Patent Application
20230275370
This application claims priority from Japanese Patent Application No. 2019-188556 filed with the Japan Patent Office on Oct. 15, 2019, the entire content of which is hereby incorporated by reference.
One aspect of the present disclosure relates to a connector assembly method, an in-vehicle equipment assembly method, a connector assembly, and in-vehicle equipment.
In-vehicle equipment such as an inverter is used under harsh environment requiring strength, waterproofing properties, heat resistance, and dust resistance as compared to general equipment. An external connector is fixed to a case of the in-vehicle equipment. An internal substrate in the case is connected to the external connector. Connection between the external connector and the internal substrate is made by, e.g., screwing of a lead of the external connector to the internal substrate, soldering of the lead of the external connector to a though-hole of the internal substrate, or cable connection of the external connector to an internal connector on the internal substrate. Considering assemblability, a method in which a single-core terminal of an external connector is sandwiched by clip-shaped terminals on an internal substrate has been also proposed (see, e.g., JP-A-2017-157418).
A connector assembly method which includes connecting an external connector fixed to a case of equipment and an internal connector on an internal substrate in the case. A lead extending inward of the case is provided at the external connector, a contact terminal is provided in a socket opening formed at the internal connector, and the connecting the external connector and the internal connector includes inserting a tip end side of the lead into the socket opening in such a manner that the socket opening of the internal connector and a tip end of the lead of the external connector relatively approach each other.
In the following detailed description, for purpose of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and devices are schematically shown in order to simplify the drawing.
In recent years, it has been demanded not only for the in-vehicle equipment but also for other types of equipment, such as industrial equipment, to reduce the size of the equipment and simplify the process of connecting the external connector and the internal substrate. However, in screwing of the lead and soldering of the lead, the process of connecting the external connector and the internal substrate is complicated. In cable connection, a component cost increases, and a cable installation space is necessary in the case. In the method described in JP-A-2017-157418, the external connector is connected to the internal substrate from a direction perpendicular thereto. Thus, the single-core terminal becomes long and the equipment becomes large as a whole, considering, e.g., the height dimension of an electronic component on the internal substrate. Moreover, the terminals are connected in an exposed state, and for this reason, it is difficult to ensure the dust resistance. For this reason, such a connection method is not suitable for the equipment used under the harsh environment.
One object of the present disclosure is to provide a connector assembly method, an in-vehicle equipment assembly method, a connector assembly, and in-vehicle equipment for realizing size reduction in equipment used under harsh environment and simplification of a connection process.
A connector assembly method according to one aspect of the present disclosure includes connecting an external connector fixed to a case of equipment and an internal connector on an internal substrate in the case. A lead extending inward of the case is provided at the external connector, a contact terminal is provided in a socket opening formed at the internal connector, and the connecting the external connector and the internal connector includes inserting a tip end side of the lead into the socket opening in such a manner that the socket opening of the internal connector and a tip end of the lead of the external connector relatively approach each other.
In the connector assembly method of one aspect of the present disclosure, the tip end side of the lead of the external connector is inserted into the socket opening of the internal connector, and in this manner, the lead and the contact terminal contact each other and the external connector and the internal substrate are electrically connected to each other. With this configuration, size reduction in the equipment is realized, and connection between the external connector and the internal substrate is simplified. Further, the contact terminal and the tip end side of the lead are housed in the socket opening, and therefore, the dust resistance is ensured. Thus, even in a case where the equipment is used under the harsh environment, connection between the external connector and the internal substrate is maintained.
Hereinafter, the present embodiment will be described in detail with reference to the attached drawings.
As illustrated in
The internal connector 30 is a socket connector (a floating connector) having a floating structure. In the internal connector 30, a pair of movable housings 33 is movably housed in a rectangular frame-shaped fixed housing 32. Socket openings 34 (see
When the internal substrate 17 is assembled in the case 10, the assembly position of the internal substrate 17 is adjusted by, e.g., a wall surface of the case 10 or a guide pin. However, it is difficult to completely eliminate position displacement between the case 10 and the internal substrate 17. Moreover, when the external connector 20 is fixed to the case 10 and when the internal connector 30 is mounted on the internal substrate 17, slight position displacement is caused. In this case, position displacement between the bus bar 27 and the socket opening 34 is caused. On this point, in the present embodiment, the internal connector 30 has the floating structure, and therefore, the movable housings 33 follow the bus bars 27. Thus, even when position displacement between the bus bar 27 and the socket opening 34 is caused, the bus bar 27 can be easily inserted into the socket opening 34.
