U.S. patent application number 15/681438 was filed with the patent office on 2018-09-13 for electrical connector and method for manufacturing electrical connector.
The applicant listed for this patent is SMK Corporation. Invention is credited to Naoyuki ONO.
Application Number | 20180261950 15/681438 |
Document ID | / |
Family ID | 60156745 |
Filed Date | 2018-09-13 |
United States Patent
Application |
20180261950 |
Kind Code |
A1 |
ONO; Naoyuki |
September 13, 2018 |
ELECTRICAL CONNECTOR AND METHOD FOR MANUFACTURING ELECTRICAL
CONNECTOR
Abstract
An electrical connector and a method for manufacturing the
electrical connector are provided to make the electrical connector
watertight, simplify assembly, and suppress an increase in
manufacturing cost. The electrical connector includes an insulating
housing, and conductive contacts held by the housing. The
conductive contacts including connection portions that are exposed
on a front side of the housing and connect to mating contacts of a
mating connector, and terminal portions that protrude behind the
housing. A portion of the housing in close contact with the
contacts along the outer peripheries of the contacts contains a
silane coupling agent.
Inventors: |
ONO; Naoyuki; (Chiba,
JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SMK Corporation |
Tokyo |
|
JP |
|
|
Family ID: |
60156745 |
Appl. No.: |
15/681438 |
Filed: |
August 21, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01R 43/24 20130101;
H01R 13/504 20130101; H01R 13/5202 20130101; H01R 24/60 20130101;
H01R 13/6581 20130101; H01R 13/405 20130101; H01R 13/521 20130101;
C07F 7/18 20130101; H01R 13/5216 20130101; B05D 1/36 20130101; H01R
2107/00 20130101 |
International
Class: |
H01R 13/52 20060101
H01R013/52; H01R 13/6581 20060101 H01R013/6581; H01R 43/24 20060101
H01R043/24; H01R 13/405 20060101 H01R013/405; H01R 13/504 20060101
H01R013/504 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 13, 2017 |
JP |
2017-46887 |
Claims
1. An electrical connector comprising: an insulating housing; and a
conductive contact held by the housing, the contact including a
connection portion that is exposed on a front side of the housing
and connects to a mating contact of a mating connector, and a
terminal portion that protrudes behind the housing, two adjacent
portions of the housing being in close contact with the contact
along an outer periphery of the contact, one of the two adjacent
portions of the housing containing a silane coupling agent, and the
other one of the two adjacent portions not containing a silane
coupling agent.
2. The electrical connector according to claim 1, further
comprising a cylindrical shell member configured to cover a
periphery of the housing, wherein the one of the two adjacent
portions of the housing is in close contact with the shell member
along an inner periphery of the shell member.
3. The electrical connector according to claim 1, wherein a third
portion of the housing is adjacent to the first one of the two
adjacent portions of the housing, the third portion of the housing
not containing a silane coupling agent, the third portion of the
housing being in a rear end portion thereof where the contact
protrudes rearward.
4. A method for manufacturing an electrical connector, the
electrical connector including an insulating housing and a
conductive contact held by the housing, the contact including a
connection portion that is exposed on a front side of the housing
and connects to a mating contact of a mating connector, and a
terminal portion that protrudes behind the housing, the method
comprising: integrally molding the housing and the contact, the
housing being formed of a first housing containing a silane
coupling agent and a second housing containing no silane coupling
agent, and simultaneously forming the first housing holding the
contact at a predetermined temperature; and melting the first
housing, after formed, again at a temperature higher than the
predetermined temperature so that the first housing makes close
contact with the contact along an outer periphery of the
contact.
5. An electrical connector comprising: an insulating housing
including a front protruding portion that protrudes to front, a
rear protruding portion that protrudes to rear, and an outward
protruding portion that lies between the front protruding portion
and the rear protruding portion and protrudes outward compared to
the front protruding portion and the rear protruding portion; a
conductive contact held by the housing, the contact including a
connection portion that is exposed on a front side of the housing
and connects to a mating contact of a mating connector, and a
terminal portion that protrudes behind the housing; and a
cylindrical shell member configured to cover a periphery of the
housing, wherein the shell member is configured with a front shell
member and a rear shell member, the front shell member including a
fitting portion to which the mating connector is fitted from the
front and being held on the front side of the outward protruding
portion, and the rear shell member being held on the rear side of
the outward protruding portion, and the rear shell member includes
a large diameter portion that is held on the rear side of the
outward protruding portion and a small diameter portion that is
continuously formed behind the large diameter portion and has a
diameter smaller than a diameter of the large diameter portion.
