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CN103221473A - 连接器外壳 - Google Patents

连接器外壳 Download PDF

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CN103221473A
CN103221473A CN2011800560506A CN201180056050A CN103221473A CN 103221473 A CN103221473 A CN 103221473A CN 2011800560506 A CN2011800560506 A CN 2011800560506A CN 201180056050 A CN201180056050 A CN 201180056050A CN 103221473 A CN103221473 A CN 103221473A
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resin material
connector housing
molding
pbt
fibers
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香川敦嗣
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Yazaki Corp
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Abstract

一种连接器外壳（1），其使用本质上含有用纤维加固的聚对苯二甲酸丁二酯的树脂材料来模制，所述聚对苯二甲酸丁二酯具有当通过ASTM D790测量时5000至7000MPa的弯曲模量以及80至130mm的棒流动长度的性质。

Description

连接器外壳
技术领域
本发明涉及一种用于汽车的、其中并入有线束和端子接头的连接器外壳，特别是涉及一种实现了模制周期时间缩短的连接器外壳。
背景技术
用于汽车的连接器外壳由树脂注塑模制。在模制中使用聚酰胺例如尼龙、聚烯烃例如聚丙烯、聚酯例如聚对苯二甲酸乙二酯和聚对苯二甲酸丁二酯，以及聚碳酸酯。其中，通常使用聚对苯二甲酸丁二酯（在后文中缩写为PBT），这是由于PBT具有出色的机械性能、电气性能、耐热性、耐水性等。此外，PBT是结晶树脂，通过实现快速结晶可以导致高生产率，并且在短时间内固化。由于这些优点，PBT常常被用作汽车用连接器外壳的模制材料。
随着线束等的尺寸减小，对于减小连接器外壳的尺寸和厚度也存在需求。在使用PBT作为连接器外壳模制材料的常规实践中，向PBT添加纤维例如玻璃纤维以满足这种需求，同时也增加连接器外壳的强度。专利文献1描述了添加纤维的一种常规技术，其中将具有平坦横截面的玻璃纤维和脂肪酸的甘油酯混合在PBT中。
引用列表
专利文献
[专利文献1]日本未经审查的专利申请公布号2009-155367
发明简述
然而，其中将纤维混合在PBT中的树脂材料的流动性大大降低，使得难以向树脂材料施加足够的注入压力。这不仅引起模制周期时间增加的问题，而且引起出现例如缩痕和由于树脂材料在模具中填充不足而造成的欠注的缺陷的问题。如果为了解决上述问题而升高模制温度以确保流动性，则这可能引起树脂材料的热降解风险增加和模制产品的耐久性降低的其他问题。
本发明的目的是提供一种连接器外壳，即使使用包含添加纤维的PBT作为树脂材料，该连接器外壳也可以被模制而不增加模制周期时间、不形成缩痕或欠注并且不需高温。
本发明的一个方面是一种连接器外壳，其通过使用本质上含有用纤维加固的聚对苯二甲酸丁二酯的树脂材料来模制，所述聚对苯二甲酸丁二酯具有当通过ASTM D790测量时5000至7000MPa的弯曲模量以及80至130mm的棒流动长度的性质。