Hereinafter, the external connector and the internal connector will be described with reference to
As illustrated in
The pair of support portions 26 supporting the pair of bus bars 27 is provided at the rear end portion of the housing 21. The support portions 26 in a pair are adjacent to each other in a right-left direction, and protrude backward of the rear end portion of the housing 21. The pair of bus bars 27 extends from rear ends of the pair of support portions 26. A tip end side of the pair of bus bars 27 is bent perpendicularly to a base end side of the pair of bus bars 27. Note that “perpendicularly” is not limited to precise perpendicularity, but also includes a substantially perpendicular state which can be taken as perpendicular. A waterproof seal 25 is provided at the periphery of the pair of support portions 26. The waterproof seal 25 liquid-tightly seals between the side wall 11 of the case 10 and the housing 21.
As illustrated in
The pair of movable housings 33 is formed in a rectangular block shape as viewed from above. The movable housings 33 in a pair are placed next to each other in the right-left direction in the fixed housing 32. The upper surface of each movable housing 33 is recessed in a truncated pyramid shape. At the center of such a recess, the socket opening 34 penetrating the movable housing 33 in an upper-lower direction is formed. The recess of the upper surface of the movable housing 33 forms a guide surface 37. The guide surface 37 guides the tip end side of the bus bar 27 toward the socket opening 34. Each movable housing 33 is coupled to the fixed housing 32 through a pair of floating springs 41. By the pair of floating springs 41, each movable housing 33 is supported in a floating state.
The floating spring 41 is formed in such a manner that a metal piece is bent. The floating spring 41 supports the movable housing 33 from below. The floating spring 41 is bent in a U-shape to enter a clearance between the fixed housing 32 and the movable housing 33. A mounting portion 43 extends outward of the fixed housing 32 from a bent portion 42 of the floating spring 41. Further, the contact terminal 44 protrudes inward of the socket opening 34 from the bent portion 42 of the floating spring 41. With this configuration, four mounting portions 43 are provided at the periphery of the fixed housing 32. Further, clip-shaped terminals as a pair of contact terminals 44 are formed in the socket opening 34 of each movable housing 33.
Each mounting portion 43 is, by soldering, fixed to an electrode pad (not shown) of the internal substrate 17. With this configuration, the internal connector 30 is electrically connected to a processing circuit of the internal substrate 17. The bus bar 27 (see
A connector assembly method will be described with reference to
As illustrated in
After the external connector 20 has been fixed to the side wall 11 of the case 10, the internal connector 30 on the internal substrate 17 is positioned above the pair of bus bars 27. The internal substrate 17 is also vertically inverted. Thus, the internal connector 30 on an upper surface of the internal substrate 17 faces down. The pair of socket openings 34 (see
The internal substrate 17 is lowered along the wall surface of the case 10. Note that the accuracy of positioning between the case 10 and the internal substrate 17 is not sufficient. For this reason, it is difficult to position the pair of socket openings 34 of the internal connector 30 relative to the pair of bus bars 27 of the external connector 20. On this point, in the present embodiment, the tip ends of the pair of bus bars 27 of the external connector 20 come into contact with the guide surfaces 37 at the periphery of the pair of socket openings 34 of the internal connector 30, and accordingly, the tip ends of the pair of bus bars 27 are guided to the pair of socket openings 34 by the guide surfaces 37. With this configuration, even when position displacement between the bus bar 27 and the socket opening 34 is caused, the tip end side of the pair of bus bars 27 is easily inserted into the pair of socket openings 34.
As illustrated in
As described above, in the connector assembly method of the present embodiment, the tip end side of the pair of bus bars 27 of the external connector 20 is inserted into the pair of socket openings 34 of the internal connector 30, and in this manner, the external connector 20 and the internal substrate 17 can be easily connected to each other. Moreover, in a state in which the case 10 is vertically inverted, the internal substrate 17 is assembled with the case 10 from above. Thus, on, e.g., an in-vehicle equipment production line, workability in the process of assembling the internal substrate 17 with the case 10 can be improved. Further, automation of the process of assembling the internal substrate 17 with the case 10 by an automatic machine can be realized.
Subsequently, the methods for connecting an external connector and an internal substrate in first to third comparative examples and the method for connecting the external connector and the internal substrate in the present embodiment will be described in comparison with each other.