6. A method for manufacturing an electrical connector, the
electrical connector including (i) an insulating housing including
a front protruding portion that protrudes to front, a rear
protruding portion that protrudes to rear, and an outward
protruding portion that lies between the front protruding portion
and the rear protruding portion and protrudes outward compared to
the front protruding portion and the rear protruding portion; (ii)
a conductive contact held by the housing, the contact including a
connection portion that is exposed on a front side of the housing
and connects to a mating contact of a mating connector, and a
terminal portion that protrudes behind the housing; and (iii) a
cylindrical shell member configured to cover a periphery of the
housing, wherein the shell member is configured with a front shell
member and a rear shell member, the front shell member including a
fitting portion to which the mating connector is fitted from the
front and being held on the front side of the outward protruding
portion, and the rear shell member being held on the rear side of
the outward protruding portion, and the rear shell member includes
a large diameter portion that is held on the rear side of the
outward protruding portion and a small diameter portion that is
continuously formed behind the large diameter portion and has a
diameter smaller than a diameter of the large diameter portion, the
method comprising: attaching the front shell member and the rear
shell member to the housing by covering the housing with the front
shell member from the front and covering the housing with the rear
shell member from behind.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] The contents of the following Japanese patent application
are incorporated herein by reference,
[0002] Japanese Patent Application No. 2017-46887 filed on Mar. 13,
2017.
FIELD
[0003] The present invention relates to an electrical connector
having a watertight function and a method for manufacturing the
electrical connector.
BACKGROUND
[0004] Conventionally, electrical connectors attached to electronic
devices have been required to have a watertight function of making
the interior of the electronic devices watertight from outside. To
fit to a mating connector, such an electrical connector includes a
fitting portion exposed to outside the casing of the electronic
device. Gaps between conductive contacts arranged on the fitting
portion and an insulating housing holding the contacts need to be
made watertight.
[0005] If an electrical connector is formed by integrally molding a
housing and contacts, the housing and the contacts are not in close
contact with each other. There are gaps between the housing and the
contacts, and a desired watertight effect is not available. If
contacts having fine grooves in the surface and a housing are
integrally molded to form an electrical connector, a desired
watertight effect can be obtained. However, the need to machine the
contacts increases product and manufacturing costs.
[0006] Under the circumstances, Patent Literature 1 discloses a
configuration of an electrical connector having a watertight
function, in which a rear end portion of a housing is provided with
a sealing material formed by filling and curing a resin material
such as a potting material. The electrical connector according to
Patent Literature 1 can be made watertight by sealing gaps between
the housing and terminals arranged on the housing with the sealing
material provided in the rear end portion of the housing.
CITATION LIST
Patent Literature
[0007] Patent Literature 1: Japanese Patent Application Laid-Open
No. 2015-111524
SUMMARY
Technical Problem
[0008] According to Patent Literature 1, the electrical connector
needs to be held so that the sealing material will not drip on
unwanted portions during filling of the sealing material. There is
also a need to wait for the sealing material to cure. The
electrical connector thus has a problem that its complex assembly
steps complicate the assembly and cause an increase in
manufacturing cost.
Solution to Problem
[0009] An object of the present invention is to provide an
electrical connector which can be made watertight, of which
assembly can be simplified, and of which an increase in
manufacturing cost can be suppressed, and a method for
manufacturing the electrical connector.
[0010] An electrical connector according to one aspect of the
present invention includes: an insulating housing; and a conductive
contact held by the housing, the contact including a connection
portion that is exposed on a front side of the housing and connects
to a mating contact of a mating connector, and a terminal portion
that protrudes behind the housing, a portion of the housing in
close contact with the contact along an outer periphery of the
contact containing a silane coupling agent.
[0011] A method for manufacturing an electrical connector according
to another aspect of the present invention is a method for
manufacturing an electrical connector, the electrical connector
including an insulating housing and a conductive contact held by
the housing, the contact including a connection portion that is
exposed on a front side of the housing and connects to a mating
contact of a mating connector, and a terminal portion that
protrudes behind the housing, the method including: integrally
molding the housing and the contact, the housing being formed of a
first housing containing a silane coupling agent and a second
housing containing no silane coupling agent, and simultaneously
forming the first housing holding the contact at a predetermined
temperature; and melting the first housing, after formed, again at
a temperature higher than the predetermined temperature so that the
first housing makes close contact with the contact along an outer
periphery of the contact.
