Information
-
Patent Grant
-
6447331
-
Patent Number
6,447,331
-
Date Filed
Monday, May 15, 200024 years ago
-
Date Issued
Tuesday, September 10, 200221 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Paumen; Gary F.
- Figueroa; Felix O
Agents
-
CPC
-
US Classifications
Field of Search
US
- 439 516
- 439 43
- 439 49
- 439 507
- 439 510
- 439 511
- 439 521
- 138 89
-
International Classifications
-
Abstract
A bus bar base member 55W is integrally joined to a holder body 51 by insert molding, thereby forming a bus bar structure 50, and the bus bar base member 55W is severed at a portion thereof into a plurality of bus bars. One side (surface) of an interconnecting portion 56 is exposed at those regions, corresponding respectively to punching holes 54, and those regions, each disposed between the adjacent punching holes 54, at an entire area thereof to provide an entire exposure surface 56A. When there is used a die 71 adapted to be held against this exposed surface, there is no need to form any convex portion of a low strength on the die 71.
Description
BACKGROUND OF THE INVENTION
This invention relates to a joint connector and a method of producing the joint connector.
There is known a joint connector of the type in which a bus bar structure is attached to a housing having a plurality of juxtaposed metal terminals received therein. The bus bar structure comprises a holder body, made of a synthetic resin, and a plurality of bus bars made of metal, and each of the bus bars has a plurality of tabs. The tabs are divided into a plurality of groups, and the group of tabs for each bus bar are electrically connected to each other. When the bus bar structure is attached to the housing, the tabs contact the associated metal terminals, respectively, so that the plurality of metal terminals are short-circuited in a predetermined pattern. One such joint connector is disclosed in the Unexamined Japanese Patent Application Publication No. Hei 4-32175.
Even in the case where there are a plurality of short-circuiting patterns, the bus bar structure includes the bus bar-forming part of a common design so that the number of the component parts can be reduced. More specifically, as shown in
FIG. 9
, a bus bar base member
102
, having a plurality of juxtaposed tabs
104
extending from a side edge of a strip-like interconnecting portion
103
, is integrally joined to a tubular holder body
101
by insert molding, thereby producing a bus bar structure
100
of a common design. Then, the interconnecting portion
103
of the bus bar structure
100
is severed at a portion thereof, thereby dividing the bus bar base member
102
into a plurality of bus bars corresponding to a predetermined short-circuiting pattern.
A plurality of upwardly and downwardly-open, punching grooves
105
are formed in the holder body
101
, and that portion of the interconnecting portion
103
, disposed between any two adjacent tabs
104
, is exposed through the corresponding punching groove
105
. For severing the connecting portion
103
, a die
106
is held against the lower surface of the interconnecting portion
103
at the predetermined punching groove
105
, and a punch
107
is driven from the upper side, as shown in FIG.
10
.
The die
106
has a pair of guide walls
106
A for fitting into the punching groove
105
from the lower side, and the punch
107
has a projecting piece-shape so as to be inserted between the two guide walls
106
A. In the severing operation, the distal ends of the guide walls
106
A are held against the lower surface of the interconnecting portion
103
, and in this condition the punch
107
is driven to punch part (a portion) of the interconnecting portion, and this removed piece is received in the gap between the two guide walls
106
A.
In the above joint connector, any two adjacent punching grooves
105
are separated from each other by a partition wall
108
, and therefore the guide walls
106
A must be formed on the die
106
so as to extend a long the opposed partition walls
108
, respectively. The smaller the width of the punching grooves
105
, the smaller the thickness of the guide walls
106
A, and the smaller the pitch of the tabs
104
(that is, the pitch of the metal terminals), the smaller the width of the punching grooves
105
. However, recently, it has been desired to achieve a compact design of the joint connector, that is, to reduce the pitch of the metal terminals, and in order to meet this requirement, the width of the punching grooves
105
must be reduced, and in this connection, the thickness of the guide walls
106
A must also be reduced. However, this invites a problem that the strength of the guide walls
106
A is reduced.
It is provided with a joint connector of the type in which a bus bar structure is attached to a housing having a plurality of juxtaposed metal terminals received therein. The bus bar structure comprises a holder body, made of a synthetic resin, and a plurality of bus bars made of metal, and each of the bus bars has a plurality of tabs. The tabs are divided into a plurality of groups, and the group of tabs for each bus bar are electrically connected to each other. When the bus bar structure is attached to the housing, the tabs contact the associated metal terminals, respectively, so that the plurality of metal terminals are short-circuited in a predetermined pattern.
Even in the case where there are a plurality of short-circuiting patterns, the bus bar structure includes the bus bar-forming part of a common design so that the number of the component parts can be reduced. More specifically, as shown in
FIG. 16
, a bus bar base member
202
, having a plurality of juxtaposed tabs
202
B extending from a side edge of a strip-like interconnecting portion
202
A, is integrally joined to a tubular holder body
201
by insert molding, thereby producing a bus bar structure
200
of a common design. Then, the interconnecting portion
202
A of the bus bar structure
200
is severed at a portion
202
C thereof, thereby dividing the bus bar base member
202
into a plurality of bus bars
203
corresponding to a predetermined short-circuiting pattern.
A plurality of punching holes
204
are formed in the holder body
201
, and each punching hole
204
is disposed in registry with that portion of the interconnecting portion
202
A disposed between the adjacent tabs
202
B. The interconnecting portion
202
A can be severed at the punching hole
204
, using a die and a punch (not shown). With respect to the severed portion of the interconnecting portion
202
A, the bus bar
203
serves to short-circuit a plurality of metal terminals (not shown), and it is clear from this that the interconnecting portion
202
A is not severed at that portion thereof disposed between each endmost tab
202
B (disposed at each end of the bus bar base member) and the adjoining tab
202
B. Therefore, the punching hole
204
is not formed at those regions corresponding respectively to the opposite end portions of the bus bar base member
202
, and the opposite end portions of the interconnecting portion
202
A are embedded in the resin-molded holder body
201
.
The punching holes
204
are formed by removing part of a mold (which holds the bus bar base member
202
) in the insert molding operation. Therefore, the formation of the punching holes
204
is significant since this facilitates the severing of the interconnecting portion
202
A, and besides can provide the regions where the bus bar base member
202
is held during the inserting molding. Therefore, in the case of the above construction in which any punching hole
204
is not formed in the opposite end portions, the end portions of the interconnecting portion
202
A are deformed by an injection pressure during the molding operation, which leads to a possibility that the alignment of the tabs
202
B, disposed respectively at the opposite end portions, are adversely affected.
A joint connector comprises a housing, having a plurality of juxtaposed metal terminals received therein, and a bus bar structure, which includes an electrically-conductive bus bar, having a plurality of juxtaposed tabs extending from a side edge of an interconnecting portion, and a holder body of a synthetic resin integrally joined to the busbar. When the busbar structure is attached to the housing, the tabs contact the associated metal terminals, respectively, so that the metal terminals are short-circuited in a predetermined pattern.
There is known a method of producing a bus bar structure for this kind of joint connector, in which a chain terminal structure, having a plurality of bus bars connected to side edges of a carrier through bridge portions, is first formed by pressing, and then the bus bar is integrally joined to a holder body by insert molding, and the bridge portions are severed, thereby separating the bus bar structure from the carrier. Such a production method is disclosed in the Unexamined Japanese Patent Application Publication No. Hei 9-213436.
In the production method disclosed in the above publication, the bus bars of the chain terminal structure are connected to the carrier in such a manner that projected ends of tabs are continuous with the bridge portions. Therefore, when the bridge portions are severed or cut off, cutting marks are formed on the tabs, which leads to a possibility that the distal end of the tab, pressed into a tapering shape, is deformed, and in the case where a flash is kept formed on the tab, there is a possibility that a metal terminal is caught by the flash when connecting the metal terminal to the tab.
SUMMARY OF THE INVENTION
This invention has been made under the above circumstances, and an object of the invention is to provide a construction in which any portion of a low strength does not need to be formed on a die.
