JPH0821457B2 - Connector manufacturing method - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for manufacturing a connector.

[Prior Art] Conventionally, as a connector for connecting an oxygen sensor, for example, as shown in FIGS. 8 to 10, a terminal metal fitting 2 is embedded in a connector body 1 made of a synthetic resin material, The sensor-side terminal 3 having a pin shape for sensor connection, which is provided on one end side of the terminal fitting 2, is projected to one end surface of the connector body 1, and is connected to the lead wire provided on the other end side of the terminal fitting 2. Connect the power supply side terminal 4 in the form of a short piece to the connector body 1
The connector main body 1 is integrally fixed to the mounting plate 5 by projecting to the other end surface of the.

And when manufacturing this kind of connector conventionally,
The sensor side terminal 3 of the terminal fitting 2 is inserted and set in a set hole provided in a part of the molding die, and the mounting plate 5 is positioned and arranged in a part of the molding die. In this state, the synthetic resin material is placed in the molding die. Was injected to mold the connector body 1 integrally with the terminal fitting 2 and the mounting plate 5.

[Problems to be Solved by the Invention] However, in this conventional connector manufacturing method, the synthetic resin material is injected into the molding die with the sensor side terminal of the terminal metal fitting inserted and set in the setting hole of the molding die. In this case, the set hole is located inside the mold, and the inner diameter of the set hole is the outer diameter of the sensor side terminal so that the synthetic resin material does not enter between the set hole and the sensor side terminal. Since it is formed to match the dimensions exactly, it is extremely difficult to align the sensor side terminal of the terminal fitting with the setting hole, and it is very difficult to insert and set the terminal in the setting hole. However, there was a problem that it was difficult to automate it.

Further, in the above-mentioned manufacturing method, since a large amount of synthetic resin material is injected into the molding die to mold the connector main body at one time, the surface of the connector main body is liable to shrink and the accuracy is improved. There was also the problem that it was difficult.

Further, when the terminal metal fitting 2 is supported by the set hole only at the end portion of the sensor side terminal 3 and the synthetic resin material is injected under pressure where the other portion is exposed, the sensor side terminal 3 is It bends and its parts deviate from a predetermined position, or they come into contact with each other and short-circuit. In addition, the welded portion between the sensor side terminal 3 and the power source side terminal 4 may be separated, resulting in poor conduction. Therefore, the conventional manufacturing method has a defect of poor yield.

The present invention has been made by paying attention to the problems existing in such a conventional technique, and the purpose thereof is to easily set the terminal fittings to the molding die. A method of manufacturing a connector in which work can be easily automated by a work robot or the like, the connector body can be molded with high accuracy without shrinkage on its surface, and the yield can be dramatically improved. To provide.

[Means for Solving the Problems] In order to achieve the above object, in the invention according to claim 1, in a state in which the insertion hole forming member is inserted into the first molding die,
A first molding step in which a synthetic resin is injected into a mold to mold a first main body portion of a connector main body, and an insertion hole for inserting a terminal of the terminal fitting is formed in a removal trace of the insertion hole forming member; A setting step of inserting and setting the terminal of the terminal fitting into the insertion hole of the first main body formed in the first forming step,
A setting step of setting the first main body portion and the terminal fitting in the second molding die, and a second step of the connector main body outside the first main body portion and the terminal fitting by injecting a synthetic resin into the second molding die. And a second molding step of molding the main body.

Further, in the invention according to claim 2, in the structure of claim 1, the insertion hole of the first main body is formed in a tapered shape whose diameter increases toward the insertion side opening end of the terminal fitting, and at least on the opposite side. The opening end is in close contact with the terminal of the terminal fitting.

Further, in the invention according to claim 3, in the structure according to claim 1, the second main body is formed in a state of covering the insertion side end of the terminal of the terminal fitting of the first main body. Is.

[Operation] According to the method of manufacturing a connector configured as described above, first, with the insertion hole forming member being inserted in the first molding die, synthetic resin is injected into the die to form the first part of the connector body. (1) After molding the main body and removing the insertion hole forming member, an insertion hole for inserting the terminal of the terminal fitting is formed. The terminal of the terminal fitting is inserted and set in the insertion hole of the first main body formed in the first molding step, the first main body and the terminal fitting are set in the second molding die, and the second molding die is combined. A resin material is injected to mold the second main body of the connector main body outside the first main body and the terminal fitting.

As described above, first, the first main body portion of the connector main body is molded, and the second main body portion of the connector main body is molded with the terminal of the terminal fitting inserted and set in the insertion hole of the first main body portion. Therefore, it is not necessary to directly insert the terminal of the terminal fitting into the setting hole in the inner part of the molding die, and the terminal of the terminal fitting is inserted and set in the setting hole through the insertion hole of the first main body. Therefore, the work of setting the terminal fittings can be easily performed, and the work can be easily automated by a work robot or the like.