The connection method of the first comparative example as illustrated in
The connection method of the third comparative example as illustrated in
Regarding the assemblability, the connection methods of the first and second comparative examples are rated low, the connection method of the third comparative example is rated intermediate, and the connection method of the present embodiment is rated highest. In the connection method of the first comparative example, a high-load screwing process is necessary in assembly of the internal substrate 53. In the connection method of the second comparative example, a high-load soldering process is necessary in assembly of the internal substrate 63. In the connection method of the third comparative example, cable connection with an intermediate level of load is necessary in assembly of the internal substrate 73. In the connection method of the present embodiment, the internal substrate 17 can be assembled by the lowest-load process of inserting the tip ends of the bus bars 27 of the external connector 20 into the socket openings 34 of the internal connector 30.
Regarding the automation, the connection methods of the first and third comparative examples are rated low, the connection method of the second comparative example is rated intermediate, and the connection method of the present embodiment is rated highest. The screwing process of the connection method of the first comparative example and the cable connection process of the connection method of the third comparative example are not suitable for the automation. The soldering process of the connection method of the second comparative example can be automated. However, it is difficult to automatically properly adjust, e.g., a solder amount. In the connection method of the present embodiment, the internal substrate 17 approaches the case 10 from above, and in this manner, the internal substrate 17 is connected to the external connector 20. Thus, automation of an assembly process can be easily realized by an automatic machine such as a robot arm.
Regarding the repair, the connection method of the first comparative example is rated intermediate, the connection method of the second comparative example is rated low, the connection method of the third comparative example is rated high, and the connection method of the present embodiment is rated highest. In the connection method of the first comparative example, a screw detachment process with an intermediate level of load is necessary in replacement of the internal substrate 53. In the connection method of the second comparative example, it is difficult to replace the internal substrate 63 soldered to the bus bars 62 of the external connector 61. In the connection method of the third comparative example, the internal substrate 17 can be replaced by a low-load cable detachment process. In the connection method of the present embodiment, the internal substrate 17 can be replaced by the lowest-load process of pulling up the internal substrate 17 from the case 10.
Regarding the space saving, the connection methods of the first and second comparative examples are rated high, the connection method of the third comparative example is rated low, and the connection method of the present embodiment is rated high. In the connection method of the first comparative example, the bus bars 52 are bent in the crank shape. In the connection method of the second comparative example, the bus bars 62 are bent in the right-angle shape. Thus, in the connection methods of the first and second comparative examples, the space saving can be realized. In the connection method of the third comparative example, an installation space for the cable 75 needs to be ensured, and for this reason, it is difficult to realize the space saving. In the connection method of the present embodiment, the bus bars 27 are bent in the right-angle shape, and therefore, the space saving can be realized as in the first and second comparative examples.
Regarding the contact reliability, the connection method of the first comparative example is rated intermediate, the connection method of the second comparative example is rated low, the connection method of the third comparative example is rated high, and the connection method of the present embodiment is rated highest. In the connection method of the first comparative example, there is a probability that contact failure is caused due to loosening of the screws. In the connection method of the second comparative example, contact failure is relatively easily caused at a soldering portion due to fatigue failure. In the connection method of the third comparative example, cable connection is employed, and for this reason, there is a low probability that contact failure is caused at a connection portion. In the connection method of the present embodiment, multipoint contact that the bus bar 27 is sandwiched by the pair of contact terminals 44 is employed, and therefore, the risk of the contact failure can be most reduced.
Regarding the vibration resistance, the connection methods of the first and second comparative examples are rated low, the connection method of the third comparative example is rated high, and the connection method of the present embodiment is rated highest. In the connection method of the first comparative example, there is a probability that loosening of the screws is caused due to vibration transmitted to a screwing location. In the connection method of the second comparative example, there is a probability that the soldering portion is damaged due to vibration transmitted to the soldering portion. In the connection method of the third comparative example, cable connection is employed, and therefore, influence of vibration is small. In the connection method of the present embodiment, the internal connector 30 employs the floating structure. Thus, the floating structure absorbs vibration, and therefore, connection between the internal substrate 17 and the external connector 20 can be favorably maintained.
