The present application is based on Japanese patent application No. 2008-287269 filed Nov. 10, 2008, the entire contents of which are incorporated herein by reference.
1. Field of the Invention
This invention relates to a connector used in hybrid vehicles, electric vehicles etc. and, particularly, a connector to be used in a wire harness for carrying large amount of power, and relates to so-called “touch protect” technology that a male terminal of a male connector can be protected from being directly touched by a foreign body such as a hand and a finger.
2. Description of the Related Art
In hybrid vehicles, electric vehicles etc. achieving a remarkable improvement in recent years, a high-power harness used for connection between a motor and an inverter, or the inverter and a battery to carry large amount of power has a two-fraction connector composed of a male connector having male terminals and a first terminal housing for housing the male terminals, and a female connector having female terminals to be connected to the male terminals and a second terminal housing for housing the female terminals, which are provided at ends of the high-power harness.
Thus far, so-called “touch protect” technology is known that the male terminals of a male connector can be protected from being directly touched by a foreign body such as a hand and a finger.
The technology is disclosed in JP-A-2008-108675, JP-A-2000-3750, JP-A-S63-190269 etc.
The technology disclosed by the above patent literatures relates to a connector with an insulator disposed at a top end thereof, but has problems below.
The problem is caused when the male terminal is inserted into the female terminal. For example, upon the insertion, the insulator at the top end of the male terminal may contact a protrusion at a dimple portion for electrical contact in the female terminal, or a spring portion for pushing the male terminal against the dimple portion for electrical contact in the female terminal. Thereby, the insertion force of the male terminal may increase that is needed for inserting the male terminal into the female terminal.
Thus, the insertion performance of the male terminal into the female terminal may lower. Also, another problem may be caused that the insulator is worn by the contact therebetween.
Therefore, it is an object of the invention to provide a connector which can protect the male terminal from being directly touched by a foreign body such as a hand and a finger without reducing the insertion performance of the male terminal into the female terminal.
a male connector part comprising a male terminal, a first main body to which the male terminal is attached, and a first terminal housing portion comprising a first housing opening portion in which an end of the male terminal is exhibited and a predetermined housing space in which the male terminal is housed;
a female connector part comprising a female terminal into which the male terminal is inserted, the male terminal being electrically connected to the female terminal by fitting the male connector part with the female connector part;
a holding means inside the female terminal for holding the male terminal in a vertical direction; and
a touch protecting means inside the first terminal housing portion for protecting the male terminal housed in the predetermined housing space from being touched by a foreign body,
wherein the touch protecting means comprises an insulating portion for covering a part of the male terminal including the end of the male terminal except a part contacting the holding means when the male terminal is inserted into the female terminal, and
a pair of projecting portions projecting in the predetermined housing space of the first terminal housing portion and at a position opposite the part contacting the holding means when the male terminal is inserted into the female terminal such that the male terminal is sandwiched therebetween in the vertical direction.
a male connector part comprising a male terminal, a first main body to which the male terminal is attached, and a first terminal housing portion comprising a first housing opening portion in which an end of the male terminal is exhibited and a predetermined housing space in which the male terminal is housed;
a female connector part comprising a female terminal into which the male terminal is inserted, the male terminal being electrically connected to the female terminal by fitting the male connector part with the female connector part;
a holding means inside the female terminal for holding the male terminals in a vertical direction; and
a touch protecting means inside the first terminal housing portion for protecting the male terminal housed in the predetermined housing space from being touched by a foreign body,
wherein the predetermined housing space has such a width in the vertical direction that a part of the male terminal contacting the holding means when the male terminal is inserted into the female terminal can be protected from being touched by the foreign body, and
the touch protecting means comprises an insulating portion for covering a part of the male terminal including the end of the male terminal except the part contacting the holding means when the male terminal is inserted into the female terminal.