[0012] A liquid intruding from outside from the front into a rear
portion through a gap between the contact and the housing is
blocked by the silane coupling agent-containing portion of the
housing in close contact with the contact along the outer periphery
of the contact. The electrical connector can thus be made
watertight without special machining on the contact and without
using a sealing material such as a potting material.
[0013] According to the aspect(s) of the present invention, an
electrical connector can be made watertight, assembly can be
simplified, and an increase in manufacturing cost can be
suppressed.
BRIEF DESCRIPTION OF DRAWINGS
[0014] FIG. 1 is a perspective view of an electrical connector
according to a first embodiment of the present invention.
[0015] FIG. 2 is a plan view of the electrical connector according
to the first embodiment of the present invention.
[0016] FIG. 3 is a cross-sectional view taken along line A-A of
FIG. 2.
[0017] FIG. 4 is a perspective view of a primary molded article
constituting the electrical connector according to the first
embodiment of the present invention.
[0018] FIG. 5 is a plan view of the primary molded article
constituting the electrical connector according to the first
embodiment of the present invention.
[0019] FIG. 6 is a cross-sectional view taken along line B-B of
FIG. 5.
[0020] FIG. 7 is a perspective view of a secondary molded article
constituting the electrical connector according to the first
embodiment of the present invention.
[0021] FIG. 8 is a plan view of the secondary molded article
constituting the electrical connector according to the first
embodiment of the present invention.
[0022] FIG. 9 is a cross-sectional view taken along line C-C of
FIG. 8.
[0023] FIG. 10 is a cross-sectional view of an electrical connector
according to a second embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
[0024] Electrical connectors according to embodiments of the
present invention will be described in detail below with reference
to the drawings as appropriate. In the drawings, an x-axis, a
y-axis, and a z-axis constitute a three-axis orthogonal coordinate
system. In the following description, a positive direction of the
y-axis will be referred to as a front direction, a negative
direction of the y-axis as a rear direction, the direction of the
x-axis as a horizontal direction, a positive direction of the
z-axis as an upward direction, and a negative direction of the
z-axis as a downward direction.
First Embodiment
[0025] <Configuration of Electrical Connector>
[0026] A configuration of an electrical connector 1 according to a
first embodiment of the present invention will be described in
detail below with reference to FIGS. 1 to 3.
[0027] The electrical connector 1 according to the present
embodiment includes a housing 10, contacts 20, a front shell member
30, a rear shell member 40, an external watertight member 50, and a
shielding plate 60.
[0028] The housing 10 is formed of an insulating material and holds
the contacts 20. A portion of the housing 10 in close contact with
the contacts 20 along the outer peripheries of the contacts 20
contains a silane coupling agent. The housing 10 contains no silane
coupling agent in its rear end portion where the contacts 20
protrude to the rear. The silane coupling agent includes reaction
groups chemically bondable to an inorganic material and reaction
groups chemically bondable to an organic material, and has a
property capable of bonding an organic material to an inorganic
material.
[0029] The housing 10 includes a main body portion 11 and a
plate-like portion 12.
[0030] The main body portion 11 includes a front protruding portion
111, a rear protruding portion 112, and an outward protruding
portion 113. The front protruding portion 111 holds the contacts 20
and protrudes to the front. The rear protruding portion 112
protrudes to the rear. The outward protruding portion 113 lies
between the front protruding portion 111 and the rear protruding
portion 112, and protrudes outward compared to the front protruding
portion 111 and the rear protruding portion 112. The outward
protruding portion 113 includes a step portion 114.
[0031] The rear protruding portion 112 includes a front end portion
112d, a rear end portion 112a, and a watertight resin portion 112c.
The front end portion 112d protrudes to the rear from the rear end
of the outward protruding portion 113 and contains no silane
coupling agent. The rear end portion 112a is arranged at the rear
end of the housing 10 and contains no silane coupling agent. The
watertight resin portion 112c is arranged between the front end
portion 112d and the rear end portion 112a and contains the silane
coupling agent.