According to the present invention, there is provided a joint connector comprising a housing having a plurality of juxtaposed metal terminals received therein; and a bus bar structure having a plurality of bus bars each having a plurality of tabs; wherein when the bus bar structure is attached to the housing, the tabs contact the associated metal terminals, respectively, so that the metal terminals are short-circuited in a predetermined pattern; and wherein a bus bar base member, having the plurality of juxtaposed tabs extending from a side edge of an interconnecting portion, is integrally joined to a holder body of a synthetic resin, having a plurality of punching holes, by insert molding, thereby forming the bus bar structure, that portion of the interconnecting portion, disposed between the adjacent tabs, being exposed through the corresponding punching hole; and the interconnecting portion is severed at any one of the plurality of punching holes, thereby dividing the bus bar base member into the plurality of bus bars; CHARACTERIZED in that that surface of the interconnecting portion, facing away from the punching holes, is exposed at those regions, corresponding respectively to the punching holes, and those regions, each disposed between the adjacent punching holes, to an outer surface of the holder body over an entire area thereof.
In the invention, a cap is attached to the housing to cover the bus bar structure.
In the invention, a seal member is provided on the housing, and is fitted watertight in an open end of the cap.
(Aspect 1)
That surface of the interconnecting portion, facing away from the punching holes, is exposed at those regions, corresponding respectively to the punching holes, and those regions, each disposed between the adjacent punching holes, to the outer surface of the holder body over the entire area thereof. Therefore, when there is used a die adapted to be held against this exposed surface, there is no need to form any convex portion of a low strength on the die.
(Aspect 2)
The one side (surface) of the interconnecting portion of the bus bar structure is exposed over the entire area thereof, and any partition portion is not provided between the bus bars separated from each other at the severed portion. Therefore, if a foreign matter is deposited on the two bus bars in a manner to bridge this severed portion, the two bus bars are electrically connected to each other. In the invention, however, the bus bar structure is covered with the cap, and therefore the deposition of such a foreign matter is prevented, thus preventing the two bus bars from being electrically connected together.
(Aspect 3)
When the cap is attached to the housing, the seal member is snugly fitted in the open end of the cap in a watertight manner, thereby preventing the intrusion of water into the cap, thus preventing the water from reaching the bus bar structure.
Further, this invention has been made under the above circumstances, and an object of the invention is to provide a construction in which the alignment of tabs are prevented from being adversely affected by an injection pressure during the insert molding of a bus bar structure.
(Aspect 4)
According to a 4th aspect of the present invention, there is provided a joint connector comprising:
a housing having a plurality of juxtaposed metal terminals received therein; and
a bus bar structure having a plurality of bus bars each having a plurality of tabs;
wherein when the bus bar structure is attached to the housing, the tabs contact the associated metal terminals, respectively, so that the metal terminals are short-circuited in a predetermined pattern;
wherein a bus bar base member, having the plurality of juxtaposed tabs extending from a side edge of an interconnecting portion, is integrally joined to a holder body of a synthetic resin, having a plurality of punching holes, by insert molding, thereby forming the bus bar structure, that portion of the interconnecting portion, disposed between the adjacent tabs, being exposed through the corresponding punching hole; and the interconnecting portion is severed at any one of the plurality of punching holes, thereby dividing the bus bar base member into the plurality of bus bars;
Characterized in that window holes are formed in the holder body, and opposite end portions of the interconnecting portion, disposed outside a severance-applying portion of the interconnecting portion, are exposed to the exterior through the respective window holes.
(Aspect 5)
According to a 5th aspect of the invention, there is provided a method of producing a joint connector comprising:
a housing having a plurality of juxtaposed metal terminals received therein; and
a bus bar structure having a plurality of bus bars each having a plurality of tabs;
wherein when the bus bar structure is attached to the housing, the tabs contact the associated metal terminals, respectively, so that the metal terminals are short-circuited in a predetermined pattern;
wherein a bus bar base member, having the plurality of juxtaposed tabs extending from a side edge of an interconnecting portion, is integrally joined to a holder body of a synthetic resin, having a plurality of punching holes, by insert molding, thereby forming the bus bar structure, that portion of the interconnecting portion, disposed between the adjacent tabs, being exposed through the corresponding punching hole; and the interconnecting portion is severed at any one of the plurality of punching holes, thereby dividing the bus bar base member into the plurality of bus bars;
Characterized in that during the insert molding, opposite end portions of the interconnecting portion, disposed outside a severance-applying region of the interconnecting portion, are held.
(The Invention of Aspect 4)
During the insert molding of the bus bar structure, part of a mold is disposed in spaces, corresponding respectively to the window holes provided respectively at the opposite end portions, to hold the opposite end portions of the interconnecting portion, and therefore the deformation of the opposite end portions of the interconnecting portion by an injection pressure is prevented, and therefore the alignment of the tabs, disposed respectively at the opposite end portions of the interconnecting portion, will not be adversely affected.
(The Invention of Aspect 5)
During the insert molding of the bus bar structure, the mold holds the opposite end portions of the interconnecting portion, and therefore the deformation of the opposite end portions of the interconnecting portion by the injection pressure is prevented, and therefore the alignment of the tabs, disposed respectively at the opposite end portions of the interconnecting portion, will not be adversely affected.
Still further, this invention has been made under the above circumstances, and an object of the invention is to provide a construction in which a cutting mark is prevented from being formed on tabs when cutting a bus bar structure off from a carrier.
(Aspect 6)
According to a 6th aspect of the invention, there is provided a joint connector comprising:
a housing having a plurality of juxtaposed metal terminals provided therein; and
a bus bar structure, which includes an electrically-conductive bus bar, having a plurality of juxtaposed tabs extending from an edge of an interconnecting portion, and a holder body of a synthetic resin integrally joined to the bus bar;
wherein when the bus bar structure is attached to the housing, the tabs contact the associated metal terminals, respectively, so that the metal terminals are short-circuited in a predetermined pattern;
wherein there is provided a chain terminal structure having a plurality of the bus bars connected to side edges of a carrier through bridge portions, and the bus bar of the chain terminal structure is integrally joined to the holder body by insert molding, and the bus bar and the holder body, thus integrally joined together, are separated from the carrier by cutting the bridge portions;
Characterized in that each of the bus bars of the chain terminal structure is connected to the carrier through the bridge portions connected to the interconnecting portion of the bus bar.
(Aspect 7)
In a 7th aspect of the invention, the bus bar of the chain terminal structure is connected to the carrier through the bridge portions connected to that edge of the interconnecting portion facing away from the tabs, and cut surfaces of the bridge portions of the bus bar structure are exposed to an outer surface of the holder body, and the bus bar structure is attached to the housing by pushing the outer surface, to which the cut surfaces of the bridge portions are exposed, by the finger; and recesses are formed respectively in those portions of the outer surface of the holder body to which the cut surfaces of the bridge portions are exposed, respectively, and each of the bridge portions is cut at a portion thereof disposed immediately adjacent to a bottom surface of the corresponding recess.
(Aspect 8)
According to an 8th aspect of the invention, there is provided a method of producing a joint connector comprising:
a housing having a plurality of juxtaposed metal terminals provided therein; and
a bus bar structure, which includes an electrically-conductive bus bar, having a plurality of juxtaposed tabs extending from an edge of an interconnecting portion, and a holder body of a synthetic resin integrally joined to the bus bar;
wherein when the bus bar structure is attached to the housing, the tabs contact the associated metal terminals, respectively, so that the metal terminals are short-circuited in a predetermined pattern; Characterized by the steps of:
forming, by pressing, a chain terminal structure having a plurality of the bus bars connected to side edges of a carrier through bridge portions, the bridge portions being connected to the edge of the interconnecting portion of the bus bar;
integrally joining the bus bar to the holder body by insert molding; and
separating the bus bar and the holder body, thus integrally joined together, from the carrier by cutting the bridge portions, thereby obtaining the bus bar structure.
(The Inventions of Aspects 6 and 8)
Each bus bar of the chain terminal structure is connected to the carrier not through the tabs but via the side edge of the interconnecting portion. Therefore, when the bridge portions are cut or severed, any cutting mark is not formed on the tabs.
(The Invention of Aspect 7)
When attaching the bus bar structure to the housing, the outer surface of the holder body, facing away from the tabs (that is, that surface to which the cut surfaces of the bridge portions are exposed), is pushed by the finger. The cut surface of each bridge portion is disposed inwardly of the outer surface of the holder body, and therefore the finger will not come into contact with the cut surface of the bridge portion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is a perspective view of an embodiment 1 of the invention, showing a condition in which a seal member and a seal holder are attached to a housing.