在上述方面中，即使厚度减小，所述连接器外壳仍可具有足够高的强度，这归因于使用了本质上含有纤维加固的PBT的所述树脂材料，所述纤维加固的PBT具有当通过ASTM D790测量时5000至7000MPa的弯曲模量。
此外，本质上含有这种纤维加固的PBT的所述树脂材料具有80至130mm的棒流动长度，并且因此具有高流动性。因此，即使在相对低的模制温度下执行模制，所述树脂材料也能够以令人满意的状况填充在模具中。因此，不会出现缺陷例如缩痕或欠注。此外，由于不需将模制温度设定到非常高的温度，因此模制周期时间随着模制后冷却时间的减少而减少，并且能够以更低成本生产所述连接器外壳。
所述纤维可以是玻璃纤维。
上面描述的构造使得能够容易地获得具有上述性质的所述纤维加固的PBT，这是由于使用玻璃纤维作为所述纤维，能够选择具有适合于PBT的所述性质的长度、直径、重量等的玻璃纤维。
附图说明
图1是在本发明的实施例中生产的连接器外壳的透视图。
图2是流程图，其示出了本发明实施例的生产的模制周期和现有生产的模制周期。
实施方式描述
使用本质上含有纤维加固的聚对苯二甲酸丁二酯（纤维加固的PBT）的树脂材料来模制本发明的连接器外壳。尽管在这里可以通过注塑模制、挤出模制、压缩模制等的任一种来执行模制，但就模制性能而言，注塑模制是优选的。
PBT是由具有4个碳原子的丁二醇（1,4-丁二醇）与对苯二甲酸或对苯二甲酸二甲酯之间的缩聚反应获得的热塑性聚酯。总的来说，PBT是一种具有出色耐热性、耐化学性、电学性质、维度稳定性和可模制性能的树脂。根据PBT与添加到PBT内的纤维之间的关系，考虑到模具中树脂材料的流动性、树脂的强度和其他条件来适当地选择PBT的聚合程度。
玻璃纤维、碳纤维、氧化铝纤维、氧化锆纤维或其他纤维可以用作所述纤维。这些类型的纤维可以单独或组合使用。向PBT添加这些纤维，能够为模制产品提供机械强度和抗冲击强度，并且也能够抑制弯曲变形。在这些类型的纤维中，玻璃纤维是优选的，因为玻璃纤维允许对适合于PBT的纤维的长度、直径和重量等进行适当选择，并且对PBT具有出色的顺应性。这样选择玻璃纤维与PBT的比率：使得作为树脂材料的纤维加固的PBT的弯曲模量和熔体粘度落入下面描述的各个值的范围内。
本发明的本质上含有纤维加固PBT的树脂材料，具有当通过ASTM D790测量时5000至7000MPa的弯曲模量以及80至130mm的棒流动长度的性质。在本发明中，以这样的方式设置PBT的聚合、纤维的长度和直径、纤维与PBT的比率以及其他条件：使得弯曲模量和熔体粘度落入上面描述的相应范围内。
弯曲模量是指树脂材料的弯曲模量。如果弯曲模量低于5000MPa，作为模制产品的连接器外壳具有非常低的强度，并且因此不能减小厚度。相反，超过7000MPa的弯曲模量使连接器外壳的强度高于必需，并且也不利地影响树脂材料的可模制性能。这样过高的弯曲模量还引起下述问题：树脂材料变得对温度而言具有不良的膨胀性能和收缩性能，并因此具有对环境温度的较低的适应能力；并且因此可能由于环境温度的变化而在连接器外壳中出现裂缝。
弯曲模量只需落入5000至7000MPa的范围内，更优选落入5500至6000MPa的范围内。使用具有这样的弯曲模量的树脂材料，即使连接器外壳的厚度减小，也能够使连接器外壳具有足够高的强度。
符合ASTM D790的弯曲模量测量，可以使用例如由Toyo SeikiSeisaku-sho,LTD.制造的Autograph（商品名）来进行。在该测量中，执行三点弯曲试验，其中：将样本置于间隔地排列的支承台上；并从上方向样本的中央施加集中的载荷。
棒流动长度是与模具中的树脂材料的流动性有关的因子。如果棒流动长度为130mm或更长，则树脂材料具有比所需更高的流动性，并且出现模制缺陷例如毛刺。如果棒流动长度短于80mm，则树脂材料的流动性过低。因此，树脂材料在模具中以低速流动，使得难以用树脂材料填充整个模具。这在模制的连接器外壳中引起欠注或缩痕。