[0032] The watertight resin portion 112c is in close contact with
the contacts 20 along the outer peripheries of the contacts 20. The
resin constituting the watertight resin portion 112c is of
different type from that constituting the plate-like portion 12,
the front protruding portion 111, the rear end portion 112a, the
front end portion 112d, and the outward protruding portion 113. The
resin has a property that its melting temperature is lower than
that of the resin constituting the plate-like portion 12, the front
protruding portion 111, the rear end portion 112a, the front end
portion 112d, and the outward protruding portion 113.
[0033] For convenience of description, FIG. 3 clearly shows the
boundaries between the front end portion 112d, the rear end portion
112a, and the watertight resin portion 112c. In fact, the
boundaries are vague since the junction between the front end
portion 112d and the watertight resin portion 112c is melted and
bonded in a manufacturing step to be described later, and the
junction between the rear end portion 112a and the watertight resin
portion 112c is melted and bonded in the manufacturing step to be
described later.
[0034] The plate-like portion 12 has a plate-like shape and
protrudes in front of the main body portion 11. The front end side
of the plate-like portion 12 protrudes in front of the front shell
member 30.
[0035] The contacts 20 are formed of a conductive material and held
by the housing 10. The contacts 20 include first contacts 20a and
second contacts 20b arranged below the first contacts 20a. The
first contacts 20a and the second contacts 20b are insulated from
each other by the housing 10.
[0036] The first contacts 20a each include a connection portion 21a
and a terminal portion 22a. The connection portion 21a is exposed
on the front side of the housing 10 and exposed in a top surface of
the plate-like member 12, and connects to a mating contact of a
not-shown mating connector. The terminal portion 22a protrudes
behind the housing 10 and is welded to a conductive portion of a
not-shown substrate. A part of the first contact 20a between the
connection portion 21a and the terminal portion 22a is embedded in
the front protruding portion 111, the rear protruding portion 112,
and the outward protruding portion 113. The first contact 20a is in
close contact with the watertight resin portion 112c along its
outer periphery. The part of the first contact 20a in close contact
with the watertight resin portion 112c is shaped to bend
horizontally and upward.
[0037] The second contacts 20b each include a connection portion
21b and a terminal portion 22b. The connection portion 21b is
exposed on the front side of the housing 10 and exposed in a bottom
surface of the plate-like portion 12, and connects to a mating
contact of the not-shown mating connector. The terminal portion 22b
protrudes behind the housing 10 and is welded to the not-shown
substrate. A part of the second contact 20b between the connection
portion 21b and the terminal portion 22b is embedded in the front
protruding portion 111, the rear protruding portion 112, and the
outward protruding portion 113. The second contact 20b is in close
contact with the watertight resin portion 112c along its outer
periphery. The part of the second contact 20b in close contact with
the watertight resin portion 112c is shaped to bend horizontally
and downward. The lower ends of the terminal portions 22a and the
lower ends of the terminal portions 22b are vertically at the same
height.
[0038] The front shell member 30 is formed of a conductive material
and has a cylindrical shape extending in a front-to-rear direction.
The front shell member 30 includes a fitting portion 31 to which
the not-shown mating connector can be fitted from the front. The
plate-like portion 12 and the front protruding portion 111 are
arranged in the fitting portion 31. The rear end of the front shell
member 30 is in contact with the step portion 114 and held on the
front side of the outward protruding portion 113.
[0039] The rear shell member 40 is made of a conductive material
and has a cylindrical shape extending in the front-to-rear
direction. The rear shell member 40 includes a large diameter
portion 41 and a small diameter portion 42, and has a narrowed
shape toward the rear. The large diameter portion 41 is held on the
rear side of the outward protruding portion 113. The small diameter
portion 42 is continuously formed behind the large diameter portion
41, and has a diameter smaller than that of the large diameter
portion 41. The small diameter portion 42 is in close contact with
the watertight resin portion 112c along its inner periphery.
[0040] The external watertight member 50 is formed of an elastic
insulating material in an annular shape, and arranged at the front
end of the front shell member 30.
[0041] The shielding plate 60 is formed of a conductive material
and has a plate-like shape. The shielding plate 60 is embedded in
the housing 10. The shielding plate 60 is arranged between the
first contacts 20a and the second contacts 20b in a state of being
insulated from the first contacts 20a and the second contacts
20b.
[0042] <Method for Manufacturing Electrical Connector>
[0043] A method for manufacturing the electrical connector 1
according to the first embodiment of the present invention will be
described in detail below with reference to FIGS. 1 to 9.