Further, since the connector body is molded separately for the first body portion and the second body portion, the connector body can be molded without shrinkage or the like on its surface.
High dimensional accuracy can be obtained, and the injection pressure of the synthetic resin is hardly applied to the terminals of the terminal fitting, so that the deformation thereof is prevented.

[Embodiment] An embodiment of a method for manufacturing an oxygen sensor connector embodying the present invention will be described in detail below with reference to FIGS. 1 to 7.

First, the first as the first molding step shown in FIG.
In the step, a synthetic resin material is injected into the first molding die 21 to mold the first body portion 8 of the connector body 1 shown in FIG. The first molding die 21 includes an upper die 22, four pins 24 provided in the center of the upper die 22, a lower die 25 that is disposed on the lower surface of the upper die 22 so as to be contactable and separable, and a lower die 25 thereof. And a core 26 having a pin hole 23 which is provided at the center of the pin and into which the pin 24 is inserted. Therefore, in the first main body portion 8 of the connector main body 1,
A plurality of insertion holes 9 for inserting the pin-shaped terminals 3 of the terminal fitting 2 are formed in the central portion thereof. In addition, a slide core (not shown) is formed on the outer periphery of the upper end of the first main body portion 8 to prevent the flange portion 10 from coming off. The insertion hole 9 is formed in a tapered shape whose diameter increases toward the insertion-side opening end of the sensor-side terminal 3.
It has an inner diameter that is in close contact with the sensor-side terminal 3 at the opening end on the opposite side.

In the second step as the setting step shown in FIG. 2, the first main body portion 8 of the connector main body 1 molded in the first step is set in the lower mold 28 of the second molding die 27. A recess 29 for setting the mounting plate 5 is provided on the upper surface of the lower mold 28, and a plurality of holding pins 30 are provided in the recess 29 in a protruding manner. Further, a core 31 is provided at the center of the lower mold 28, and a plurality of setting holes 32 communicating with the insertion holes 9 of the set first main body portion 8 are formed on the upper surface thereof.

In the third step shown in FIG. 3B, the aluminum mounting plate 5 is set in the recess 29 of the lower mold 28 of the second molding die 27, and the small hole 11 of the mounting plate 5 is moved to the lower mold. Fit the retaining pin 30 on the 28. As shown in FIGS. 3A and 3B, a through hole 12 corresponding to the first main body portion 8 of the connector main body 1 is formed in the center of the mounting plate 5. A mounting screw is inserted into the small hole 11 when it is assembled to a device such as an engine.

In the fourth step as the setting step shown in FIG. 4 (b), the insertion hole 9 and the core 31 of the first main body 8 are set on the lower die 28 of the second molding die 27. Hole 32
Then, the sensor side terminal 3 of the terminal fitting 2 is inserted and set.

In this case, the sensor-side terminal 3 has the insertion hole 9 of the first body portion 8
Is not only inserted into the set hole 32 surely, but also the insertion hole 9 has an upward expanding taper shape, the insertion hole 9
Is also easy to insert. Moreover, since the sensor-side terminal 3 and the lower end of the insertion hole 9 are in close contact with each other in the inserted state, the terminal fitting 2 is held in a stable state. Fig. 4 (a) (b)
As shown in FIG. 3, the terminal fitting 2 is a connecting piece integrally formed with a plurality of sensor-side terminals 3 for connecting sensors and a plurality of power-side terminals 4 for connecting lead wires holding the pin-shaped terminals 3.
It is composed of 14 and.

In the fifth step as the second molding step shown in FIG. 5, the lower mold 28 of the second molding die 27 is opposed to the upper mold 33, and the synthetic resin material is injected into the second molding die 27 to The second main body portion 15 of the connector main body 1 is formed outside the first main body portion 8 and the terminal metal fitting 2 so as to cover the end portion of the first main body portion 8 on which the terminal metal fitting 2 is inserted. As a result, the connector body 1 made of a synthetic resin and having a predetermined shape is integrally formed in the through hole 12 of the mounting plate 5, and
The terminal fitting 2 is embedded and fixed in the center of the connector body 1. In this case, since the sensor-side terminal 3 and the lower end portion of the insertion hole 9 are in close contact with each other, it is possible to prevent the resin from leaking from the insertion hole 9, while the resin enters the gap between the insertion hole 9 and the sensor-side terminal 3. And fill the gap.

In the sixth step shown in FIG. 6, the lower mold 28 of the second molding mold 27 is separated from the upper mold 33, and then the connecting piece 14 of the terminal fitting 2 is cut by the cutting device 34. The cutting device 34 has a receiving blade 35 and a movable blade.
36 and an elastic body 35a that allows the receiving blade 35 to retreat during cutting, and the suction airflow from the air passage 37 provided in the movable blade 36 attracts the cut connecting piece 14 to lower the mold 28. It is designed to be removed into the storage portion 38 outside the. As a result, the terminals 3 and 4 of the terminal fitting 2 are projected to both ends of the connector body 1.

