laser via the mold resin portion4to weld the constituent materials of the housing31and the mold resin portion4together. An example of laser irradiation includes irradiating from outside the mold resin portion4in a normal line direction of the outer circumferential surface of the housing31. The mold resin portion4allows the laser to pass through, and the housing31absorbs the laser. The housing31absorbs the laser and builds up heat, and this built up heat melts the constituent material of the housing31. The melting heat from the housing31transfers to the mold resin portion4, causing heat to build up in the mold resin portion4, and this built up heat melts the mold resin portion4. The housing31and the mold resin portion4solidify with the melted constituent material of the housing31and the melted constituent material of the mold resin portion4adhered together to form the welded portion5.

The laser irradiation is performed collectively around the entire periphery of the housing31. In the case of collective irradiation, a plurality of emitting ports of the laser are arranged in a line along the circumferential direction of the housing31and laser is simultaneously emitting from the plurality of emitting ports of the laser.

The emitting ports of the laser are arranged so that the laser spots are in line and evenly spaced along the circumferential surface of the housing31. Adjacent laser spots preferably slightly overlap one another. There may be a gap between adjacent laser spots, but the gaps are preferably sufficiently small.

In a representative example, the laser spots are circles. The emitting ports of the laser are preferably arranged so that the center of the laser spots on the circumferential surface of the housing31are located on the same straight line. Also, the emitting ports of the laser are preferably disposed so that, in the overlapping region of adjacent laser spots on the circumferential surface of the housing31, the maximum length of the laser spot in the aligned direction ranges from ⅛ times to ½ times the spot diameter of the laser. By setting the maximum length in the overlapping region to ⅛ times the spot diameter of the laser or greater, the laser can be reliably emitted around the entire periphery of the housing31. Also, by setting the maximum length in the overlapping region to ½ times the spot diameter of the laser or less, an excessive number of laser emitting ports is not necessary.

Examples of the type of the laser source include a solid-state laser, a semiconductor laser, a fiber laser, and the like.

The wavelength of the laser ranges, for example, from 800 nm to 990 nm, preferably from 850 nm to 990 nm, and particularly preferably from 930 nm to 950 nm. A suitable wavelength of the laser is 940 nm. The output of the laser depends on the material of the housing31and the mold resin portion4but ranges, for example, from 10 W to 100 W, preferably from 20 W to 90 W, and particularly preferably from 30 W to 60 W.

The laser is preferably emitted with the mold resin portion4pressed against the housing31side. By the mold resin portion4being pressed against the housing31side, gaps tend to not form between the housing31and the mold resin portion4. By emitting the laser with essentially no gaps between the housing31and the mold resin portion4, the constituent material of the housing31and the mold resin portion4easily weld together, which tends to improve the adhesion between the housing31and the mold resin portion4.

The entire periphery of the housing31is irradiated with the laser all at once with the mold resin portion4pressed against the housing31side using a pressing apparatus400such as that illustrated inFIG.6, for example. The pressing load from the pressing apparatus400ranges from 1 kgf to 10 kgf, for example. By the pressing load being 1 kgf or greater, gaps tend to not form between the housing31and the mold resin portion4. Also, by the pressing load being 10 kgf or less, deformation of the mold resin portion4due to excessive pressure on the connector apparatus1can be suppressed. The pressing load preferably ranges from 2 kgf to 8 kgf, and particularly preferably from 3 kgf to 5 kgf, for example.

The pressing apparatus400is a tube-shaped member disposed around the periphery of the mold resin portion4. The pressing apparatus400has an inner circumferential shape that corresponds to the external shape of the mold resin portion4. In the present example, the inner circumferential shape of the pressing apparatus400is quadrangular.

The pressing apparatus400is configured of a plurality of divided pieces divided in the circumferential direction. In the present example, the pressing apparatus400is configured of four divided pieces. Each divided piece is configured to press against a corner portion of the mold resin portion4.

The pressing apparatus400is provided with a metal portion410located on the outer circumferential side and a glass portion420located on the inner circumferential side. The metal portion410is provided with the plurality of laser emitting ports along the circumferential direction of the pressing apparatus400. Specifically, optical fibers411running from the outer circumferential surface to the inner circumferential surface extend through the metal portion410, with the distal ends of the optical fibers411corresponding to the laser emitting ports. The laser emitting ports are provided flush with the inner circumferential surface of the metal portion410. The glass portion420comes into direct contact with the mold resin portion4. The laser emitted from the emitting ports travels through the glass portion420, irradiates the outer side of the mold resin portion4, passes through the mold resin portion4, and is absorbed by the housing31. The optical fibers411and the emitting ports are disposed so that the interval between the laser spots on the housing31are even. In the present example, the cross-sectional shape of the housing31is a stadium. Thus, the optical fibers411and the emitting ports are disposed so that the laser is emitted in a normal line direction to the outer circumferential surface at the linear portions and the arc portions forming the outer circumferential surface of the housing31.