FIG. 2
a partly-broken, perspective view of a bus bar structure.
FIG. 3
is a perspective view of a cap.
FIG. 4
a cross-sectional view showing an assembled condition.
FIG. 5
is a partly-broken, plan view of the bus bar structure.
FIG. 6
is a partly-broken, front-elevational view of the bus bar structure.
FIG. 7
is a fragmentary, enlarged cross-sectional view showing a condition in which a bus bar base member is severed.
FIG. 8
is a fragmentary, enlarged cross-sectional view showing a condition before the bus bar base member is severed.
FIG. 9
is a plan view of a conventional bus bar structure.
FIG. 10
is a fragmentary, enlarged cross-sectional view showing the manner of severing a conventional bus bar base member.
FIG. 11
is a cross-sectional view showing a condition in which the seal member and the seal holder are attached to the housing.
FIG. 12
is a partly-broken, plan view of the bus bar structure.
FIG. 13
is across-sectional view of the bus bar structure.
FIG. 14
is a cross-sectional view of a cap.
FIG. 15
is a cross-sectional view showing the process of insert molding of the bus bar structure.
FIG. 16
is a partly-broken, plan view of a conventional bus bar structure.
FIG. 17
a horizontal cross-sectional view showing an assembled condition.
FIG. 18
is a vertical cross-sectional view of the bus bar structure.
FIG. 19
is a partly-broken, plan view showing a condition in which the bus bar structure is cut off from a carrier of a chain terminal structure.
FIG. 20
is a plan view of the chain terminal structure.
FIG. 21
is a partly-broken, plan view showing a condition in which a bus bar is integrally joined to a holder body by insert molding.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(Embodiment 1)
An embodiment 1 of the present invention will now be described with reference to
FIGS. 1
to
8
.
A joint connector of this embodiment comprises a housing
10
, a plurality of metal terminals
20
, a seal member
30
, a seal holder
40
, two bus bar structures
50
, and a cap
60
. The plurality of metal terminals
20
are short-circuited in a predetermined pattern by a plurality of bus bars
55
.
(Housing
10
)
The housing
10
is made of a synthetic resin, and a plurality of cavities (chambers)
11
are formed within the housing
10
, and are arranged in two (upper and lower) rows (stages), and these cavities
11
extend through the housing
10
from its front side to its rear side, each row of cavities
11
being arranged at
10
a predetermined pitch. The upper row of cavities
11
are open at their generally front half portions to the upper side of the housing
10
whereas the lower row of cavities
11
are open at their generally front half portions to the lower side of the housing
10
. A lance
12
, projecting forwardly in a cantilever manner, is
15
formed at each of these open portions. A slot-like recess
13
for receiving peripheral walls of the bus bar structures
50
is formed between the upper and lower rows of cavities
11
, and is elongate in a direction of the width of the housing. Notches are formed in an upper wall of the recess
13
, and communicate with the upper row of cavities
11
, whereas notches are formed in a lower wall of the recess
13
, and communicate with the lower row of cavities
11
.
(Metal Terminal
20
)
The metal terminal
20
is formed by bending a metal sheet blank of a predetermined shape, and a generally front half portion of the metal terminal is formed into a fitting portion
21
of a square tubular shape having open front and rear ends, and a generally rear half portion of the metal terminal is formed into a wire connection portion
22
to which a wire
25
is clamped by pressing. A resilient contact piece
23
for resilient contact with a tab
57
of the bus bar structure
50
is provided within the fitting portion
21
, and a retaining hole
24
for retaining engagement with the lance
12
on the housing
10
is formed through a peripheral wall of the fitting portion
21
. The metal terminal
20
is passed through the seal holder
40
and the seal member
30
, attached to the housing
10
, from the rear side of the housing
10
, and is inserted into the cavity
11
in the housing
10
. Immediately before the metal terminal
20
reaches its proper inserted position, the lance
12
interferes with the outer surface of the peripheral wall of the fitting portion
21
, and therefore is elastically deformed outwardly from the housing
10
, and then when the metal terminal
20
reaches its proper inserted position, the lance
12
is elastically restored into its original shape to be retainingly engaged in the retaining hole
24
, thereby retaining the metal terminal
20
against withdrawal.
(Seal Member
30
)
The seal member
30
is made of rubber, and comprises a thick plate of an elongate oval shape, and is held between the rear end surface of the housing
10
and the front end surface of the seal holder
40
. A plurality of seal holes
31
are formed through the seal member
30
, and are open to the front and rear sides of the seal member
30
, and are aligned respectively with the cavities
11
in the housing
10
. Each of the seal holes
31
has a circular shape, and three lips
31
A of a generally triangular cross-section are formed circumferentially on an inner peripheral surface of the seal hole
31
. The inner diameter of each lip
31
A is smaller than the outer diameter of the wire
25
. The wire
25
is passed through the seal hole
31
, and the lips
31
A are elastically held in intimate contact with the outer peripheral surface of the wire
25
, thereby forming a seal between the wire
25
and the inner surface of the seal hole
31
. Three lips
34
of a generally semi-circular cross-section are formed on the outer peripheral surface of the seal member
30
, and extend in a direction of the periphery thereof. The lips
34
are elastically held against the inner peripheral surface of the cap
60
to form a seal between the outer peripheral surface of the seal member
30
and the inner peripheral surface of the cap
60
, thereby keeping the interior of the cap
60
in a waterproof, dust-proof condition.
(Seal Holder
40
)
The seal holder
40
is made of a synthetic resin, and comprises a thick plate of an elongate oval shape like the seal member
30
. The lips
34
on the outer peripheral surface of the seal member
30
are a size larger than the outer periphery of the seal holder
40
. Terminal insertion holes
41
are formed through the seal holder
40
, and extend from the front side thereof to the rear side thereof, and are aligned with the cavities
11
, respectively, and also with the seal holes
31
, respectively. The metal terminal
20
is inserted through the terminal insertion hole
41
into the cavity
11
. Projections (not shown), projecting from the housing
10
, extend watertight through the seal member
30
, and are retainingly engaged at their distal ends with the seal holder
40
, thereby holding the seal member
30
and the seal holder
40
on the housing
10
.
Four lock projections
44
are formed on the outer
10
peripheral surface of the seal holder
40
, and more specifically two lock projections
44
are formed respectively on opposite end portions of each of upper and lower flat surfaces of the seal holder
40
. These lock projections
44
are engagedwith the cap
60
, thereby preventing the cap
60
from being disengaged from the housing
10
, the seal member
30
and the seal holder
40
. A pair of index projections
45
are formed on the outer peripheral surface of the seal holder
40
, and are symmetrically disposed respectively at arcuate portions of right and left end portions of the seal holder
40
, the index projections
45
projecting upwardly beyond the upper surface of the seal holder
40
. These index projections
45
serve as index means by which the upper and lower sides of the housing
10
are determined when inserting the metal terminals
20
.
(Bus Bar Structure
50
)
Referring to the bus bar structure
50
, a bus bar base member
55
W of metal is integrally joined to a holder body
51
of a synthetic resin by insert molding, and then this bus bar base member
55
W is divided (or severed) into a plurality of bus bars
55
. The holder body
51
includes a plate-like holder portion
52
(which is elongate in a direction of the width of the holder body
51
), and a flattened, tubular portion
53
extending rearwardly (toward the housing
10
) from the plate-like holder portion
52
. The bus bar base member
55
W includes a plurality of juxtaposed tabs
57
extending from a side edge of a strip-like interconnecting portion
56
in a cantilever manner. The bus bar base member
55
W is held in the holder body
51
in such a manner that the interconnecting portion
56
extends along the plate-like holder portion
52
in contiguous relation thereto, with the tabs
57
projecting into the interior of the tubular portion
53
.
In the description given below, “the upper and lower sides” of the bus bar structure
50
will be referred to on the basis of the bus bar structure (shown in
FIGS. 6
to
8
) to be mounted in the lower stage of the housing
10
.