a male connector part comprising a male terminal, a first main body to which the male terminal is attached, and a first terminal housing portion comprising a first housing opening portion in which an end of the male terminal is exhibited and a predetermined housing space in which the male terminal is housed;
a female connector part comprising a female terminal into which the male terminal is inserted, the male terminal being electrically connected to the female terminal by fitting the male connector part with the female connector part;
a holding means inside the female terminal for holding the male terminals in a vertical direction; and
a touch protecting means inside the first terminal housing portion for protecting the male terminal housed in the predetermined housing space from being touched by a foreign body,
wherein the predetermined housing space has such a width in the vertical direction that a part of the male terminal contacting the holding means when the male terminal is inserted into the female terminal can be protected from being touched by the foreign body,
the touch protecting means comprises an insulating portion for covering a part of the male terminal including the end of the male terminal except the part contacting the holding means when the male terminal is inserted into the female terminal, and
the touch protecting means further comprises a projecting portion projecting in the predetermined housing space of the first terminal housing portion and at a position opposite the part contacting the holding means when the male terminal is inserted into the female terminal.
In the above embodiments (1) to (3), the following modifications and changes can be made.
(i) The insulating portion at the end of the male terminal projects a predetermined amount from the part contacting the holding means when the male terminal is inserted into the female terminal.
(ii) The male terminal is nearly U-shaped in a cross section, and comprises a pair of sidewall portions and a bottom portion contacting the holding means, and
the insulating portion covers a front surface, an outside surface, an upper surface and a bottom surface of the sidewall portions of the male terminal, and
a front end of the pair of sidewall portions covered with the insulating portion projects a predetermined amount from a front end of the bottom portion.
(iii) The bottom portion comprises a concave portion formed at an end potion thereof.
(iv) The projecting portion has substantially a same width in a horizontal direction as that of the male terminal covered with the insulating portion.
Points of the Invention
A connector of the invention uses (A) a predetermined housing space having such a width in the vertical direction that a part of the male terminal contacting the holding means when the male terminal is inserted into the female terminal can be protected from being touched by the foreign body, and/or (B) a touch protecting means composed of (B1) an insulating portion for covering a part of the male terminal including the end of the male terminal except the part contacting the holding means when the male terminal is inserted into the female terminal, and/or (B2) a projecting portion projecting in the predetermined housing space of the first terminal housing portion and at a position opposite the part contacting the holding means when the male terminal is inserted into the female terminal, in order to protect the male terminal from being directly touched by a foreign body such as a hand and a finger without reducing the insertion performance of the male terminal into the female terminal.
The preferred embodiments according to the invention will be explained below referring to the drawings, wherein:
Hereinafter, a connector according to a first embodiment will be explained with reference to
As shown in
Further, the electric power harness 1 is used for connecting a motor and an inverter which drive HEV (Hybrid Electric Vehicle), the HEV being capable of reducing poisonous gas emissions and fuel consumption drastically, such a large amount of current as not less than 100 A is applied in some HEV system.
Then, a switching between a fit mode that the male connector part 3 and the female connector part 4 are fitted (a mode shown in
If the turning lever 8 is positioned in the mode shown in
Next, the male connector part 3 will be explained.
As shown in
Further, each of the three male terminal 5 is configured to have a structure that the one top end portion faces to the first housing opening portion 15, and the other top end portion is connected to a device side male terminal 17 of a plate-like shape in which a device connection hole 16 of a round shape is formed, the hole 16 being used for engaging with a device side projection portion (not shown) (actually, the male terminal 5 and the device side male terminal 17 are integrally formed from the same material: see
Then, as shown in
Further, the male terminal 5 formed to have a roughly U-shaped cross-section is configured to have a structure that front surfaces 23a of a pair of the sidewall portions 23 are located in advance of a front surface 24a of the bottom portion 24, as shown in
Further, the first terminal housing portion 13 is made of metal, such as aluminum, the internal space thereof forms the predetermined housing space A. Further, in the embodiment, the predetermined housing space A means an internal space from the end portion side of the first main body 14 to the first housing opening portion 15. And, as shown in
Then, a mounting plate 27 is installed on an exterior surface located in a side being near the device side male terminal 17 of the first terminal housing portion 13. Further, in four corners of the mounting plate 27 mounting holes 28 are formed, which can be used when mounted on the device.