As described above, according to the present embodiment, the tip end side of the bus bars 27 of the external connector 20 is inserted into the socket openings 34 of the internal connector 30, and in this manner, the bus bars 27 and the contact terminals 44 contact each other and the external connector 20 and the internal substrate 17 are electrically connected to each other. With this configuration, size reduction in the in-vehicle equipment is realized, and connection between the external connector 20 and the internal substrate 17 is simplified. Moreover, before the internal connector 30 is connected to the pair of bus bars 27 of the external connector 20, the external connector 20 is fixed to the case 10. With this configuration, waterproofing can be performed for the periphery of the external connector 20 in advance. Further, the contact terminals 44 and the tip end side of the bus bars 27 are housed in the socket openings 34, and therefore, the dust resistance is ensured. Thus, even in a case where the in-vehicle equipment is used under the harsh environment, connection between the external connector 20 and the internal substrate 17 is maintained.
Note that in the present embodiment, after the external connector 20 has been fixed to the case 10, the internal substrate 17 is placed in the case 10, and the tip ends of the bus bars 27 of the external connector 20 are inserted into the socket openings 34 of the internal connector 30. However, the order of these processes is not limited to above. As illustrated in a variation of
Hereinafter, the variation will be described.
As illustrated in
As illustrated in
As illustrated in
As illustrated in
In the present embodiment and the variation, the floating connector has been described as an example of the internal connector. However, the internal connector is not limited to the floating connector. In the present embodiment and the variation, even when the internal connector is not the floating connector, a high rating can be obtained in terms of five points of the assemblability, the automation, the repair, the space saving, and the contact reliability.
Moreover, in the present embodiment and the variation, the external connector and the internal connector may be any of power connectors configured to receive power from an external power source and signal connectors configured to receive a signal from external equipment.
Further, in the present embodiment and the variation, the clip-shaped terminals are provided in the socket opening. On this point, the contact terminal in the socket opening is not necessarily the clip-shaped terminal.
In addition, in the present embodiment and the variation, the guide surfaces are formed at the internal connector. However, the guide surfaces are not necessarily formed at the internal connector.
Moreover, in the present embodiment and the variation, the internal substrate is connected to the external connector from above. Instead, the internal substrate may be connected to the external connector from below.
Further, in the present embodiment and the variation, the pair of bus bars as the leads extends from the external connector. Instead, a single lead may extend from the external connector. Alternatively, three or more leads may extend from the external connector.
In addition, in the present embodiment and the variation, the in-vehicle equipment has been described as an example of the equipment. On this point, the equipment may be other types of equipment, such as industrial equipment.
As described above, the connector assembly method of the present embodiment includes connecting the external connector (20, 80) fixed to the case (10) of the equipment and the internal connector (30, 90) on the internal substrate (17) in the case. In this connector assembly method, the lead (the bus bar 27, 87) extending inward of the case is provided at the external connector. Moreover, the contact terminal (44) is provided in the socket opening (34, 94) formed at the internal connector. Further, the connecting the external connector and the internal connector includes inserting the tip end side of the lead into the socket opening in such a manner that the socket opening of the internal connector and the tip end of the lead of the external connector relatively approach each other. According to this method, the tip end side of the lead of the external connector is inserted into the socket opening of the internal connector, and in this manner, the lead and the contact terminal contact each other and the external connector and the internal substrate are electrically connected to each other. With this configuration, size reduction in the equipment is realized, and connection between the external connector and the internal substrate is simplified. Further, the contact terminal and the tip end side of the lead are housed in the socket opening, and therefore, the dust resistance is ensured. Thus, even in a case where the equipment is used under the harsh environment, connection between the external connector and the internal substrate is maintained.
In the connector assembly method of the present embodiment, the internal connector may be the floating connector, and the movable housing (33, 93) may be supported in the floating state in the fixed housing (32, 92) fixed to the internal substrate through the floating spring (41, 99). According to this method, position displacement of the external connector relative to the case, position displacement of the internal connector relative to the internal substrate, and position displacement of the internal substrate relative to the case are absorbed by movement of the movable housing relative to the fixed housing. Moreover, by the floating spring, vibration transmitted to the in-vehicle equipment is absorbed. With this configuration, connection between the lead of the external connector and the contact terminal of the internal connector is maintained.
In the connector assembly method of the present embodiment, the clip-shaped terminals as the pair of contact terminals may be formed in the socket opening. According to this method, the lead is sandwiched by the pair of contact terminals. Thus, even in a case where the in-vehicle equipment is used under the harsh environment, the contact reliability is improved by multipoint contact among the contact terminals and the lead.