Effect

The connector apparatus1of this embodiment can achieve the following effects.

1. Excellent Waterproof Performance

Because the adhesion between the housing31and the mold resin portion4is excellent due to the welded portion5, liquid entering in from the gaps between the housing31and the mold resin portion4can be easily suppressed. In particular, because the welded portion5formed around the entire periphery of the housing31has little variation in terms of width, the welded portion5can easily be formed strong. Thus, liquid adhering to the conductive members, such as the circuit board2and the terminal32, covered by the mold resin portion4can be suppressed.

2. Easy to Make Compact

By collectively covering the conductive members, such as the circuit board2and the terminal32, with the mold resin portion4, a housing for housing the circuit board2does not need to be separately provided. Because a housing is not provided, there is also no need for a sealant to waterproof gaps between the housing.

3. Easy to Manufacture

The connector apparatus1of this embodiment has excellent waterproof performance due to the welded portion5described above, and a housing and a sealant are not required. Thus, the number of parts is low and the work to assemble a housing or dispose a sealant can be omitted. In particular, because the welded portion5is formed using laser irradiation all at once around the entire periphery of the housing31, variation in the width of the welded portion5can be easily reduced, making the laser irradiation apparatus easy to make compact.

Modified Example

As illustrated inFIG.7, the connector apparatus1described above can be provided with a projection portion311on the housing31. The projection portion311is provided around the entire periphery of the housing31that comes into contact with the mold resin portion4. In a case in which the projection portion311is provided, the welded portion5is provided on the projection portion311. Hereinafter, the description will focus mainly on the projection portion311, which is a point of difference with the connector apparatus1described above, and description of redundant matters will be omitted.

The projection portion311has the function of absorbing the laser heat in a concentrated manner when the welded portion5is formed. The shape and dimensions of the projection portion311do not substantially change from before to after the laser welding.

The shape of the projection portion311can be appropriately selected to allow the projection portion311to absorb the laser heat in a concentrated manner. The projection portion311is preferably provided with a distal end surface311sthat runs parallel with the axial direction of the housing31. By the projection portion311being provided with the distal end surface311s, the surface of the projection portion311that receives the laser can be easily stabilized and secured. Also, by the projection portion311being provided with the distal end surface311s, the region where laser heat is produced can be provided on the distal end side of the projection portion311, and the heat is easily suppressed from transferred to the base end side of the projection portion311.

The cross-sectional shape of the projection portion311is not particularly limited. The cross-sectional shape of the projection portion311may be quadrangular, for example. The cross-sectional shape of the projection portion311is a shape with a cross-section taken along a direction orthogonal to the extending direction of the projection portion311. The extending direction of the projection portion311is the radial direction of the housing31. The projection portion311may extend along the circumferential direction of the housing31by being provided along the circumferential direction of the housing31or may have a wave shape or the like that bends away from the circumferential direction of the housing31. In a case in which the cross-sectional shape of the projection portion311is quadrangular, the shape of the projection portion311is simple, making the adhesion between the projection portion311and the mold resin portion4easy to improved. Also, the projection portion311having a quadrangular cross-sectional shape makes manufacture of the projection portion311simple. The cross-sectional shape of the projection portion311may be triangular. Also, the cross-sectional shape of the projection portion311may be a semi-circular shape with the distal end surface311shaving an arc-shaped surface. The cross-sectional shape of the projection portion311may be trapezoidal. The cross-sectional shape of the projection portion311may be an inverted trapezoid with the width decreasing from the distal end side to the base end side.

The maximum width of the projection portion311preferably ranges from 1 mm to 2 mm or less. By the maximum width of the projection portion311being 1 mm or greater, the surface that receives the laser can be easily secured, and the laser heat is easily concentrated at the projection portion311. Also, by the maximum width of the projection portion311being 2 mm or less, though this depends on the intensity distribution of the laser, the laser heat is easily concentrated at the projection portion311. The maximum width of the projection portion311more preferably ranges from 1 mm to 1.7 mm, and particularly preferably from 1 mm to 1.5 mm.

The maximum height of the projection portion311preferably ranges from 0.2 mm to 0.5 mm By the maximum height of the projection portion311being 0.2 mm or greater, the region where laser heat is produced can be provided on the distal end side of the projection portion311, and the heat is easily suppressed from transferred to the base end side of the projection portion311. Also, by the maximum height of the projection portion311being 0.5 mm or less, the diffusion of heat by the laser can be made constant, and the constituent material of the projection portion311can be melted in a constant manner. The maximum height of the projection portion311more preferably ranges from 0.2 mm to 0.4 mm, and particularly preferably from 0.2 mm to 0.3 mm.