Further, in the embodiment, the first main body 14 which is made from insulating resin and is wholly built into the first terminal housing portion 13 has been explained, but the body 14 not being built into the portion 13 can be also used. In other words, for example, the first main body 14 can be installed as the first terminal housing portion 13 covers the end portion constituting a part of the first main body 14. However, if the composition is adopted, it is preferable that a part corresponding to the mounting plate 27 in the embodiment is formed in the side of the first main body 14.
The first main body 14 is made from resin and fabricated by an insert molding method including steps of inserting insert articles (the male terminal 5 and the device side male terminal 17) into a molding, injecting resin in order that the insert articles are wrapped with molten resin, and then solidifying and integrating the insert articles.
In the first main body 14, projecting portions 29 constituting a part of a touch protecting means described below are respectively formed, the projecting portions 29 being located in the upper and lower directions of the male terminal 5, contacting the upper and lower surfaces of the bottom portion 24 of the male terminal 5 and projecting so as to sandwich the male terminal 5 from above and below.
The main points of the invention, the touch protecting means will be explained below.
The touch protecting means comprises rubber caps 26 as insulating portions for covering a part of the male terminal 5 with the exception of parts which contact the holding means described below when the male terminals 5 are inserted into the female terminals 6, including a predetermined region at least from a part facing to the first housing opening portion 15 to the first main body 14 with insulators, and projecting portions 29 installed so as to project in the predetermined housing space A of the first terminal housing portion 13, at the locations opposed to the parts contacting the holding means described below (particularly, the upper and lower surfaces of the bottom portion 24 of the male terminal 5) when the male terminals 5 are inserted into the female terminals 6, and in a state of holding (sandwiching) the male terminals 5 from above and below.
Further, in the embodiment, the predetermined region covered with the rubber caps 26 is defined as a region from the front surfaces 23a of the sidewall portions 23 of the male terminal 5 (refer to
The projecting portions 29 are installed in the first main body 14 corresponding to each of the male terminals 5 so as to extend from the first main body 14 to the first housing opening portion 15 and along the internal surface of the first terminal housing portion 13. Further, as shown in
Further, the top portions of the projecting portions 29, particularly, as shown in
Further, as shown in
Further, as shown in
Then, as shown in
As shown in
Further, the rubber cap 26 covers predetermined regions of the front surfaces 23a of the pair of sidewall portions 23, the external side surface 23b, the upper surface 23c and the lower surface 23d of the male terminal 5, at least including regions from a part facing to the first housing opening portion 15 to the first main body 14, and further, the front surfaces 23a of the pair of sidewall portions 23 covered with the rubber caps 26 are more outstanding than the front surface 24a of the bottom portion 24 of the male terminal 5 in a predetermined amount. Further, in the embodiment, the predetermined amount has been appropriately designed in view of shape of finger.
This structure is capable of protecting the front surface 24a of the bottom portion 24 of the male terminal 5 from being touched by a foreign body such as a hand, a finger even if the front surface 24a of the bottom portion 24 of the male terminal 5 is not covered with the rubber cap 26.
Hereinafter, an operation of applying the rubber cap 26 to the male terminal 5 will be explained with reference to
The top portion of the male terminal 5 is covered with the pocket portion 41 of the rubber cap 26, the one end portion of the lead wire 42 is passed into a hole 38 formed in a predetermined location of the first main body 14 and the one end portion of the lead wire 42 is pulled out from the opposite side of the first main body 14. And, the one end portion of the lead wire 42 pulled out of the hole 38 in the opposite side is further pulled, and it is stopped to pull the lead wire 42 when an engaging portion 43 formed in a predetermined location of the lead wire 42 is pulled out of the hole 38 in the opposite side. And then, a state that the rubber cap 26 is pulled by the top portion of the male terminal 5 is caused, so as to complete the operation of applying the rubber cap 26 to the male terminal 5. Further, in the state that the applying operation is completed, the one end portion of the lead wire 42 which protrudes from the first main body 14 and becomes unnecessary can be cut if needed.
To the first main body 14, a vibration absorption mat 44 for absorbing vibration is attached. This can prevent the male connector part 3 and the female connector part 4 from jouncing in the fitting part therebetween. Namely, this contributes to enhancement of stability of the fitting condition.