In the seventh step shown in FIG. 7, the entire connector is taken out from the lower mold 28 by the chuck 39 and mounted on the continuity inspection device 40 to conduct the continuity inspection between the terminals 3 and 4.

As described above, according to the connector manufacturing method of this embodiment, the first main body portion 8 of the connector main body 1 is first molded, and the sensor-side terminal 3 of the terminal fitting 2 is inserted into the insertion hole 9 of the first main body portion 8. Since the second main body portion 15 of the connector main body 1 is molded in a state where the sensor terminal 3 is inserted and set,
Is guided by the insertion hole 9 of the first main body 8 and reaches the set hole 32, so that the terminal 3 is aligned with the set hole 32 by the first
It may be performed for the insertion hole 9 exposed at the upper end of the main body portion 8. Furthermore, since the insertion hole 9 is tapered,
It is easy to insert the terminal 3 of the terminal fitting 2 into the insertion hole 9.
Therefore, the work of setting the terminal fitting 2 can be easily performed, and the work can be easily automated by a work robot or the like. In addition, since the insertion hole 9 and the sensor-side terminal 3 of the terminal fitting 2 are in close contact with each other, it is possible to reliably prevent the synthetic resin from entering the set hole 32 side.

Further, since the connector body 1 is molded separately into the first body portion 8 and the second body portion 15, the connector body 1 can be molded without shrinkage or the like on its surface, High dimensional accuracy can be achieved.

Furthermore, most of the sensor-side terminals 3 of the terminal fitting 2 are first
Since the synthetic resin is injected while being covered by the main body portion 8, the sensor side terminal 3 may be bent or moved, or the welded portion between the sensor side terminal 3 and the power source side terminal 4 may come off. Can be prevented and a high yield rate can be obtained.

The present invention is not limited to the configuration of the above-described embodiment, and for example, the configuration of each part may be changed without departing from the spirit of the present invention, such as arbitrarily changing the shape configurations of the connector body 1 and the terminal fitting 2. It is also possible to arbitrarily change and embody.

EFFECTS OF THE INVENTION Since the present invention is configured as described above, it is possible to easily set the terminal metal fitting to the molding die, and the work can be easily automated by a work robot or the like. At the same time, the connector body can be molded with high dimensional accuracy without shrinkage or the like on its surface, and the yield can be increased.

[Brief description of drawings]

1A is a perspective view of the first main body portion, FIG. 1B is a sectional view showing a first step, and FIG. 2 is a sectional view showing a second step.
3 (a) is a perspective view of the mounting plate, FIG. 3 (b) is a sectional view showing a third step, FIG. 4 (a) is a perspective view of the terminal fitting, and FIG. 4 (b) is a fourth view. FIG. 5 is a sectional view showing the fifth step, FIG. 6 is a sectional view showing the sixth step, FIG. 7 is an exploded view showing the seventh step, and FIG. 8 is a plan view of the connector. ,
FIG. 9 is a bottom view of the same, and FIG. 10 is a sectional view of an essential part of the same. 1 …… Connector body, 2 …… Terminal fittings, 3,4 …… Terminals,
8 ... 1st body part, 9 ... insertion hole, 15 ... 2nd body part.

Claims (3)

[Claims] 1. A connector body (1) made of a synthetic resin material.
In a method of manufacturing a connector in which a terminal fitting (2) is embedded in the connector body and terminals (3, 4) are projected at both ends of the connector body (1), an insertion hole forming member is formed in a first molding die (21). With the (24) inserted, a synthetic resin is poured into the mold to mold the first main body part (8) of the connector main body (1), and the insertion hole forming member (24) is formed.
A first forming step of forming an insertion hole (9) for inserting the terminal (3) of the terminal fitting (2) into the first body portion (8) in the removal trace of A setting step of inserting and setting the terminal (3) of the terminal fitting (2) into the insertion hole (9) of the molded first body portion (8); and the first body portion in the second molding die (27). (8) and the terminal metal fitting (2) are set, and a synthetic resin is injected into the second molding die (27) so that the connector body is provided outside the first main body (8) and the terminal metal fitting (2). (2) A second molding step of molding the second body portion (15) of (1). 2. The insertion hole (9) of the first main body (8) is
A tapered shape in which the opening end of the terminal fitting (2) is expanded toward the insertion side opening end, and the terminal fitting (2) is in close contact with the terminal (3) of the terminal fitting (2) at least at the opposite opening end. The method for manufacturing the connector according to. 3. The second main body portion (15) according to claim 1, wherein the second main body portion (15) is formed so as to cover an end of the terminal fitting (2) of the first main body portion (8) on the insertion side of the terminal (3). Manufacturing method of connector.