棒流动长度只需落入80至130mm的范围内，优选落入90至120mm的范围内。使用具有这种棒流动长度的树脂材料，能够以相对低的模制温度令人满意地将树脂材料填充在模具中，而不形成任何缺陷例如缩痕或欠注。此外，由于模制温度不需升高至非常高的温度，因此模制的周期时间随着模制后冷却时间的减少而减少，因此能够以更低成本生产连接器外壳。
在这里，棒流动长度使用深度为0.5mm、宽度为15mm、并且长度为380mm的空腔，在260℃的树脂温度、60℃的模具温度以及150MPa的注入压力进行测量。
本发明的树脂材料可以包括一种或多种其他类型的树脂，只要所述树脂材料本质上含有纤维加固的聚对苯二甲酸丁二酯即可，该纤维加固的聚对苯二甲酸丁二酯具有当通过ASTM D790测量时5000至7000MPa的弯曲模量以及80至130mm的棒流动长度的性质。一种或多种类型的聚酯例如聚对苯二甲酸乙二酯和聚对苯二甲酸丙二酯、聚烯烃例如聚丙烯、聚酰胺例如尼龙、聚碳酸酯类、聚苯乙烯类、聚缩醛类等，可以用作其他树脂。
根据需要，可以将抗氧化剂、紫外线吸收剂、润滑剂、脱膜剂、抗静电剂以及着色剂例如颜料和染料混合在本发明的树脂材料中。
实施例
图1示出了在本实施例中形成的连接器外壳。连接器外壳1被整体地包括外壳主体2以及在外壳主体2顶上的锁定部3。锁定部3可以与配合连接器相连接。
多个配合端子插入孔4在外壳主体2内开口，配合端子分别地可插入该多个配合端子插入孔4内。
每个配合端子插入孔4的后侧与端子外壳室相连通，装接于电线末端的端子配件可插入所述端子外壳室内。本实施例的连接器外壳1具有两排配合端子插入孔4，其一行设置于另一行顶上，每行包括横向设置的10个配合端子插入孔4。
图2示出通过注塑模制来模制图1的连接器外壳1的周期时间。参考标记A表示比较例的周期时间，参考标记B表示本实施例的周期时间。连接器外壳1的模制如下进行。在模制开始时将模具关闭，然后将树脂材料注入到模具中。在树脂材料在模具中在压力下保持一定时间段后，执行冷却，包括测量。随后将模具打开，模制完成。
在比较例A和实施例B任一个中，使用其中将玻璃纤维掺混到PBT中的树脂材料来进行模制。比较例A使用具有当通过ASTM D790测量时4700MPa的弯曲模量以及49mm的棒流动长度的性质的玻璃纤维加固的PBT（由Du Pont制造的SK602）。实施例B使用具有当通过ASTM D790测量时5799MPa的弯曲模量以及116mm的棒流动长度的性质的玻璃纤维加固的PBT（由Polyplastics Co.,Ltd.制造的SF315AC），并且也使用具有当通过ASTM D790测量时5537MPa的弯曲模量以及97mm的棒流动长度的性质的玻璃纤维加固的PBT（由Toray Industries,Inc.制造的5101GF01）。
如图2中所示，在比较例A中，冷却时间占整个周期的50%。同时，实施例B可以将冷却时间减少至比较例A的整个周期的17%。
在比较例A中，与实施例B相比，树脂材料具有更高的熔体粘度，因此具有更低的流动性。因此，模制中的模具温度需要设置得更高，并且冷却时间因此变得更长。另一方面，在实施例B中，树脂材料具有较低的熔体粘度，并因此具有较高的流动性。因此，与比较例A相比，实施例B可以在更低的模具温度下模制。因此，如图2中的箭头所示，实施例B与比较例A相比，将模制周期时间减少了33%。
上面描述了本发明的实施方式。然而，本发明不限于上面描述的实施方式，并且可以做出各种修改。

Claims (2)

1.一种连接器外壳，该连接器外壳通过使用本质上含有用纤维加固的聚对苯二甲酸丁二酯的树脂材料来模制，所述聚对苯二甲酸丁二酯具有当通过ASTM D790测量时5000至7000MPa的弯曲模量以及80至130mm的棒流动长度的性质。
2.根据权利要求1所述的连接器外壳，其中所述纤维是玻璃纤维。
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