Electrical connectors – Coupling part including flexing insulation – Sealing
Reexamination Certificate
1999-11-05
2001-06-12
Paumen, Gary F. (Department: 2833)
Electrical connectors
Coupling part including flexing insulation
Sealing
Reexamination Certificate
active
06244897
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a watertight connector with a one-piece waterproofing means and to a method for mounting such a watertight connector.
2. Description of the Related Art
A prior art watertight connector with a plurality of contacts often will have a one-piece waterproofing means to facilitate assembly. The one-piece waterproofing means in the prior art connectors typically will be either a one-piece waterproof rubber plug or a silicone gel.
Connectors of the former type are constructed as disclosed, for example, in Japanese Utility Model Publication No. 4-76269. These prior art connectors have a one-piece watertight rubber plug fitted on the rear surface of a housing. The plug is formed with a plurality of through holes. Terminal fittings connected with the ends of the wires are accommodated into corresponding cavities by being pushed into the through holes while widening them. Sealing is realized by holding the inner surfaces of the through holes elastically in close contact with the outer surfaces of the wires.
The above described prior art rubber plug works if the terminal fittings are in the form of round pins or have a smooth outer surface. However, many terminal fittings are of box-shaped type and are obtained, for example, by press-forming a metal plate. The edges of the box-shaped fittings, a stabilizer for preventing the upside-down insertion of the fittings and like members on the fitting may scratch or damage the inner surfaces of the through holes when the terminal fittings are pushed into the through holes of the waterproof rubber plug. Such scratches or damage may cause water leakage.
On the other hand, connectors of the latter type are constructed as disclosed in, for example, U.S. Pat. No. 4,875,870. These prior art connectors have a silicone gel layer formed in a portion at the rear end of the housing where wires are inserted to seal around the respective wires. However, the elasticity of silicone gel is extremely reduced upon being exposed to high-temperature atmosphere, and a force to adhere to the wire surface is weakened, thereby making a clearance between the silicone gel and the wires. This likewise causes water leakage.
In view of the above problems, an object of the present invention is to provide a watertight connector and a mounting method allowing for an improved sealability.
SUMMARY OF THE INVENTION
According to the invention, there is provided a watertight connector, comprising a connector housing with one or more cavities into which one or more corresponding terminal fittings are insertable. An elastic plug is mounted into a fitting insertion end of the connector housing and is formed with corresponding through holes in positions corresponding to the respective cavities. A gel layer is arranged adjacent to or in proximity of the elastic plug.
According to a preferred embodiment of the invention, the terminal fittings are connected with ends of wires and the wires are substantially closely insertable through the through holes of the elastic plug.
The through holes may be provided with one or more sealing projections for contacting portions of the wires. The sealing projections preferably are provided circumferentially.
Further preferably, the elastic plug is a waterproof rubber plug. Additionally, the gel layer preferably is arranged adjacent to or in proximity of the elastic plug while being compressed.
According to a further preferred embodiment of the invention there is provided a watertight connector, comprising a connector housing with a plurality of cavities into which terminal fittings connected with ends of wires are insertable. A waterproof rubber plug is mounted into a rear end of the connector housing and is formed with through holes in positions corresponding to the respective cavities. Wires are closely inserted through the through holes.
A gel layer is formed on the rear surface of the waterproof rubber plug while being compressed.
The terminal fittings are inserted into the corresponding cavities by widening the through holes of the waterproof rubber plug against the elastic force of the plug after penetrating the gel layer. As a result, the inner surfaces of the through holes are held in close contact with the outer surface of the wires connected with the terminal fittings. The inner surfaces of the through holes may be damaged when the terminal fittings are pushed into the through holes. However since the gel layer behind the rubber plug is in its compressed state, gel enters into damaged portions to fill them out. If the gel would lose its elasticity upon being exposed to high-temperature atmosphere, the inner surfaces of the through holes of the rubber plug having the damaged portions filled out by the gel would be elastically in close contact with the wires since the gel at the side of the rubber plug still has elasticity. Therefore, the through holes can be sealed securely.
Preferably, the gel is formed beforehand into a plate to be brought substantially into contact with the fitting insertion surface, preferably the rear surface of the elastic plug or, specifically the waterproof rubber plug. A cover for preventing the gel layer from coming out is mountable at the fitting insertion end, preferably the rear end of the connector housing. Thus the gel layer is compressed as or when the cover is mounted. When the gel layer in the form of a plate is brought into contact with the rear surface of the watertight rubber plug and the cover then is mounted, the gel layer is held compressed. Thus, the gel layer is allowed to at least partially enter a damaged portion of the elastic plug, preferably of a sealing projection thereof, due to the compression of the gel.
According to the invention, there is further provided a method for mounting or assembling a watertight connector, comprising a step of mounting an elastic plug into or onto a fitting insertion end of a connector housing such that one or more through holes thereof substantially correspond to one or more cavities of the connector housing into which one or more corresponding terminal fittings are insertable. The method further includes arranging a gel layer adjacent to or in proximity of the elastic plug, and compressing the gel layer.
According to a preferred embodiment, the compressing step comprises a step of mounting a cover on the connector housing.
Preferably, the method further comprises a step of closely inserting ends of wires connected with the terminal fittings through the through holes of the elastic plug. Portions of the wires preferably are sealed by being brought into contact with one or more sealing projections of the through holes.
Most preferably, the method further comprises a step of allowing the gel layer to at least partially enter a damaged portion of the elastic plug that has been damaged by an inserted terminal fitting, preferably of a sealing projection thereof, preferably due to the compression of the gel.
These and other objects, features and advantages of the present invention will become more apparent upon a reading of the following detailed description and accompanying drawings.
REFERENCES:
patent: 4662692 (1987-05-01), Uken et al.
patent: 4875870 (1989-10-01), Hardy et al.
patent: 5529508 (1996-06-01), Chiotis et al.
patent: 5588856 (1996-12-01), Collins et al.
patent: 5596176 (1997-01-01), Everitt
patent: 5931699 (1999-08-01), Saito
patent: 6095859 (2000-08-01), Maeda
patent: 4-76269 (1992-07-01), None
Casella Anthony J.
Hespos Gerald E.
Nguyen Phuongchi
Paumen Gary F.
Porco Michael J.
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