[0044] The contacts 20 and the shielding plate 60 formed in advance
are initially set in a not-shown mold. A resin containing no silane
coupling agent is injected into the mold at a predetermined
injection molding temperature, followed by curing. By such integral
molding, a primary molded article 100 shown in FIGS. 4 to 6 is
formed. The primary molded article 100 includes the plate-like
portion 12, the contacts 20, the front protruding portion 111, the
outward protruding portion 113, the front end portion 112d, the
rear end portion 112a, and the shielding plate 60. An example of
the injection molding temperature is 300.degree. C.
[0045] The primary molded particle 100 has a space 112b between the
front end portion 112d and the rear end portion 112a. The front end
portion 112d and the rear end portion 112a are opposed to each
other. In the space 112b, part of the first contacts 20a and part
of the second contacts 20b are exposed to outside.
[0046] Next, the primary molded article 100 is set in a not-shown
mold. A resin containing the silane coupling agent is injected into
the space 112b at a predetermined temperature, followed by curing.
By such integral molding, a secondary molded article 150 shown in
FIGS. 7 to 9 is formed. The secondary molded article 150 includes
the primary molded article 100 and the watertight resin portion
112c. In other words, the secondary molded article 150 is
configured by adding the watertight resin portion 112c to the
primary molded article 100.
[0047] The resin poured into the space 112b is of different type
from that constituting the plate-like portion 12, the front
protruding portion 111, the rear end portion 112a, the front end
portion 112d, and the outward protruding portion 113 of the primary
molded article 100. The resin has a property that its melting point
is lower than that of the resin constituting the plate-like portion
12, the front protruding portion 111, the rear end portion 112a,
the front end portion 112d, and the outward protruding portion 113
of the primary molded article 100. The temperature in forming the
secondary molded article 150 is thus set to be lower than the
injection molding temperature in forming the primary molded article
100. An example of the temperature in molding the secondary molded
article 150 is 150.degree. C.
[0048] Since the temperature in forming the secondary molded
article 150 is set to be lower than the injection molding
temperature, the resin constituting the plate-like portion 12, the
front protruding portion 111, the rear end portion 112a, the front
end portion 112d, and the outward protruding portion 113 will not
melt when the secondary molded article 150 is formed. In forming
the secondary molded article 150, the contacts 20 can thus be
securely held by the plate-like portion 12, the front protruding
portion 111, the rear end portion 112a, the front end portion 112d,
and the outward protruding portion 113. In particular, the contacts
20 can be securely held by the rear end portion 112a. The
protruding positions of the terminal portions 22a and 22b from the
rear end portion 112a can thus be prevented from shifting when the
secondary molded article 150 is formed. This can prevent poor
connection of the terminal portions 22a and 22b with the conductive
portions of the substrate.
[0049] Next, the secondary molded article 150 is covered with the
front shell member 30 from the front and covered with the rear
shell member 40 from behind.
[0050] Next, the front shell member 30 and the rear shell member 40
are attached to the secondary molded article 150 by welding the
rear end of the front shell member 30 and the front end of the rear
shell member 40.
[0051] Next, the external watertight member 50 is attached to the
front end of the front shell member 30.
[0052] Next, the secondary molded article 150 to which the front
shell member 30 and the rear shell member 40 are attached is heated
to a temperature higher than that in forming the watertight resin
portion 112c, whereby the watertight resin portion 112c is melted
again. The temperature to which the secondary molded article 150
having the front shell member 30 and the rear shell member 40
attached thereto is heated may be the same as or different from the
injection molding temperature in forming the primary molded article
100.
[0053] Here, the part of the watertight resin portion 112c in
contact with the outer peripheries of the contacts 20 is melted and
bonded to the outer peripheries of the contacts 20 by the bonding
action of the silane coupling agent contained in the watertight
resin portion 112c. The part of the watertight resin portion 112c
in contact with the inner periphery of the rear shell member 40 is
melted and bonded to the inner periphery of the rear shell member
40 by the bonding action of the silane coupling agent contained in
the watertight resin portion 112c. The watertight resin portion
112c and the outer peripheries of the contacts 20 are thereby put
in close contact with each other, and the watertight resin portion
112c and the inner periphery of the rear shell member 40 are put in
close contact with each other.
[0054] Heating the secondary molded article 150 to which the front
shell member 30 and the rear shell member 40 are attached to a
temperature higher than that in forming the watertight resin
portion 112c can melt at least the watertight resin portion 112c
again, whereby the watertight resin portion 112c can be firmly
adhered to the rear end portion 112a and the front end portion
112d.