A plurality of punching holes
54
are formed in the plate-like holder portion
52
, and are open to an upper surface thereof. The punching hole
54
is provided at that portion of the interconnecting portion
56
disposed between the adjacent tabs
57
. At a lower surface of the plate-like holder portion
52
, a lower surface of the interconnecting portion
56
is exposed at that region (i.e., those regions, corresponding respectively to the punching holes
54
, and those regions each disposed between the adjacent punching holes
54
), which is to be severed, over an entire area thereof to provide an entire exposure surface
56
A. The entire exposure surface
56
A is disposed flush with the lower surface of the plate-like holder portion
52
. Ribs
59
(serving as positioning means which is one feature of the invention) are formed on and project downwardly respectively from those portions of the plate-like holder portion
52
disposed adjacent respectively to the opposite (right and left) ends of the entire exposure surface.
After the insert molding in the process of production of the bus bar structure
50
, that portion (i.e., part) of the interconnecting portion
56
, exposed to any one of the punching holes
54
selected in accordance with a predetermined short-circuiting pattern, is punched at this punching hole
54
, using a die
71
and a punch
72
, and as a result the interconnecting portion
56
is severed, so that the bus bar base member is divided (or severed) into a plurality of bus bars
55
. Each bus bar
55
has at least two tabs
57
, and the metal terminals
20
are connected respectively to these tabs
57
, and therefore the plurality of metal terminals
20
for each bus bar
55
are short-circuited. The means for severing the interconnecting portion
56
will be more fully described hereafter.
The bus bar structures
50
are attached to the housing
10
from the front side thereof in such a manner that the upper row of cavities
11
and the lower row of cavities
11
are covered with the tubular portions
53
of these bus bar structures
50
, respectively. In this attached condition, the tabs
57
are connected to the metal terminals
20
, respectively. The holder bodies
51
have different colors so that the short-circuiting patterns can be distinguished. The holder body
51
is a symmetrical with respect to a median plane thereof between the upper and lower surfaces thereof. Therefore, by confirming the color of the holder body
51
and the upper and lower sides of the holder body
51
, the proper bus bar structures
50
can be attached to the housing in their respective proper postures, and therefore the group of metal terminals
20
can be short-circuited in a proper short-circuiting pattern.
Guide grooves
58
are formed respectively in opposite (right and left) sides of the tubular portion
53
, and extend in the forward-rearward direction, and two pairs of front and rear retaining projections
17
and
18
, corresponding respectively to the guide grooves
58
, are formed on each of the upper and lower portions of the housing
10
. When a rear edge of each guide groove
58
and the rear end of the tubular portion
53
are retainingly engaged with opposed surfaces of the associated retaining projections
17
and
18
, respectively, the bus bar structure
50
is held in a provisionally-retained position. When the front and rear edges of each guide groove
58
are retainingly engaged with the rear surface of the retaining projection
17
and the front surface of the retaining projection
18
, the bus bar structure
50
is held in a properly-attached position.
(Cap
60
)
The cap
60
is made of a synthetic resin, and has a tubular shape of an elongate oval cross-section (as seen from the front side thereof) with a closed bottom. Lock holes
61
are formed in a peripheral edge portion of the open end of the cap
60
, and the lock projections
44
on the seal holder
40
can be retainingly engaged in these lock holes
61
, respectively. When the lock projections
44
are engaged in the lock holes
61
, respectively, the cap
60
is locked in its attached condition. Outwardly-bulging relief portions
62
for avoiding the interference of the cap
60
with the index projections are formed on the peripheral edge portion of the open end of the cap
60
. That portion of an inner peripheral surface of the cap
60
, disposed adjacent to the open end thereof, serves as a seal surface against which the lips
34
on the outer peripheral surface of the seal member
30
can be elastically held.
(Assembling of the Parts)
The procedure of assembling the above parts are as follows. First, the seal member
30
and the seal holder
40
are attached to the housing
10
, and the metal terminals
20
are inserted into the respective terminal insertion holes
41
, and are passed through the respective seal holes
31
, and are inserted into the respective cavities
11
. Then, each bus bar structure
50
is attached to the housing
10
, and is held in the provisionally-retained position. In this condition, this assembly is set in an assembling apparatus (not shown), and the bus bar structure
50
is forced from the provisionally-retained position into the properly-attached position. As a result, the tabs
57
are connected to the associated metal terminals
20
, respectively, so that these metal terminals
20
are short-circuited in the predetermined pattern.
(Means for Severing the Bus Bar Base Member Into a Plurality of Bus Bars)
As described above, the bus bar structure
50
is insert molded, using the bus bar base member
55
W common to all short-circuiting patterns, and thereafter the bus bar base member
55
W is divided (or severed) into a plurality of bus bars
55
. In this severing operation, the die
71
, the punch
72
and a stripper
73
are used.
The die
71
is held against the lower surface (the entire exposure surface
56
A) of the interconnecting portion
56
, exposed to the lower surface of the plate-like holder portion
52
, from the lower side, and an upper surface
71
A of the die
71
for abutment against the entire exposure surface
56
A is flat as a whole. A plurality of juxtaposed recesses
71
B are formed in the upper surface
71
A of the die
71
so as to be aligned with the punching holes
54
, respectively. A lower end of each recess
71
B serves as a discharge port
71
C open to the lower surface of the die
71
, and a piece
56
B, punched or removed from the interconnecting portion
56
, is discharged to the exterior through this discharge port
71
C. The recesses
71
B are formed so as to be aligned with all of the punching holes
54
, respectively, and therefore the die
71
can be used as the device common to all of the short-circuiting patterns. The ribs
59
are held respectively against opposite ends (not shown) of the die
71
to prevent the movement of the die
71
in the right-left direction, and therefore the recesses
71
B are positioned and aligned relative to the punching holes
54
, respectively.
The punch
72
has a downwardly-directed, severing projection
72
A, and this severing projection
72
A is driven into the punching hole
54
to punch a portion of the interconnecting portion
56
, thereby severing this interconnecting portion
56
. The severing projection
72
A can be fitted into the recess
71
B in the die
71
, with a very small clearance formed therebetween.
The stripper
73
has a generally square tubular shape, and can be fitted in the punching hole
54
against movement. The interior of the stripper
73
is formed into a guide hole
73
A, and in the severing operation, the severing projection
72
A, while guided by the guide hole
73
A, passes through this guide hole
73
A.
(Operation and Effects of this Embodiment)
The entire exposure surface
56
A (those regions, corresponding respectively to the punching holes
54
, and those regions each disposed between the adjacent punching holes
54
) of the interconnecting portion
56
, facing away from the punching holes
54
, is exposed to the outer surface of the holder body
51
, and any convex portion (that is, any portion of a low strength) does not need to be formed on the upper surface
71
A of the die
71
which is to be held against the entire exposure surface
56
A.
In the range of the entire exposure surface
56
A of the interconnecting portion
56
against which the die
71
is to be held, the positioning of the die
71
can not be effected by engaging any resin portion, formed on the holder body
51
, with the die
71
. However, since the ribs S
9
are formed respectively at the opposite end portions of the holder body
51
disposed outside the range of the entire exposure surface
56
A, the positioning of the die
71
can be effected. Therefore, the recesses
71
B in the die
71
can be aligned with the respective punching holes
54
, and also the selected recess
71
B can be aligned with the severing projection
72
A of the punch
72
.
The region of the interconnecting portion
56
to be severed is exposed as the entire exposure surface
56
A over the entire area thereof, and any partition portion is not provided between the two bus bars
55
separated from each other by the severing operation. Therefore, if a foreign matter is deposited on the two bus bars in a bridging manner, the two bus bars are electrically connected to each other. In this embodiment, however, the whole of the bus bar structure
50
is covered with the cap
60
, and therefore the deposition of such a foreign matter is prevented, thus preventing the two bus bars from being electrically connected together. And besides, the cap
60
, snugly fitted watertight on the outer periphery of the seal member
30
, achieves not only the dust-proof function but also the waterproof function.
(Other Embodiments)
The present invention is not limited to the above description and the drawings, and for example, the following embodiments fall within the scope of the invention. Further, various modifications other than the following can be made without departing from the scope of the invention.
(1) Although the above embodiment is directed to the shield connector of the waterproof type, the invention can be applied to a joint connector of the non-waterproof type.
(2) In the above embodiment, although the cap has the waterproof function, the cap of the invention can have only the dust-proof function.
(3) In the above embodiment, although the dust-proof cap is provided for preventing the deposition of a foreign matter on the bus bar structure, the provision of the cap can be omitted in the invention if any other foreign matter deposition prevention means is provided.