The connector apparatus1of the present example is provided with a plurality of recess portions312on the housing31. The recess portions312are each provided around the entire periphery of the housing31. Also, the recess portions312are disposed side by side in the axial direction of the housing31. The projection portion311is provided so as to form the side walls of adjacent recess portions312. The recess portions312are filled with the mold resin portion4. Thus, in addition to the mold resin portion4in the recess portions312functioning as an anchor, compared to a case in which the projection portion311has a uniform height and the recess portions312are not provided, the contact area between the housing31and the mold resin portion4is increased. Accordingly, by the recess portions312being provided, the adhesion between the housing31and the mold resin portion4can be improved.

In the present example, two recess portions312are provided. Of the plurality of recess portions312, the recess portions312located on the closed end surface side of the housing31is formed by a cutout connected to the closed end surface. The closed end surface side of the housing31is the right side inFIG.7. Of the plurality of recess portions312, the recess portions312located on the opening side of the housing31is formed by a groove with a side wall on either side. The opening side of the housing31is the left side inFIG.7.

The depth of the recess portions312in the present example is the same as the maximum height of the projection portion311. By the projection portion311being formed by the recess portions312in this manner, compared to a case in which no recess portions312are provided, the projection amount of the projection portion311from the outer surface of the housing31can be reduced. Because the projection amount of the projection portion311from the outer surface of the housing31is small, the thickness of the mold resin portion4from the outer surface of the housing31can be decreased, making decreasing the size easy.

Three or more recess portions312may be provided. In this case, two projection portions311are provided side by side in the axial direction of the housing31. Only one recess portion312may be provided. In this case, one of the side walls of the projection portion311is formed by the side wall of the recess portion312and the other side wall is formed by the closed end surface of the housing31. There may be no recess portions312provided. In this case, the projection portion311projects from the outer surface of the housing31.

Test Examples

A connector apparatus provided with a welded portion was manufactured, and the adhesive performance between the housing and the mold resin portion of the connector was examined. The adhesive performance was evaluated using a test piece500illustrated inFIG.8. The test piece500is a member simulating the join section between the housing and the mold resin portion of the connector.

Test Piece

Sample No.1-1

An absorbing member510simulating the section of the housing that is joined to the mold resin portion was prepared. The absorbing member510is made of PBT resin with a transmittance of 1%. The absorbing member510has a column-like shape shaped like a stadium with a circumferential length of 50 mm.

A transmitting member520was injection molded covering a portion of the prepared absorbing member510. The transmitting member520is made of a thermoplastic polyester resin with a transmittance of 40%. VYLOSHOT (registered trademark) available from TOYOBO CO., LTD. was used as the thermoplastic polyester resin. The transmitting member520was formed covering the absorbing member510in an area of 5 mm from a first end surface side in the axial direction of the absorbing member510. The transmitting member520is a quadrangular prism. The length of the region where the absorbing member510and the transmitting member520overlap was 50 mm. The length of the overlapping region is the length in the circumferential direction of the absorbing member510. The circumferential length of the transmitting member520was 76 mm.

In the region where the absorbing member510and the transmitting member520overlap, the entire periphery of the absorbing member510was irradiated all at once through the transmitting member520, with the transmitting member520pressed against the absorbing member510. In the all at once laser irradiation, the pressing apparatus400illustrated inFIG.6was used. The pressing load was 2 kgf. The laser source was a fiber laser. Each spot diameter of the laser was 2.0 mm. The wavelength of the laser was 940 nm. As a result, a welded portion550was formed around the entire periphery of the absorbing member510.

Sample No.1-2

With the sample no.1-2, the transmitting member520was formed covering the absorbing member510in an area of 3 mm from a first end surface side in the axial direction of the absorbing member510. Also, with the sample no.1-2, the laser irradiation method was changed from that used for the sample no.1-1. With the sample no.1-2, in the region where the absorbing member510and the transmitting member520overlap, the entire periphery of the absorbing member510was scanned and irradiated through the transmitting member520. A laser scan of one revolution was performed on the absorbing member510and the transmitting member520. In other words, the scan start position of the laser is essentially the same as the scan end position. The scan speed of the laser was 50 mm/min. In the scanning irradiation, the spot diameter of the laser was 1.5 mm Other conditions are as with the sample no.1-1. As a result, a welded portion550was formed around the entire periphery of the absorbing member510.

Measuring Variation in Width of Welded Portion

Using the obtained test piece500of each sample, the width of the welded portion550along the circumferential direction of the absorbing member510was measured by separating the absorbing member510and the transmitting member520and exposing the welded portion550. Here, the absorbing member510and the transmitting member520were separated by using pliers to separate the transmitting member520from the absorbing member510. Also, the ratio of the difference between the maximum width and the minimum width to the maximum width of the welded portion550in the circumferential direction of the absorbing member510was obtained. The ratio is referred to as the width ratio. The results are listed in Table 1.