[0055] The watertight resin portion 112c thus has adhesiveness to
the contacts 20 made of metal and the rear and front end portions
112a and 112d made of a resin material.
[0056] Next, the secondary molded article 150 to which the front
shell member 30 and the rear shell member 40 are attached is cooled
to complete the electrical connector 1.
[0057] In the electrical connector 1 manufactured by the foregoing
manufacturing method, the watertight resin portion 112c containing
the silane coupling agent makes close contact with the outer
peripheries of the contacts 20 to seal the gaps between the
watertight resin portion 112c and the contacts 20. The interior of
an electronic device to which the electrical connector 1 is
attached can thus be sealed off from the gaps between the housing
10 and the contacts 20 and made watertight. In the electrical
connector 1, the watertight resin portion 112c containing the
silane coupling agent makes close contact with the inner periphery
of the rear shell member 40 to seal the gap between the watertight
resin portion 112c and the rear shell member 40. The interior of
the electronic device to which the electrical connector 1 is
attached can thus be sealed off from the gap between the housing 10
and the rear shell member 40 and made watertight.
[0058] In the foregoing manufacturing method, the watertight resin
portion 112c is formed before the front shell member 30 and the
rear shell member 40 are provided. However, the front shell member
30 and the rear shell member 40 may be provided before the
formation of the watertight resin portion 112c. A resin containing
the silane coupling agent may be injected into the space 112b
through a gap of the rear shell member 40 and then heated to form
the watertight resin portion 112c.
[0059] As described above, according to the present embodiment, a
portion of the housing 10 in close contact with the contacts 20
along the outer peripheries of the contacts 20 contains the silane
coupling agent. The gaps between the housing 10 and the contacts 20
can thus be made watertight. This can eliminate the need for
elastic parts and potting agents for sealing to simplify assembly.
An increase in manufacturing cost can be suppressed as well.
[0060] According to the present embodiment, a portion of the
housing 10 in close contact with the rear shell member 40 along the
inner periphery of the rear shell member 40 contains the silane
coupling agent. The gap between the housing 10 and the rear shell
member 40 can thus be made watertight. This can simplify assembly
and suppress an increase in manufacturing cost.
[0061] While the present embodiment includes the external
watertight member 50, the external watertight member 50 does not
need to be provided.
[0062] In the present embodiment, two types of contacts, namely,
the first contacts 20a and the second contacts 20b are arranged on
the housing 10. However, one type of contacts may be arranged on
the housing.
[0063] While the present embodiment includes the shielding plate
60, the shielding plate 60 does not need to be provided.
[0064] In the present embodiment, the housing 10 may have any shape
as long as the silane coupling agent-containing part of the housing
makes close contact along the outer peripheries of the contacts 20
and makes close contact along the inner periphery of the rear shell
member 40.
[0065] In the present embodiment, the front shell member 30 and the
rear shell member 40 are formed of a conductive material. However,
either one or both of the front and rear shell members 30 and 40
may be formed of an insulating material.
[0066] In the present embodiment, the shell member includes two
members, namely, the front shell member 30 and the rear shell
member 40. However, the shell member may be configured as a single
member.
Second Embodiment
[0067] <Configuration of Electrical Connector>
[0068] A configuration of an electrical connector 2 according to a
second embodiment of the present invention will be described in
detail below with reference to FIG. 10.
[0069] The electrical connector 2 according to the present
embodiment includes a housing 210, contacts 220, and a shell member
230.
[0070] The housing 210 is formed of an insulating material and
holds the contacts 220. The housing 210 contains a silane coupling
agent in its watertight resin portion R1 which is a portion to make
close contact with the contacts 220 along the outer peripheries of
the contacts 220. The housing 210 includes a plate-like portion 212
of plate-like shape protruding to the front.
[0071] The contacts 220 are formed of a conductive material and
held by the housing 210. The contacts 220 each include a connection
portion 221 and a terminal portion 222. The connection portion 221
is exposed to the front and exposed in a top surface of the
plate-like portion 212. The connection portion 221 connects to a
mating contact of a not-shown mating connector. The terminal
portion 222 protrudes behind the housing 210 and is welded to a
conductive portion of a not-shown substrate. A part of the contact
220 between the connection portion 221 and the terminal portion 222
is embedded in the housing 210 and makes close contact with the
portion R1.