(4) In the above embodiment, although that surface of the interconnecting portion, exposed over the entire area thereof, is disposed flush with the outer surface of the holder body, the two surfaces may be stepped with respect to each other in the invention.
(Embodiment 2)
An embodiment 2 of the present invention will now be described with reference to
FIGS. 1
to
14
.
A joint connector of this embodiment comprises a housing
210
, a plurality of metal terminals
220
, a seal member
230
, a seal holder
240
, two bus bar structures
250
, and a cap
260
. The plurality of metal terminals
220
are short-circuited in a predetermined pattern by a plurality of bus bars
255
.
(Housing
210
)
The housing
210
is made of a synthetic resin, and a plurality of cavities (chambers)
211
are formed within the housing
210
, and are arranged in two (upper and lower) rows (stages), and these cavities
211
extend through the housing
210
from its front side to its rear side, each row of cavities
211
being arranged at a predetermined pitch. The upper row of cavities
211
are open at their generally front half portions to the upper side of the housing
210
whereas the lower row of cavities
211
are open at their generally front half portions to the lower side of the housing
210
. A lance
212
, projecting forwardly in a cantilever manner, is formed at each of these open portions. A slot-like recess
213
for receiving peripheral walls of the bus bar structures
250
is formed between the upper and lower rows of cavities
211
, and is elongate in a direction of the width of the housing. Notches are formed in an upper wall of the recess
213
, and communicate with the upper row of cavities
211
, whereas notches are formed in a lower wall of the recess
213
, and communicate with the lower row of cavities
211
.
(Metal Terminal
220
)
The metal terminal
220
is formed by bending a metal sheet blank of a predetermined shape, and a generally front half portion of the metal terminal is formed into a fitting portion
221
of a square tubular shape having open front and rear ends, and a generally rear half portion of the metal terminal is formed into a wire connection portion
222
to which a wire
225
is clamped by pressing. A resilient contact piece
223
for resilient contact with a tab
257
of the bus bar structure
250
is provided within the fitting portion
221
, and a retaining hole
224
for retaining engagement with the lance
212
on the housing
210
is formed through a peripheral wall of the fitting portion
221
. The metal terminal
220
is passed through the seal holder
240
and the seal member
230
, attached to the housing
210
, from the rear side of the housing
210
, and is inserted into the cavity
211
in the housing
210
. Immediately before the metal terminal
220
reaches its proper inserted position, the lance
212
interferes with the outer surface of the peripheral wall of the fitting portion
221
, and therefore is elastically deformed outwardly from the housing
210
, and then when the metal terminal
220
reaches its proper inserted position, the lance
212
is elastically restored into its original shape to be retainingly engaged in the retaining hole
224
, thereby retaining the metal terminal
220
against withdrawal.
(Seal Member
230
)
The seal member
230
is made of rubber, and comprises a thick plate of an elongate oval shape, and is held between the rear end surface of the housing
210
and the front end surface of the seal holder
240
. A plurality of seal holes
231
are formed through the seal member
230
, and are open to the front and rear sides of the seal member
230
, and are aligned respectively with the cavities
211
in the housing
210
. Each of the seal holes
231
has a circular shape, and three lips
231
A of a generally triangular cross-section are formed circumferentially on an inner peripheral surface of the seal hole
231
. The inner diameter of each lip
231
A is smaller than the outer diameter of the wire
225
. The wire
225
is passed through the seal hole
231
, and the lips
231
A are elastically held in intimate contact with the outer peripheral surface of the wire
225
, thereby forming a seal between the wire
225
and the inner surface of the seal hole
231
. Three lips
234
of a generally semi-circular cross-section are formed on the outer peripheral surface of the seal member
230
, and extend in a direction of the periphery thereof. The lips
234
are elastically held against the inner peripheral surface of the cap
260
to form a seal between the outer peripheral surface of the seal member
30
and the inner peripheral surface of the cap
260
.
(Seal Holder
240
)
The seal holder
240
is made of a synthetic resin, and comprises a thick plate of an elongate oval shape like the seal member
230
. The lips
234
on the outer peripheral surface of the seal member
230
are a size larger than the outer periphery of the seal holder
240
. Terminal insertion holes
241
are formed through the seal holder
240
, and extend from the front side thereof to the rear side thereof, and are aligned with the cavities
211
, respectively, and also with the seal holes
231
, respectively. The metal terminal
220
is inserted through the terminal insertion hole
241
into the cavity
211
. Projections (not shown), projecting from the housing
210
, extend watertight through the seal member
230
, and are retainingly engaged at their distal ends with the seal holder
240
, thereby holding the seal member
230
and the seal holder
240
on the housing
210
.
Four lock projections
244
are formed on the outer peripheral surface of the seal holder
240
, and more specifically two lock projections
244
are formed respectively on opposite end portions of each of upper and lower flat surfaces of the seal holder
240
. These lock projections
244
are engaged with the cap
260
, thereby preventing the cap
260
from being disengaged from the housing
210
, the seal member
230
and the seal holder
240
. A pair of index projections
245
are formed on the outer peripheral surface of the seal holder
240
, and are symmetrically disposed respectively at arcuate portions of right and left end portions of the seal holder
240
, the index projections
245
projecting upwardly beyond the upper surface of the seal holder
240
. These index projections
245
serve as index means by which the upper and lower sides of the housing
210
are determined when inserting the metal terminals
220
.
(Bus Bar Structure
250
)
Referring to the bus bar structure
250
, a bus bar base member
255
W of metal is integrally joined to a holder body
251
of a synthetic resin by insert molding, and then this bus bar base member
255
W is divided (or severed) into a plurality of bus bars
255
. The holder body
251
includes a plate-like holder portion
252
(which is elongate in a direction of the width of the holder body
251
), and a flattened, tubular portion
253
extending rearwardly (toward the housing
210
) from the plate-like holder portion
252
. The bus bar base member
255
W includes a plurality of juxtaposed tabs
257
extending from a side edge of a strip-like interconnecting portion
256
in a cantilever manner. The bus bar base member
255
W is held in the holder body
251
in such a manner that the interconnecting portion
256
extends along the plate-like holder portion
252
in contiguous relation thereto, with the tabs
257
projecting into the interior of the tubular portion
253
. Punching holes
254
are formed in the plate-like holder portion
252
, and the punching hole
254
is provided at that portion of the interconnecting portion
256
disposed between the adjacent tabs
257
. After the insert molding in the process of production of the bus bar structure
250
, that portion (i.e., part) of the interconnecting portion
256
, exposed to any one of the punching holes
254
selected in accordance with a predetermined short-circuiting pattern, is punched at this punching hole
254
, using a punch and a die (not shown), and as a result the interconnecting portion
256
is severed, so that the bus bar base member is divided (or severed) into a plurality of bus bars
255
. Each bus bar
255
has at least two tabs
257
, and the metal terminals
220
are connected respectively to these tabs
257
, and therefore the plurality of metal terminals
220
for each bus bar
255
are short-circuited.
The interconnecting portion
256
will not be severed at that portion thereof disposed between each endmost tab
257
(disposed at each end of the bus bar base member) and the adjoining tab
257
. Therefore, the punching holes
254
are formed only at a severance-applying region H of the interconnecting portion
256
(extending between those tabs
257
disposed adjacent respectively to the opposite endmost tabs
257
), and any punching hole
254
is not formed at the opposite end regions disposed outside the severance-applying region H.
Window holes
259
are formed respectively in the opposite end portions of the plate-like holder portion
252
in which any punching hole
254
is not formed. The window holes
259
are disposed respectively in registry with the proximal end portions of the opposite endmost tabs
257
disposed respectively at the opposite ends of the interconnecting portion
256
, and these window holes
259
are open to the upper and lower surfaces of the plate-like holder portion
252
of the holder body
251
. The interconnecting portion
256
is disposed generally centrally of the height of the window holes
259
. In other words, the upper and lower surfaces of the interconnecting portion
256
are exposed to the exterior through each of the window holes
259
.
