Electrical connectors – Coupling part including flexing insulation – Sealing
Reexamination Certificate
2001-03-15
2001-12-04
Ta, Tho D. (Department: 2833)
Electrical connectors
Coupling part including flexing insulation
Sealing
C439S936000, C439S274000
Reexamination Certificate
active
06325670
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to a waterproof connector wherein a waterproofing gel through which a terminal passes is provided inside a connector housing, and relates in particular to a waterproof connector wherein a preferable sealing portion is formed when a gel is penetrated and the generation of gel chips is prevented.
Conventionally, grease is employed in certain cases to seal connector housings and electric wires led therefrom. However, high temperatures adversely affect and reduce the viscosity of grease, and when this occurs, the grease will leak from a sealed portion, thereby such a seal unstable. In addition to grease, an epoxy resin adhesive may be used for this type of sealing structure. But in this case, although a reliable sealing structure can be provided, after the adhesive has hardened, the insertion or re-insertion of a electric wire is impossible.
To resolve this problem, a waterproof connector is disclosed, in, for example, in Japanese Patent No. 2763300. As is shown in
FIG. 12
, a frame-shaped stopper
5
is projected inward along the inner periphery of an opening
3
at one end of a quadrilateral rear holder
1
, in which openings are formed in parallel opposing ends. A plate-shaped base
7
, in which a grid-shaped pattern of multiple terminal through holes
9
is formed, is inserted into the rear holder
1
and is positioned so that it contacts the stopper
5
, which retains the base
7
and prevents it from slipping out through the opening
3
.
Subsequently, a mat-shaped sealing member (gel)
13
is inserted through another opening
11
into the rear holder
1
wherein the base
7
is retained. As is shown in
FIG. 13
, the outer peripheral faces of the gel
13
closely contact the inner faces of the rear holder
1
, and its forward surface is held against the rear of the base
7
by a protrusion
15
. Then, as is shown in
FIG. 14
, the rear portion of a housing
17
is fitted into the rear holder
1
through the opening
11
. As is shown in
FIG. 15
, for the insertion of terminals, openings
19
, which communicate with terminal chambers, are formed in the rear portion of the housing
17
. These openings
19
, each of which is arranged opposite a corresponding terminal through hole
9
in the base
7
, are separated from the terminal through holes
9
by the intervening gel
13
.
To employ the thus assembled waterproof connector, terminals
23
, connected to electric wires
21
, are inserted into the terminal through holes
9
in the exposed face of the base
7
in the rear holder
1
. As the terminals
23
are inserted, they break the surface of and pass through the gel
13
into the openings
19
and enter the terminal chambers in the housing
17
, wherein they are retained. During this process, as the electric wires
21
pass through the gel
13
, some of the gel
13
, which adheres closely to the outer circumferences of the electric wires
21
, is carried into the housing
17
and seals the gaps between the electric wires
21
and the housing
17
.
Use of this waterproof connector forestalls the possibility that grease will leak out at high temperatures, which can occur if grease is used, and ensures that terminals can be removed and re-inserted, which is impossible when an epoxy adhesive is employed.
However, when the related waterproof connector is used, and the rear holder is fitted over the rear portion of the housing, the gel is sandwiched between the rear holder and the housing, and compressed. As a result, resistance to the passage of the terminals is increased, and since then the electric wires may be bent or the terminals may not be able to break through and penetrate the gel, deterioration of the operational efficiency of the terminal attachment occurs. Further, when there is excessive resistance to the passage of the terminals, the terminals may rub against and displace gel, and incomplete-sealing may occur at the areas penetrated by the terminals.
In addition, since the gel closely contacts all the surface around the circumferences of the terminal insertion openings, when, as is shown in
FIG. 15
, a terminal
23
is pressed against the gel
13
until it breaks the surface and passes through it, part of the gel
13
, on the through hole exit side, that closely contacts the inner wall
25
can not recover and is extended and carried into the opening
19
with the terminal
23
. This extended portion
13
a
is cut off, and forms chips
13
b,
as is shown in
FIG. 16
, and the chips
13
are carried into a terminal chamber
27
with the terminal
23
. In this state, when this connector is coupled with another connector, the chips
13
b
may work in between the contact points of the terminals, and cause a conductive failure.
SUMMARY OF THE INVENTION
To resolve this problem, it is one objective of the present invention to provide a superior waterproof connector that can provide increased terminal insertion efficiency and improved sealing capability when terminals pass through a gel, and that can prevent any deterioration in conduction reliability resulting from gel chips that are transported into terminals.
In order to achieve the above object, according to the invention, there is provided a waterproof connector, comprising:
a housing, provided with an abutment face formed inside thereof so as to define an insertion opening to which a electric wire terminal is inserted, and a chamber for accommodating the inserted terminal;
a gel member, through which the terminal penetrates before being inserted to the chamber;
a holder, provided with an insertion passage through which the terminal passes before penetrating the gel member, the holder engaged with the housing while being movable between a provisional engagement position and a plenary engagement position,
wherein the gel member is compressed against the abutment face of the housing when the holder is placed in the plenary engagement position; and
wherein the gel member is held by the holder without compressing against the abutment face, when the holder is placed in the provisional engagement position.
In this configuration, since the holder is located at a provisional engagement position, the terminal can penetrate the gel member before pressure is applied thereto, so that resistance to the passage of the terminals is reduced.
Preferably, the holder includes an engagement member for holding the gel member while preventing the gel member from moving toward the penetrating direction of the terminal.
In this configuration, since the overall distortion of the gel member is prevented, a local shearing force is efficiently acted on the gel member. Therefore, when the terminal penetrates through the gel member, the gel member is protected from being pulled and extended more than is necessary, and from experiencing extreme deformation and thinning. Thus, at those locations through which the terminal penetrates, a superior sealing effect is obtained.
Preferably, projections are formed in the housing so as to surround the insertion opening, while defining a space for which, a part of the compressed gel member runs off.
In this configuration, when a terminal is inserted into the connector housing, it first abuts against the gel member, and then, as the insertion process is continued, it breaks through and penetrates the gel member. At this time, as the terminal urges the gel member forward, part of the gel member escapes through the runoff space, thereby preventing the occurrence of the phenomenon wherein an extended portion of the compressed gel member can not escape and is carried into the chamber. Furthermore, when two connectors are coupled, gel chips do not enter the electrical contact portions, and all conductive failures due to gel chips can be prevented.
Preferably, a guide projection is formed in the housing so as to surround the insertion opening. The guide projection is inserted into the insertion passage of the holder, for guiding the insertion of the terminal, when the holder is placed in the provisional engagement position.
In this configuration, when the te
Sughrue Mion Zinn Macpeak & Seas, PLLC
Ta Tho D.
Yazaki -Corporation
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