In the connector assembly method of the present embodiment, the guide surface (37, 97) configured to guide the tip end side of the lead may be formed toward the socket opening at the internal connector. According to this method, the tip end of the lead contacts the guide surface of the internal connector. With this configuration, the tip end of the lead is guided to the socket opening by the guide surface. Thus, the tip end side of the lead is easily inserted into the socket opening.
In the connector assembly method of the present embodiment, the tip end side of the lead may be bent perpendicularly to the base end side of the lead. According to this method, the internal connector approaches the external connector from the direction perpendicular to an internal connector attachment direction so that the external connector and the internal connector can be connected to each other.
In the connector assembly method of the present embodiment, the inserting the tip end side of the lead into the socket opening may include causing, after the external connector has been fixed to the case, the socket opening of the internal connector to approach the tip end of the lead of the external connector. According to this method, the internal substrate can be placed in the case after the external connector has been fixed to the case.
In the connector assembly method of the present embodiment, the external connector may be fixed to the side wall of the case, and the tip end of the lead may face up. The inserting the tip end side of the lead into the socket opening may include causing the socket opening of the internal connector to approach the tip end of the lead of the external connector from above. According to this method, on, e.g., the in-vehicle equipment production line, the workability in the assembly process can be improved. Further, the assembly process can be automated by the automatic machine.
In the connector assembly method of the present embodiment, the lead includes the multiple leads extending inward of the case from the external connector. The socket opening may include the multiple socket openings formed at the internal connector. The contact terminals may be provided in each socket opening. According to this configuration, the multiple leads of the external connector and the contact terminals in the multiple socket openings of the internal connector can be easily connected to each other.
In the in-vehicle equipment in the in-vehicle equipment assembly method of the present embodiment, the external connector is fixed to the case, and the internal substrate is placed in the case. The lead extending inward of the case is provided at the external connector. The internal connector is provided on the internal substrate. The contact terminal is provided in the socket opening formed at the internal connector. This assembly method includes fixing the external connector to the case and placing the internal substrate in the case such that the tip end side of the lead is inserted into the socket opening in such a manner that the socket opening of the internal connector and the tip end of the lead of the external connector relatively approach each other. According to this method, size reduction in the in-vehicle equipment is realized, and connection between the external connector and the internal substrate is simplified. Further, even in a case where the in-vehicle equipment is used under the harsh environment, connection between the external connector and the internal substrate is maintained.
The connector assembly of the present embodiment includes the external connector fixed to the case of the equipment, and the internal connector provided on the internal substrate in the case. The lead extending inward of the case is provided at the external connector. The contact terminal is provided in the socket opening formed at the internal connector. The internal connector and the external connector are formed in such shapes that the tip end side of the lead is insertable into the socket opening in such a manner that the socket opening of the internal connector and the tip end of the lead of the external connector relatively approach each other. According to this configuration, size reduction in the equipment is realized, and connection between the external connector and the internal substrate is simplified. Further, even in a case where the equipment is used under the harsh environment, connection between the external connector and the internal substrate is maintained.
The in-vehicle equipment of the present embodiment includes the case, the external connector fixed to the case, the internal substrate placed in the case, and the internal connector provided on the internal substrate. The lead extending inward of the case is provided at the external connector. The contact terminal is provided in the socket opening formed at the internal connector. The internal connector and the external connector are formed in such shapes that the tip end side of the lead is insertable into the socket opening in such a manner that the socket opening of the internal connector and the tip end of the lead of the external connector relatively approach each other. According to this configuration, size reduction in the in-vehicle equipment is realized, and connection between the external connector and the internal substrate is simplified. Further, even in a case where the in-vehicle equipment is used under the harsh environment, connection between the external connector and the internal substrate is maintained.
The present embodiment and the variation have been described above. Other embodiments of the present disclosure may be those obtained by entirely or partially combining the present embodiment and the variation described above.
Moreover, the technique of the present disclosure is not limited to the above-described embodiment. The above-described embodiment may be changed, replaced, or modified in various manners without departing from the gist of the technical idea. Further, in a case where the technical idea can be implemented in another way by development of the technique or another derived technique, the technique of the present disclosure may be implemented using such a method. Thus, the scope of the claims covers all embodiments included in the scope of the technical idea.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2019-188556 | Oct 2019 | JP | national |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17064643 | Oct 2020 | US |
| Child | 18142815 | US |