The bus bar structures
250
are attached to the housing
210
from the front side thereof in such a manner that the upper row of cavities
211
and the lower row of cavities
211
are covered with the tubular portions
253
of these bus bar structures
250
, respectively. In this attached condition, the tabs
257
are connected to the metal terminals
220
, respectively. The holder bodies
251
have different colors so that the short-circuiting patterns can be distinguished. The holder body
251
is asymmetrical with respect to a median plane thereof between the upper and lower surfaces thereof. Therefore, by confirming the color of the holder body
251
and the upper and lower sides of the holder body
251
, the proper bus bar structures
250
can be attached to the housing
210
in their respective proper postures, and therefore the group of metal terminals
220
can be short-circuited in a proper short-circuiting pattern.
Guide grooves
258
are formed respectively in opposite (right and left) sides of the tubular portion
253
, and extend in the forward-rearward direction, and two pairs of front and rear retaining projections
217
and
218
, corresponding respectively to the guide grooves
258
, are formed on each of the upper and lower portions of the housing
210
. When a rear edge of each guide groove
258
and the rear end of the tubular portion
253
are retainingly engaged with opposed surfaces of the associated retaining projections
217
and
218
, respectively, the bus bar structure
250
is held in a provisionally-retained position. When the front and rear edges of each guide groove
258
are retainingly engaged with the rear surface of the retaining projection
217
and the front surface of the retaining projection
218
, the bus bar structure
250
is held in a properly-attached position.
(Cap
260
)
The cap
260
is made of a synthetic resin, and has a tubular shape of an elongate oval cross-section (as seen from the front side thereof) with a closed bottom. Lock holes
261
are formed in a peripheral edge portion of the open end of the cap
260
, and the lock projections
244
on the seal holder
240
can be retainingly engaged in these lock holes
261
, respectively. When the lock projections
244
are engaged in the lock holes
261
, respectively, the cap
260
is locked in its attached condition. Outwardly-bulging relief portions
262
for avoiding the interference of the cap
260
with the index projections are formed on the peripheral edge portion of the open end of the cap
260
. That portion of an inner peripheral surface of the cap
260
, disposed adjacent to the open end thereof, serves as a seal surface against which the lips
234
on the outer peripheral surface of the seal member
230
can be elastically held.
(Assembling of the Parts)
The procedure of assembling the above parts are as follows. First, the seal member
230
and the seal holder
240
are attached to the housing
210
, and the metal terminals
220
are inserted into the respective terminal insertion holes
241
, and are passed through the respective seal holes
231
, and are inserted into the respective cavities
211
. Then, each bus bar structure
250
is attached to the housing
210
, and is held in the provisionally-retained position. In this condition, this assembly is set in an assembling apparatus (not shown), and the bus bar structure
250
is forced from the provisionally-retained position into the properly-attached position. As a result, the tabs
257
are connected to the associated metal terminals
220
, respectively, so that these metal terminals
220
are short-circuited in the predetermined pattern.
(Operation and Effects of this Embodiment)
In the insert molding during the process of production of the bus bar structure
250
, there is used a mold
270
as shown in FIG.
15
. The mold
270
comprises an upper mold
271
for molding the upper surface of the plate-like holder
252
, a lower mold
272
for molding the lower surface of the plate-like holder portion
252
, and a slide mold
273
for molding the tubular portion
253
. Upper portion-molding projections
274
for respectively molding upper halves of the window holes
259
are formed on the upper mold
271
, and lower portion-molding projections
275
for respectively molding the lower halves of the window holes
259
are formed on the lower mold
272
. In a mold-closed condition, a gap is formed between the opposed surface of each pair of upper and lower projections
274
and
275
, and the opposite end portions (at which the window holes
259
are to be formed, respectively) of the interconnecting portion
256
are received in these gaps, respectively, in such a manner that each of these opposite end portions is firmly held between the corresponding pair of upper and lower projections
274
and
275
against movement. Although not shown in the drawings, the interconnecting portion
256
is firmly held between the upper and lower dies
271
and
272
not only at the regions where the window holes
259
are to be formed, but also at the region where the punching holes
254
are to be formed. The tabs
257
are fitted respectively in recesses
276
in the slide mold
273
, and therefore are held against movement.
In this condition, a molten resin material is injected into the mold
270
from a gate (not shown), and is filled in a mold cavity, defined by the upper mold
271
, the lower mold
272
and the slide mold
273
, so that the bus bar structure
250
, having the bus bar base member
255
W integrally joined to the holder body
251
, is molded. Then, the bus bar structure
250
is removed from the mold
270
, and a portion
256
A of the interconnecting portion
256
is severed or removed at the punching hole
254
, so that the bus bar base member
255
W is divided into the plurality of bus bars
255
.
As described above, in this embodiment, during the insert molding of the bus bar structure
250
, the interconnecting portion
256
of the bus bar base member
255
W is held against movement by the mold
270
not only at the region (severance-applying region H) where the punching holes
254
are formed, but also at the opposite end regions (where the window holes
259
are formed) disposed outside the region where the punching holes
254
are formed. Namely, the interconnecting portion
256
is held against movement over the entire length thereof, and therefore the interconnecting portion
256
will not be deformed by the injection pressure, and therefore an error in the alignment of the tabs
257
due to the deformation of the interconnecting portion
256
is positively prevented.
(Other Embodiments)
The present invention is not limited to the above description and the drawings, and for example, the following embodiments fall within the scope of the invention. Further, various modifications other than the following can be made without departing from the scope of the invention.
(1) In the above embodiment, although the window holes are disposed in registry with the opposite endmost tabs, respectively, each window hole may be disposed in offset relation to the corresponding endmost tab, that is, disposed between the endmost tab and its adjoining tab, and alternatively each window hole may be formed into a larger size over the range generally covering the endmost tab and its adjoining tab.
(2) Although the above embodiment is directed to the joint connector of the waterproof type, the invention can be applied to a joint connector of the non-waterproof type.
(Embodiment 3)
An embodiment 3 of the present invention will now be described with reference to
FIGS. 7
to
21
.
A joint connector of this embodiment comprises a housing
310
, a plurality of metal terminals
320
, a seal member
330
, a seal holder
340
, two bus bar structures
350
, and a cap
360
. The plurality of metal terminals
320
are short-circuited in a predetermined pattern by a plurality of bus bars
355
.
(Housing
310
)
The housing
310
is made of a synthetic resin, and a plurality of cavities (chambers)
311
are formed within the housing
310
, and are arranged in two (upper and lower) rows (stages), and these cavities
311
extend through the housing
310
from its front side to its rear side, each row of cavities
311
being arranged at a predetermined pitch. The upper row of cavities
311
are open at their generally front half portions to the upper side of the housing
310
whereas the lower row of cavities
311
are open at their generally front half portions to the lower side of the housing
310
. A lance
312
, projecting forwardly in a cantilever manner, is formed at each of these open portions. A slot-like recess
313
for receiving peripheral walls of the bus bar structures
350
is formed between the upper and lower rows of cavities
311
, and is elongate in a direction of the width of the housing. Notches are formed in an upper wall of the recess
313
, and communicate with the upper row of cavities
311
, whereas notches are formed in a lower wall of the recess
313
, and communicate with the lower row of cavities
311
.
(Metal Terminal
320
)
The metal terminal
320
is formed by bending a metal sheet blank of a predetermined shape, and a generally front half portion of the metal terminal is formed into a fitting portion
321
of a square tubular shape having open front and rear ends, and a generally rear half portion of the metal terminal is formed into a wire connection portion
322
to which a wire
325
is clamped by pressing. A resilient contact piece
323
for resilient contact with a tab
357
of the bus bar structure
350
is provided within the fitting portion
321
, and a retaining hole
324
for retaining engagement with the lance
312
on the housing
310
is formed through a peripheral wall of the fitting portion
321
. The metal terminal
320
is passed through the seal holder
340
and the seal member
330
, attached to the housing
310
, from the rear side of the housing
310
, and is inserted into the cavity
311
in the housing
310
. Immediately before the metal terminal
320
reaches its proper inserted position, the lance
312
interferes with the outer surface of the peripheral wall of the fitting portion
321
, and therefore is elastically deformed outwardly from the housing
310
, and then when the metal terminal
320
reaches its proper inserted position, the lance
312
is elastically restored into its original shape to be retainingly engaged in the retaining hole
324
, thereby retaining the metal terminal
320
against withdrawal.
