Electrical connectors – Coupling part including flexing insulation – Sealing
Reexamination Certificate
2001-10-31
2002-06-25
Bradley, P. Austin (Department: 2833)
Electrical connectors
Coupling part including flexing insulation
Sealing
C439S279000, C439S604000
Reexamination Certificate
active
06409541
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a waterproof structure in a cable insertion section, that is, a section into which a cable member of the waterproof connector or the like is inserted is waterproofed and to a method of manufacturing the waterproof structure.
The present invention also relates to a waterproof molding die for forming a waterproof mold to be attached to wiring material having lead wires provided therein.
2. Description of the Related Art
In relation to a waterproof connector, an attempt has hitherto been made to block intrusion of liquid into a space defined between an outer peripheral surface of each wire and an inner peripheral surface of a wire insertion hole into which a corresponding wire is to be inserted, by means of attaching a rubber plug to each wire to be assembled (a first related-art example). In another attempt to block intrusion of liquid, there is employed a water proof structure utilizing a plate-like single-piece rubber plug, wherein a plurality of electric wires to be assembled are fitted into a plurality of previously-formed wire conduit sections, thus collectively rendering the electric wires waterproof (a second related-art example). In still another attempt to block intrusion of liquid, there is employed a structure which renders electric wires waterproof by means of filling an electric wire insertion section, into which electric wires are to be inserted, with resin and solidifying the resin (a third related-art example).
For example,
FIG. 10
shows structure of a waterproof connector
2
utilizing a single-piece rubber
1
. A housing body
3
of the waterproof connector
2
molded from resin has a plurality of terminal attachment sections
3
a
into which connector terminals
5
connected to conductor terminal sections of electric wires
4
, respectively, are to be fitted in an unremovable manner and an electric wire insertion section
3
b
projectingly formed in a substantially-angular cylindrical shape, situated on one end face side of the terminal attachment sections
3
a
, and inserted the electric wires
4
.
The single-piece rubber
1
is formed from rubber material having a shape of a substantially-rectangular plate and being elastically deformable, the rubber material which is slightly larger than an inner shape of the electric wire insertion section
3
b
so as to come into closely contact with the inner peripheral surface of the electric wire insertion section
3
b
when the single-piece rubber
1
is pushed into and fitted to the electric wire insertion section
3
b
. Wire through holes
1
a
are formed in the single-piece rubber plug
1
so as to correspond to the terminal attachment sections
3
a
, respectively, and each electric wire
4
passes through and is held in a corresponding wire through hole
1
a.
The waterproof connector is further provided with a holder body
6
for pressing the single-piece rubber plug
1
fitted into the electric wire insertion section
3
b
from an outside thereof. Similarly, the holder body
6
is formed wire insertion holes
6
a
through which the connector terminals
5
and the electric wires
4
passes so as to correspond to the connector terminals
5
and the electric wires
4
. A latch piece
6
b
is formed so as to extend from each side edge of the holder body
6
. A latch projection
3
c
formed so as to protrude from an outer peripheral side on either side of the electric wire insertion section
3
b
is removably latched in a latch hole
6
c
formed in each latch piece
6
b
, thereby pressing the outer side surface of the single-piece rubber plug
1
and unremovably hold the plug
1
.
However, the waterproof structure of the waterproof connector according to the first related-art example adopts a method of attaching each of rubber plugs to each of electric wires. Because of this, attaching a rubber plug to a wire involves consumption of time during an assembly operation. Further, use of the rubber plugs hinders miniaturization of a waterproof connector associated with miniaturization of a connector terminal.
The waterproof structure according to the second related-art example has a merit of contributing to realization of a compact multi-contact waterproof connector. However, when each electric wire
4
is caused to pass through a corresponding wire through hole
1
a
of the single-piece rubber plug
1
, there is a necessity of first squeezing the connector terminal
5
connected to the electric wire
4
. At this time, the connector terminal
5
is squeezed into the wire through hole
1
a
while holding the electric wire
4
. In association with miniaturization of the connector terminal
5
, the diameter of the electric wire
4
has become reduced. It is difficult to pass the connector terminals
5
through wire through holes
1
while holding the electric wires
4
due to buckling of the electric wires
4
and the like.
Further, as a result of an increase in the number of contacts in a connector, a task for assembling a connector by means of inserting the connection terminal
5
and the electric wire
4
into a corresponding wire through hole
1
a
formed in the single-piece rubber plug
1
takes a lot of trouble to be the task difficult. Even when the single-piece rubber plug
1
is used, there is a necessity of a countermeasure for sealing unoccupied wire through holes
1
a
through use of a dummy plug or film.
The waterproof structure according to the third related-art example obviates a necessity of use of an individual rubber plug to be attached to each electric wire, such as that described in connection with the first related-art example. Further, the waterproof structure according to the third related-art example also obviates a necessity of a task for causing the connector terminal
5
and the electric wire
4
to pass through a corresponding wire through hole
1
a
formed in the single-piece rubber plug
1
, such as that described in connection with the second related-art example. On the other hand, the waterproof structure, however, involves solidification of the wire insertion section by means of filling it with resin. Because of this, upon discovery of an attachment failure having arisen when the connector terminal is attached to the terminal attachment section or upon the connector terminal sustaining damage, the plug can be neither replaced or subjected to maintenance.
SUMMARY OF THE INVENTION
The present invention has been conceived in light of the problems set forth the above and aims at providing a waterproof structure in a cable insertion section in an attempt to improve ease of assembly and maintenance, as well as at providing a method of manufacturing the waterproof structure.
According to a first aspect of the invention, there is provided a waterproof structure in a cable insertion section, wherein an inner peripheral surface of the cable insertion section and an outer peripheral surface of a cable member are sealed together in a cable-inserted state in which connector terminals of cable members connected to ends of individual conductors are inserted into the cable insertion section formed in a housing body and are provided at predetermined positions, the waterproof structure comprising: a plug molded on the outer peripheral surfaces of the cable members situated in the cable insertion section and detachably fitted into the cable insertion section with a slight gap between the inner peripheral surface of the cable insertion section and the plug; and a elastically deformable annular sealing body retained in a retention groove formed along an outer peripheral surface of the plug and brought into close contact with the inner peripheral surface of the cable insertion section.
According to a second aspect of the invention, there is provided the waterproof structure according to the first aspect of the invention, further comprising a holder member having a cable insertion opening smaller than the plug, wherein the holder member having a cable insertion opening smaller than the plug may be detachably engaged with the c
Hattori Yasuhiro
Yamada Hirotaka
Autonetworks Technologies Ltd.
Bradley P. Austin
Gushi Ross
Oliff & Berridg,e PLC
LandOfFree
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