Electrical generator or motor structure – Dynamoelectric – Rotary
Reexamination Certificate
1999-06-08
2001-09-25
Mullins, Burton S. (Department: 2834)
Electrical generator or motor structure
Dynamoelectric
Rotary
C310S071000, C310S089000, C029S596000
Reexamination Certificate
active
06294851
ABSTRACT:
CROSS-REFERENCE TO RELATED APPLICATION
This application is related to and claims priority from Japanese Patent Applications No. Hei. 10-162009 filed on Jun. 10, 1998, and No. Hei. 10-339099 filed on Nov. 30, 1998, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a resin molding method for inserting a terminal in a resinous housing, relates to a connector in which the terminal is inserted in the resinous housing using the resin molding method, and relates to a motor having the connector.
2. Description of Related Art
As a driving source for driving a unit such as a power window device, an actuator having a motor portion and a deceleration portion integrally assembled is used. In the actuator, the deceleration portion is provided in a housing made of a synthetic resin, and a motor case for rotatably supporting a motor is fixed to an attachment portion of the housing. Further, a connector for supplying power from a battery to the motor is formed in the housing, and a terminal is inserted in the housing between the connector and the attachment portion of the motor. The terminal is exposed from the housing so that the motor and the battery are electrically connected.
As shown in
FIG. 14
, a terminal
150
is inserted in a connector
151
of a housing made of resin, an insertion recess portion
151
a
engaging with a connector of a battery is provided in the connector
151
, and the terminal
150
is exposed from the insertion recess portion
151
a
of the connector
151
. The housing having the connector
151
is molded by a pair of first and second dies
152
a,
152
b
as shown in FIG.
15
. That is, a molding recess
152
c
for molding an outer shape of the connector
151
is formed over both of the first and second dies
152
a,
152
b.
Further, a molding protrusion
152
d
for forming the insertion recess portion
151
a
is formed in the first die
152
a,
and an insertion hole
152
e
for inserting the terminal
150
therein is formed in the molding protrusion
152
d
so that the terminal
150
is exposed after molding. On the other hand, the second die
152
b
has a supporting protrusion
152
f
which extends to contact the terminal
150
when the terminal
150
is inserted into the insertion hole
152
e.
The supporting protrusion
152
f
prevents the terminal
150
from being removed from the insertion hole
152
e
when melted resin is poured into the first and second dies
152
a,
152
b,
and sets an attachment position of the terminal
150
. Due to the supporting protrusion
152
f
of the second die
152
b,
a hole
151
b
is formed in the connector
151
as shown in FIG.
14
. When the actuator is used as the driving source for driving the power window device, water may be attached onto the outer surface of the actuator. Therefore, after forming the connector
151
, a liquid seal material or a malted resin material
153
is filled in the hole
151
b,
for preventing water from being introduced to the terminal
150
from the hole
151
b.
However, in this case, a filling step for filling the resin material
153
in the hole
151
b
is necessary. Further, when the resin material
153
filled in the hole
151
b
solidifies, the resin material
153
is contracted. Therefore, the volume of the resin material
153
becomes smaller, and a clearance is formed between the inner peripheral surface of the hole
151
b
and the resin material
153
. Thus, sealing performance of the hole
151
b
is insufficient, and water may be introduced to the terminal
150
from the hole
151
b.
SUMMARY OF THE INVENTION
In view of the foregoing problems, it is an object of the present invention to provide a resin molding method for inserting a terminal in a resinous member, which sufficiently prevents liquid from being introduced to the terminal in the resinous member while having a simple molding step.
It is an another object of the present invention to provide a connector having a terminal inserted in a resinous housing using the resin molding method, and a motor having the connector.
According to a resin molding method of a resinous member of the present invention, an insulation member is engaged with a terminal, the insulation member contacts a die for molding the resinous member so that an attachment position of the terminal relative to the die is set through the insulation member, and thereafter, a melted resin is poured into the die having the terminal and the insulation member therein to form the resinous member in which the insulation member is inserted together with the terminal. Because the insulation member contacts the die, the terminal is not exposed from a resinous member in a contacting position between the insulation member and the die. Therefore, it can prevent liquid from being introduced to the terminal in the resinous housing from the contacting portion, and the resinous member having the terminal is molded with a simple method.
Preferably, the insulation member has a melting point equal to or lower than that of the resin for molding the resinous member. Therefore, at least a portion of the insulation member contacting the resin is melted by heat from the melted resin, and the insulation member is bonded to the resinous member. Thus, a clearance between the insulation member and the resinous member can be sufficiently closed, and it can accurately prevent liquid from being introduced to the terminal in the resinous member.
According to the present invention, a connector for a motor includes a housing formed by molding resin from a die, a terminal disposed in the housing in such a manner that both ends of the terminal are exposed from the housing, and an insulation member having a first portion contacting the die and a second portion contacting the terminal. The insulation member contacts the die at the first position so that the terminal is disposed at a predetermined position in the die for forming the housing, and the insulation member is inserted in the housing together with the terminal by pouring melted resin into the die. Because the insulation member contacts the die, the terminal is not exposed from the housing in a contacting portion between the insulation member and the die. Therefore, it can prevent liquid from being introduced to the terminal in the resinous housing from the contacting portion, and the resinous member is molded with a simple structure.
Preferably, the insulation member has a groove around a contacting portion contacting the die. When the melted resin forming the housing is solidified, resin filled in the groove is contracted, and the resin filled in the groove is air-tightly bonded to an inner surface of the groove. Therefore, seal performance between the insulation member and the housing can be improved.
More preferably, the insulation member has a melting point equal to or lower than that of the resin for molding the housing. Further, the insulation member has a thin wall portion having a thinness thinner than the other portion, and the thin wall portion is melted by the melted resin pouring into the die. Thus, a clearance between the housing and the insulation member can be further accurately closed. As a result, even when liquid is introduced from a contacting portion between the die of the housing and the insulation member, it can prevent liquid from being introduced to the terminal in the housing.
Still more preferably, the second portion of the insulation member is engaged with the terminal at a predetermined position. Further, the first portion of the insulation member is an engagement portion engaging with the die at a predetermined position. Therefore, the terminal can be inserted in the housing at a predetermined position.
REFERENCES:
patent: 4847528 (1989-07-01), Eguchi et al.
patent: 5073735 (1991-12-01), Takagi
patent: 5334897 (1994-08-01), Ineson et al.
patent: 5423117 (1995-06-01), Okada et al.
patent: 5636431 (1997-06-01), Ade
patent: 5806169 (1998-09-01), Trago et al.
patent: A-10-164789 (1998-06-01), None
Matsuyama Youichi
Tsujita Kazuaki
Asmo Co. Ltd.
Fish & Richardson P.C.
Mullins Burton S.
LandOfFree
Resin molding method for inserting terminal and connector... does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Resin molding method for inserting terminal and connector..., we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Resin molding method for inserting terminal and connector... will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2535210