(Seal Member
330
)
The seal member
330
is made of rubber, and comprises a thick plate of an elongate oval shape, and is held between the rear end surface of the housing
310
and the front end surface of the seal holder
340
. A plurality of seal holes
331
are formed through the seal member
330
, and are open to the front and rear sides of the seal member
330
, and are aligned respectively with the cavities
311
in the housing
310
. Each of the seal holes
331
has a circular shape, and three lips
331
A of a generally triangular cross-section are formed circumferentially on an inner peripheral surface of the seal hole
331
. The inner diameter of each lip
331
A is smaller than the outer diameter of the wire
325
. The wire
325
is passed through the seal hole
331
, and the lips
331
A are elastically held in intimate contact with the outer peripheral surface of the wire
325
, thereby forming a seal between the wire
325
and the inner surface of the seal hole
331
. Three lips
334
of a generally semi-circular cross-section are formed on the outer peripheral surface of the seal member
330
, and extend in a direction of the periphery thereof. The lips
334
are elastically held against the inner peripheral surface of the cap
360
to form a seal between the outer peripheral surface of the seal member
30
and the inner peripheral surface of the cap
360
, thereby keeping the interior of the cap
360
in a waterproof, dust-proof condition.
(Seal Holder
340
)
The seal holder
340
is made of a synthetic resin, and comprises a thick plate of an elongate oval shape like the seal member
330
. The lips
334
on the outer peripheral surface of the seal member
330
are a size larger than the outer periphery of the seal holder
340
. Terminal insertion holes
341
are formed through the seal holder
340
, and extend from the front side thereof to the rear side thereof, and are aligned with the cavities
311
, respectively, and also with the seal holes
331
, respectively. The metal terminal
320
is inserted through the terminal insertion hole
341
into the cavity
311
. Projections (not shown), projecting from the housing
310
, extend watertight through the seal member
330
, and are retainingly engaged at their distal ends with the seal holder
340
, thereby holding the seal member
330
and the seal holder
340
on the housing
310
.
Four lock projections
344
are formed on the outer peripheral surface of the seal holder
340
, and more specifically two lock projections
344
are formed respectively on opposite end portions of each of upper and lower flat surfaces of the seal holder
340
. These lock projections
344
are engaged with the cap
360
, thereby preventing the cap
360
from being disengaged from the housing
310
, the seal member
330
and the seal holder
340
. A pair of index projections
345
are formed on the outer peripheral surface of the seal holder
340
, and are symmetrically disposed respectively at arcuate portions of right and left end portions of the seal holder
340
, the index projections
345
projecting upwardly beyond the upper surface of the seal holder
340
. These index projections
345
serve as index means by which the upper and lower sides of the housing
310
are determined when inserting the metal terminals
320
.
(Bus Bar Structure
350
)
The bus bar structure
350
is formed by integrally joining a bus bar
355
of metal to a holder body
351
of a synthetic resin by insert molding. A method of producing the bus bar structure
350
will be more fully described hereafter. The holder body
351
includes a plate-like holder portion
352
(which is elongate in a direction of the width of the holder body
351
), and a flattened, tubular portion
353
extending rearwardly (toward the housing
310
) from the plate-like holder portion
352
. The bus bar
355
includes a plurality of juxtaposed tabs
357
extending from a side edge of a strip-like interconnecting portion
356
in a cantilever manner. The bus bar
355
is held in the holder body
351
in such a manner that the interconnecting portion
356
extends along the plate-like holder portion
352
in contiguous relation thereto, with the tabs
357
projecting into the interior of the tubular portion
353
. A plurality of punching holes
354
are formed in one side (surface) of the plate-like holder portion
352
, and the punching hole
354
is provided at that portion of the interconnecting portion
356
disposed between the adjacent tabs
357
. The interconnecting portion
356
is severed at any one of the punching holes
354
, thereby dividing the bus bar
355
into a predetermined short-circuiting pattern.
The bus bar structures
350
are attached to the housing
310
from the front side thereof in such a manner that the upper row of cavities
311
and the lower row of cavities
311
are covered with the tubular portions
353
of these bus bar structures
350
, respectively. In this attached condition, the tabs
357
are connected to the metal terminals
320
, respectively.
Guide grooves
358
are formed respectively in opposite (right and left) sides of the tubular portion
353
, and extend in the forward-rearward direction, and two pairs of front and rear retaining projections
317
and
318
, corresponding respectively to the guide grooves
358
, are formed on each of the upper and lower portions of the housing
310
. When a rear edge of each guide groove
358
and the rear end of the tubular portion
353
are retainingly engaged with opposed surfaces of the associated retaining projections
317
and
318
, respectively, the bus bar structure
350
is held in a provisionally-retained position. When the front and rear edges of each guide groove
358
are retainingly engaged with the rear surface of the retaining projection
317
and the front surface of the retaining projection
318
, the bus bar structure
350
is held in a properly-attached position.
(Cap
360
)
The cap
360
is made of a synthetic resin, and has a tubular shape of an elongate oval cross-section (as seen from the front side thereof) with a closed bottom. Lock holes
361
are formed in a peripheral edge portion of the open end of the cap
360
, and the lock projections
344
on the seal holder
340
can be retainingly engaged in these lock holes
361
, respectively. When the lock projections
344
are engaged in the lock holes
361
, respectively, the cap
360
is locked in its attached condition. Outwardly-bulging relief portions
362
for avoiding the interference of the cap
360
with the index projections are formed on the peripheral edge portion of the open end of the cap
360
. That portion of an inner peripheral surface of the cap
360
, disposed adjacent to the open end thereof, serves as a seal surface against which the lips
334
on the outer peripheral surface of the seal member
330
can be elastically held.
(Assembling of the Parts)
The procedure of assembling the above parts are as follows. First, the seal member
330
and the seal holder
340
are attached to the housing
310
, and the metal terminals
320
are inserted into the respective terminal insertion holes
341
, and are passed through the respective seal holes
331
, and are inserted into the respective cavities
311
. Then, each bus bar structures
350
is attached to the housing
310
, and is held in the provisionally-retained position. At this time, the distal end surface (remote from the tubular portion
353
) of the holder body
351
of the bus bar structure
350
is pushed by the finger. Then, the housing, having the bus bar structures
350
mounted thereon in their respective retained positions, is set in an assembling apparatus (not shown), and the bus bar structure
350
is forced from the provisionally-retained position into the properly-attached position. As a result, the tabs
357
are connected to the associated metal terminals
320
, respectively, so that these metal terminals
320
are short-circuited in the predetermined pattern.
(Method of producing the Bus Bar Structure
350
and Operation and Effects of this Embodiment)
The process of producing the bus bar structure
350
comprises the steps of (1) forming a chain terminal structure
370
, (2) integrally joining bus bars
355
of the chain terminal structure
370
respectively to holder bodies
351
, by insert molding, (3) cutting off each bus bar
355
and holder body
351
, thus integrally joined together, to provide the bus bar structure
350
, and (4) dividing (or severing) the bus bar
355
of each bus bar structure
350
into a predetermined short-circuiting pattern if necessary.
(1) The chain terminal structure
370
is blanked or stamped from an electrically-conductive metal strip of a predetermined width by the use of a press. As shown in
FIG. 20
, this chain terminal structure of a predetermined shape has many bus bars
355
connected to opposite side edges of a long carrier
371
. Each bus bar
355
is connected to the carrier
371
by four bridge portions
372
. The narrow, elongate bridge portions
372
extend perpendicularly to the direction of the length of the carrier
371
, and the four bridge portions
372
are connected to that side edge of the interconnecting portion
356
of the bus bar
355
facing away from the projected tabs
357
. Namely, the interconnecting portion
356
is parallel to the carrier
371
, and the tabs
357
are perpendicular to the carrier
371
.
(2) The bus bars
355
, connected to the carrier
371
, are insert molded independently of each other, using an automatic machine (not shown). In the insert molded condition, the bridge portions
372
pass through the holder body
351
of the bus bar structure
350
, and further extend from the distal end surface
352
A of the plate-like holder portion
352
(remote from the tubular portion
353
) to the carrier
371
. Recesses
359
of a trapezoidal shape are formed respectively in those portions of the distal end surface
352
A of the holder body
351
from which the bridge portions
372
project, respectively. These recesses
359
are much smaller in size than the tip of the finger of the operator. This is determined in view of the fact that the distal end surface
352
A of the holder body
351
is pushed by the finger when attaching the bus bar structure
350
to the housing
310
. With this arrangement, the finger will not be inserted deep into the recess
359
.