Next, the female connector part 4 will be explained.
As shown in
Further, the female terminal box 19 is made from resin, in which three housing spaces are formed so that the respective three female terminals 6 can be housed. Namely, anything can be used as the female terminal box in the embodiment if it is configured to have a plurality of housing spaces for housing the female terminals.
Further, the female terminals 6 are connected to electric wires 22 at the one end portions thereof. The electric wires 22 have excellent heat resistance and oil resistance, and for example, are configured to have a center conductor (copper or aluminum), an insulator (cross-linked polyethylene), a shield, and a seal in this order. Further, the main body of the female terminal 6 is formed so as to have a box-like shape and includes the holding means for holding the male terminals 5 from above and below in the internal portions thereof.
As shown in
In the present application, as to the male terminal 5, “part contacting the holding means when the male terminal is inserted into the female terminal” means, as shown in
Further, as shown in
Further, the second terminal housing portion 21 is made of metal, for example, aluminum. Furthermore, a relationship between the above-mentioned first terminal housing portion 13 and the second terminal housing portion 21 corresponds to the relationship between male and female, and in the first embodiment, the first terminal housing portion 13 corresponds to a male terminal housing portion and the second terminal housing portion 21 corresponds to a female terminal housing portion.
Hereinafter, a connector according to a second embodiment will be explained with reference to
The connector in the second embodiment according to the invention, has a lot of the same portions as those of the above-mentioned connector 2 according to the first embodiment so that only differences from the connector 2 will be explained. Further, the same reference numbers as those of the connector 2 according to the first embodiment will be used throughout the drawings according to the second embodiment shown in
The differences between the connector in the second embodiment according to the invention and the above-mentioned connector 2 according to the first embodiment are as described below.
First, as shown in
Second, as shown in
Third, as shown in
In the first and second embodiments, the projecting portions 29 are installed so as to project in the predetermined housing space A of the first terminal housing portion 13, at the locations opposed to the parts contacting the holding means installed in the female terminal 6 when the male terminal 5 are inserted into the female terminal 6, and at a state of sandwiching the male terminal 5 from above and below, however, the following composition can be also used.
Namely, in the first and second embodiments, where the predetermined housing space A of the first terminal housing portion 13 is relatively large, the projecting portions 29 are installed so as to hold (or sandwich) the male terminal 5 from above and below, however, the width in the vertical direction of the first terminal housing portion 13 may be determined so as to omit one or both of the projecting portions 29. On the other hand, if one of the top surface and the bottom face of the male terminal 5 contacting the holding means is relatively distant from the first terminal housing portion 13 to provide a large housing space therebetween, the projecting portion 29 may be in the large housing space toward the male terminal 5 such that the top surface or the bottom face of the male terminal 5 contacting the holding means can be protected from being touched through the large housing space by the foreign body.
Also due to this, when the male terminals 5 are inserted into the female terminals 6, the top and bottom surfaces of the male terminal 5 which contact the holding means of the female terminal 6 can be protected from being touched by the foreign body.
In the first and second embodiments and the first modification, so-called “three polar type connector” is used, however, so-called “single polar type connector” can be also used.
In the first and second embodiments and the first and second modifications, the male terminal 5 is formed to have a roughly U-shaped cross-section, however, the other shapes (for example, linear shape) can be also used.
In the first and second embodiments and the first, second and third modifications of the embodiment, the projecting portions 29 are formed integrally with the first main body 14, however, they can be formed separately from the first main body 14 so as to be installed in the first main body 14. And, as a different aspect, the projecting portions 29 can be formed integrally with the first terminal housing portion 13 or separately from the first terminal housing portion 13 so as to be installed in the first terminal housing portion 13. Further, in the first and second embodiments and the first, second and third modifications of the embodiment, the engaging structure of the first main body 14 and the first terminal housing portion 13 (see
Although the invention has been described with respect to the specific embodiments for complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art which fairly fall within the basic teaching herein set forth.
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2008-287269 | Nov 2008 | JP | national |
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0 951 099 | Oct 1999 | EP |
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Number | Date | Country | |
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20100120284 A1 | May 2010 | US |