Also, seven measurement points were provided along the circumferential direction of the absorbing member510and the average width of the welded portion550using these seven measurement points was obtained. With the sample no.1-2, the laser scan start position was set as measurement point1, the laser scan end position was set as measurement point7, and points evenly spaced between measurement points1and7were set as measurement points2to6. With the sample no.1-2, the scan start position of the laser is essentially the same as the scan end position. However, with the sample no.1-2, at the same position, a step is produced at the welded portion550. The width at measurement point1and the width at measurement point7can be measured from the step of the welded portion550. With the sample no.1-1, measurement points are set at positions as with the sample no.1-2. With the sample no.1-1also, the width at measurement point1and the width at measurement point7can be measured from the step of the welded portion550. Also, the ratio of the maximum width to the average width and the ratio of the minimum width to the average width are obtained. The ratio of the maximum width to the average width is referred to as the maximum width ratio. The ratio of the minimum width to the average width is referred to as the minimum width ratio. The results of the width of the welded portion550at each measurement point, the maximum width ratio, and the minimum width ratio are listed in Table 1.

Adhesive Performance Evaluation

A shear tensile test was used to evaluate the obtained test pieces500of each sample on adhesive performance. The shear tensile testing instrument used was the Autograph AGS-X Series available from Shimadzu Corporation. In the shear tensile test, the absorbing member510and the transmitting member520were pulled in opposite direction in the length direction as illustrated by the white arrows inFIG.8and the maximum tensile stress when the absorbing member510and the transmitting member520separated was obtained. This measurement was performed five times for each sample. The average value of the maximum tensile stress is indicated in Table 1.

Also, the adhering surface of the absorbing member510and the transmitting member520was visually observed. It was found that for the welded portion550of all samples material failure occurred. Material failure means that failure occurred inside either the absorbing member510or the transmitting member520and the constituent material of one was adhered to the surface of the separated other.

TABLE 1Sample No.1-11-2Laser irradiationAll at onceScanningWidth (mm)Measurement point 12.9650.880Measurement point 22.9241.079Measurement point 33.0111.211Measurement point 43.0351.473Measurement point 53.0631.680Measurement point 63.1051.821Measurement point 73.0912.044Width ratio (%)657Maximum width ratio (%)103140Minimum width ratio (%)9760Maximum tensile stress (MPa)4.601.70

As listed in Table 1, the sample no.1-1using all at once irradiation has a small width ratio of 10% or less. Also, the sample no.1-1using all at once irradiation has a small maximum width ratio of 110% or less and a large minimum width ratio of 90% or greater. In other words, in the sample no.1-1using all at once irradiation, the width of the welded portion is uniform along the circumferential direction of the absorbing member and there is little variation. Thus, the sample no.1-1using all at once irradiation is considered to have high adhesive strength between the absorbing member and the transmitting member and improved adhesion. The sample no.1-2using scanning irradiation has a very large width ratio of 57%. Also, the sample no.1-2using scanning irradiation has a large maximum width ratio of 140% and a small minimum width ratio of 60%. In other words, in the sample no.1-2using scanning irradiation, the width of the welded portion is non-uniform along the circumferential direction of the absorbing member and there is much variation. In the case of scanning irradiation, the heat from the laser is transferred in the scanning direction, with welding tending to occur as the scanning proceeds. Thus, with the sample no.1-2, it is considered that the welded portion was formed with the width increasing as the scanning proceeded. In reality, with the sample no.1-2, the width was the smallest at measurement point1, which is the scan start position, gradually increased in width as the scanning proceeds, and was the largest at measurement point7, which is the scan end position. In the sample no.1-2using scanning irradiation, the width of the welded portion is non-uniform along the circumferential direction of the absorbing member and there is much variation. Thus, it is considered that the adhesive strength between the absorbing member and the transmitting member is low and the adhesion is reduced.

All at once irradiation can be performed with a configuration in which the welded portion is simultaneously irradiated around the entire periphery of the absorbing member. Accordingly, compared to scanning irradiation, it can be considered able to make the laser irradiation apparatus simpler.

The present invention is not limited to these examples and is defined by the scope of the claims, and all modifications that are equivalent to or within the scope of the claims are included.

LIST OF REFERENCE NUMERALS

1Connector apparatus2Circuit board20Conductor path21Conductive pattern22Solder3Connector31Housing311Projection portion311sDistal end surface312Recess portion32Terminal33Attachment portion34Fixing member4Mold resin portion40Trace portion5Welded portion100Assembled article200Integrated article400Pressing apparatus410Metal portion411Optical fiber420Glass portion500Test piece510Absorbing member520Transmitting member550Welded portion