(3) After the insert molding, the bus bar
355
and holder body
351
, integrally joined together, are cut off from the carrier
371
by severing the bridge portions
372
, as shown in FIG.
19
. At this time, each bridge portion
372
is severed or cut at a portion thereof disposed immediately adjacent to the bottom surface of the recess
359
, that is, disposed inwardly of the distal end surface
352
A of the holder body
351
. Therefore, although a cut surface
372
A of the bridge
372
, resulting from this cutting operation, is exposed to the distal end surface
352
A of the holder body
351
, the finger will not come into contact the cut surface
372
A when the finger is pressed against the distal end surface
352
A of the holder body
351
. By thus severing the bridge portions
372
, the bus bar structure
350
, separated from the carrier
371
, is obtained.
(4) If necessary, the interconnecting portion
356
of the bus bar structure
350
, cut off from the carrier
371
, is severed at the selected punching hole
354
, thereby dividing the bus bar
355
into a plurality of sections to obtain the predetermined short-circuiting pattern. If this is not necessary, the severance of the bus bar
355
is not effected.
As described above, in the production of the bus bar structure
350
, each bus bar
355
of the chain terminal structure
370
is connected to the carrier
371
not through the tabs
357
but through the bridge portions
372
connected to the side edge of the interconnecting portion
356
. Therefore, when the bridge portions
372
are cut or severed, any cutting mark is not formed on the tabs
357
. Therefore, the distal end of the tab
357
, pressed into a tapering shape, is not deformed, and therefore any flash is not formed on the tab
357
, and the metal terminal
320
is not caught by such flash when connecting the metal terminal to the tab.
(Other Embodiments)
The present invention is not limited to the above description and the drawings, and for example, the following embodiments fall within the scope of the invention. Further, various modifications other than the following can be made without departing from the scope of the invention.
(1) In the above embodiment, although the bridge portions of the chain terminal structure are connected to that side edge of the interconnecting portion facing away from the tabs, the bridge portions may be connected to that side edge of the interconnecting portion disposed perpendicularly to that side edge of the interconnecting portion from which the tabs project.
(2) In the above embodiment, although the tabs of the chain terminal structure extend in the direction perpendicular to the direction of the length of the carrier, the tabs may extend in the direction of the length of the carrier.
(3) In the above embodiment, although those portions of the outer surface of the holder body, to which the cut surfaces of the bridge portions are exposed, respectively, are recessed, a pair of projections may be formed respectively on opposite sides of each cut surface-exposed portion. With this construction, the finger will not come into contact with the cut surface.
Claims
- 1. A joint connector comprising:a housing having a plurality of juxtaposed metal terminals received therein; a bus bar base member having a plurality of juxtaposed tabs extending from a side edge of an interconnecting portion; a holder body of a synthetic resin having a first side and a second side, only the first side having a plurality of punching holes, integrally joined to said bus bar base member; a portion of said interconnecting portion, disposed between adjacent tabs, being exposed through a corresponding one of the punching holes and when said portion of said interconnecting portion is severed, forming a bus bar structure having a plurality of bus bars each having a plurality of tabs; said tabs contact the associated metal terminals, respectively so that said metal terminals are short-circuited in a predetermined pattern; and an entire surface of said interconnecting portion facing away from said punching holes is exposed.
- 2. The joint connector according to claim 1, whereina cap is attached to said housing to cover said bus bar structure.
- 3. The joint connector according to claim 2, whereina seal member is provided on said housing, and is fitted watertight in an open end of said cap.
- 4. A joint connector as claimed in claim 1, further comprising:a carrier having side edges connected to the interconnecting portion through bridge portions, connected to a side of the interconnecting portion facing away from the tabs; said plurality of bus bars and said holder body, integrally joined together, are separated from said carrier by cutting surfaces of said bridge portions; and each of said plurality of bus bars are connected to said carrier through said bridge portions connected to said interconnecting portion of said plurality of said bus bars.
- 5. The joint connector according to claim 4, whereinsaid bus bar of said chain terminal structure is connected to said carrier through said bridge portions connected to that edge of said interconnecting portion facing away from said tabs, cut surfaces of said bridge portions of said bus bar structure are exposed to an outer surface of said holder body, said bus bar structure is attached to said housing by pushing said outer surface, to which said cut surfaces of said bridge portions are exposed, by the finger, recesses are formed respectively in those portions of said outer surface of said holder body to which said cut surfaces of said bridge portions are exposed, respectively, and each of said bridge portions is cut at a portion thereof disposed immediately adjacent to a bottom surface of the corresponding recess.
- 6. A joint connector as claimed in claim 1 wherein:the bus bar base member is integrally joined to the holder body by insert molding, window holes are formed in said holder body, and opposite end portions of said interconnecting portion, disposed outside a severance-applying portion of said interconnecting portion, are exposed to the exterior through the respective window holes.
- 7. A method of producing a joint connector including a housing having a plurality of juxtaposed metal terminals received therein, said method comprising the steps of:joining integrally by insert molding, a bus bar base member having a plurality of juxtaposed tabs extending from a side edge of an interconnecting portion, to a holder body formed of a synthetic resin and having a first side and a second side, only the first side having a plurality of punching holes, a portion of said interconnecting portion, disposed between adjacent tabs, being exposed through a corresponding one of the punching holes, an entire surface portion of said interconnecting portion facing away from said punching hole is exposed and during the insert molding, opposite end portions of said interconnecting portion, disposed outside a severance-applying region of said interconnecting portion are held; severing said interconnecting portion at any one of said plurality of punching holes; forming a bus bar structure by dividing said bus bar base member into a plurality of bus bars each having a plurality of tabs; attaching said bus bar structure to said housing; contacting said tabs to the associated metal terminals, respectively; and making said metal terminals short-circuited in a predetermined pattern.
- 8. A method of producing a joint connector including:a housing having a plurality of juxtaposed metal terminals provided therein; and a bus bar structure, which includes an electrically-conductive bus bar, having a plurality of juxtaposed tabs extending from an edge of an interconnecting portion, and a holder body formed of a synthetic resin and having a first side and a second side, only the first side having a plurality of punching holes, the holder body integrally joined to said bus bar, an entire surface of said interconnecting portion facing away from said punching holes is exposed; wherein when said bus bar structure is attached to said housing, said tabs contact the associated metal terminals, respectively, so that said metal terminals are short-circuited in a predetermined pattern; said method comprising the steps of: forming, by pressing, a chain terminal structure having a plurality of said bus bars connected to side edges of a carrier through bridge portions, said bridge portions being connected to a side of said interconnecting portion of said bus bar facing away from the tabs; integrally joining said bus bar to said holder body by insert molding; and separating said bus bar and said holder body, thus integrally joined together, from said carrier by cutting said bridge portions, thereby obtaining said bus bar structure.
- 9. A joint connector comprising:a housing having a plurality of juxtaposed metal terminals received therein; a bus bar base member having a plurality of juxtaposed tabs extending from a side edge of an interconnecting portion; a holder body of a synthetic resin and having a first side and a second side, only the first side having a plurality of punching holes, the holder body integrally joined to said bus bar base member; a portion of said interconnecting portion, disposed between adjacent tabs, being exposed through a corresponding one of the punching holes, and when said portion of said interconnecting portion is severed, forming a bus bar structure having a plurality of bus bars each having a plurality of tabs; said tabs contact the associated metal terminals, respectively so that said metal terminals are short-circuited in a predetermined pattern; an entire surface of said interconnecting portion facing away from said punching holes is exposed; and a portion of said housing is removed to expose a surface of said interconnecting portion facing away from said punching holes over an entire area thereof, a die being in contact with said entire area.
Priority Claims (3)
| Number |
Date |
Country |
Kind |
| 11-138423 |
May 1999 |
JP |
|
| 11-138424 |
May 1999 |
JP |
|
| 11-154175 |
Jun 1999 |
JP |
|
US Referenced Citations (5)
Foreign Referenced Citations (3)
| Number |
Date |
Country |
| 0 438 120 |
Jan 1991 |
EP |
| A-4-32175 |
Apr 1992 |
JP |
| A-9-213436 |
Aug 1997 |
JP |