[0072] The shell member 230 is formed of a conductive material and
has a cylindrical shape extending in a front-to-rear direction. The
shell member 230 includes a fitting part 231 in which the
plate-like portion 212 is arranged and to which the not-shown
mating connector can be fitted from the front. The rear end of the
shell member 230 is held by the housing 210.
[0073] <Method for Manufacturing Electrical Connector>
[0074] A method for manufacturing the electrical connector 2
according to the second embodiment of the present invention will be
described in detail below.
[0075] Initially, the contacts 220 and the watertight resin portion
R1 containing the silane coupling agent are integrally molded at a
predetermined temperature to form a primary molded article. An
example of the predetermined temperature is 150.degree. C.
[0076] Next, the primary molded article and the shell member 230
are set in a not-shown mold. A resin containing no silane coupling
agent is injected into the mold at a predetermined injection
molding temperature, followed by curing. By such integral molding,
the electrical connector 2 is formed. An example of the injection
molding temperature is 300.degree. C.
[0077] The injection molding temperature is higher than the
predetermined temperature in forming the foregoing primary molded
article. The part of the watertight resin portion R1 in contact
with the outer peripheries of the contacts 220 is thus melted again
and bonded to the outer peripheries of the contacts 220 by the
bonding action of the silane coupling agent contained in the
watertight resin portion R1. The watertight resin portion R1 and
the outer peripheries of the contacts 220 are thereby put in close
contact with each other. Melting the watertight resin portion R1
again firmly adheres the watertight resin portion R1 to the
portions of the housing 210 other than the watertight resin portion
R1.
[0078] The watertight resin portion R1 thus has adhesiveness to the
metal contacts 220 and the portions of the resin housing 210 other
than the watertight resin portion R1.
[0079] In the electrical connector 2 manufactured by the foregoing
manufacturing method, the watertight resin portion R1 containing
the silane coupling agent makes close contact with the outer
peripheries of the contacts 220 to seal the gaps between the
watertight resin portions R1 and the contacts 220. The interior of
an electronic device to which the electrical connector 2 is
attached can thus be sealed off from the gaps between the housing
210 and the contacts 220 and made watertight.
[0080] As described above, according to the present embodiment, the
portion of the housing 210 in close contact with the contacts 220
along the outer peripheries of the contacts 220 contains the silane
coupling agent. The gaps between the housing 210 and the contacts
220 can thus be made watertight. This can eliminate the need for
elastic parts and potting agents for sealing to simplify assembly.
An increase in manufacturing cost can be suppressed as well.
[0081] According to the present embodiment, the watertight resin
portion R1 can provide the watertight effect in the step of
integrally molding the primary molded article and the shell member
230. Such a configuration can simplify the assembly steps to
facilitate manufacturing, with a reduction in manufacturing
cost.
[0082] The present invention is not limited to the foregoing
embodiments in terms of the types, arrangement, numbers, or the
like of the members. It will be understood that appropriate
modifications may be made without departing from the gist of the
invention. For example, the components may be replaced with ones
having similar operations and effects as appropriate.
[0083] The embodiment of the present invention is suitable for an
electrical connector having a watertight function and a method for
manufacturing the electrical connector.
REFERENCE SIGNS LIST
[0084] 1 electrical connector
[0085] 2 electrical connector
[0086] 10 housing
[0087] 11 main body portion
[0088] 12 plate-like portion
[0089] 20 contact
[0090] 20a first contact
[0091] 20b second contact
[0092] 21a connection portion
[0093] 21b connection portion
[0094] 22a terminal portion
[0095] 22b terminal portion
[0096] 30 front shell member
[0097] 31 fitting portion
[0098] 40 rear shell member
[0099] 41 large diameter portion
[0100] 42 small diameter portion
[0101] 50 external watertight member
[0102] 60 shielding plate
[0103] 100 primary molded article
[0104] 111 front protruding portion
[0105] 112 rear protruding portion
[0106] 112a rear end portion
[0107] 112b space
[0108] 112c watertight resin portion
[0109] 112d front end portion
[0110] 113 outward protruding portion
[0111] 114 step portion
[0112] 150 secondary molded article
[0113] 210 housing
[0114] 212 plate-like portion
[0115] 220 contact
[0116] 221 connection portion
[0117] 222 terminal portion
[0118] 230 shell member
[0119] 231 fitting part
[0120] R1 watertight resin portion
* * * * *