Insulator displacement type waterproof connector and manufacturing method of the same

[0002] 1. Field of the Invention

[0003] This invention relates to a multipolar insulator displacement type waterproof connector which prevents an inconvenience that an insulated electric wire is in a state of non pressure-contact to an insulator displacing portion of a terminal from occurring and has excellent reliability and assemble efficiency.

[0004] 2. Description of Relevant Art

[0005] This kind of an insulator displacement type water proof connector is disclosed in Japanese Patent Application Laid-open No. 5-152028, for example. The waterproof connector is composed of a waterproof plug (rubber plug) which has a plurality of electric wire through holes through which electric wires (insulated electric wires) pass, an inner housing which accommodates a plurality of terminals which are pressure contacted with the electric wires, an outer housing which accommodated the inner housing therein and is fitted to the waterproof plug in one opening portion thereof.

[0006] In case of assembling the insulator displacement type waterproof connector, the electric wires are passed through the respective electric wire through holes first. The respective electric wires are pressure contacted to a pair of insulator displacing blades of the terminals which is accommodated in respective terminal accommodating chamber of the inner housing. Therefore, the insulator displacement type waterproof connector is assembled, and a mated connector is to be fitted in and detached from other opening of the outer housing.

[0007] However, in the conventional insulator displacement type water-proof connector, in case of assembling the insulator displacement type waterproof connector, there are passed through the step of passing the electric wires through the waterproof plug, the step of pressure contacting the electric wires to the terminal, and the step of fitting the inner housing in the outer housing. Thus assembling steps of the insulator displacement type waterproof connector are complicated, and assemble efficiency is deteriorated. Further, when assembling the insulator displacement type waterproof connector, the step of pressure contacting is skipped over. If the inner housing is fitted in the outer housing in a state of non pressure-contact that the insulated electric wires are not pressure contacted to the terminals, the electric wires in the state of non pressure-contact to the terminals can not be detected. Further, the terminals are accommodated only in terminal accommodating chamber of the inner housing and there is not provided a engaging structure. Thus, reliability is lacked.

[0008] It is an object of the present invention to provide a multipolar insulator displacement type waterproof connector in which an insulated electric wire in a state of non pressure-contact is detected easily and which improves reliability and assemble efficiency.

[0009] From a first aspect of the invention, there is provided an insulator displacement type waterproof connector for an insulated electric wire. The connector comprises a terminal having an insulator displacing portion; a first housing which surrounds the terminal and has a first through hole opposite to the insulator displacing portion of the terminal; and a pressure body which is inserted in the first through hole of the first housing in a temporarily retained position and is movable from the temporarily retained position to a regularly retained position to pressure contact the insulated electric wire with the insulator displacing portion.

[0010] Preferably, the connector further comprises a second housing which is fitted in the first housing, accommodates the terminal, and has a second through hole opposite to the insulator displacing portion of the terminal.

[0011] Preferably, the connector further comprises a spacer which is interposed between the first housing and the second housing, and has a third through hole opposite to the insulator displacing portion of the terminal.

[0012] From a second aspect of the invention, there is provided a method of manufacturing an insulator displacement type waterproof connector for an insulated electrical wire. The method comprises the steps of: providing a first housing which has a first through hole; providing a terminal which has an insulator displacing portion; positioning the insulator displacing portion opposite to the first through hole; inserting a pressure body in the first through hole in a temporarily retained position where the insulated electric wire is held between the insulator displacing portion and the pressure body; and moving the pressure body to a regularly retained position, and thereby pressure contacting the insulated electric wire with the insulator displacing portion.

[0013] In the above-mentioned invention, the term “pressure contact” means that an insulator of the insulated electric wire is displaced by the insulator displacing portion of the terminal and a conductor of the insulated electric wire is contacted with the insulator displacing portion.

[0014] In the insulator displacement type waterproof connector, the insulated electric wire is arranged above the insulator displacing portion of the terminal which is accommodated in the first housing, the second housing and the spacer assembled together previously. The insulated electric wire is pressure contacted to the insulator displacing portion of the terminal by movement of the pressure body. Thus, assemble steps of the insulator displacement type waterproof connector are simplified and assemble efficiency is improved. The terminal is doubly engaged with the spacer and pressure body, and reliability is improved. Further, whether the insulated electric wire has already been pressures contacted or has not yet been is easily detected by movement amount of the pressure body, and thus the inconvenience that the insulated electric wire is in the state of non pressure-contact is prevented from occurring.

[0015] FIG. 1 is a cross-sectional view of an insulator displacement type waterproof connector according to an embodiment of the present invention before insulated electrical wires thereof are pressure contacted;

[0016] FIG. 2 is a cross-sectional view of the insulator displacement type waterproof connector in which the insulated electric wires are in a state of pressure-contact;

[0017] FIG. 3 is a cross-sectional view of the insulator displacement type waterproof connector in which insulated electric wires are in a state of non pressure-contact;

[0018] FIG. 4A is an explanation view of a state before a state of pressure contacting the insulated electric wires of the insulator displacement type waterproof connector is measured by a measuring gage; and

[0019] FIG. 4B is an explanation view of a state that a state of pressure contacting the insulated electric wires is measured by the measuring gage which has depressed.

[0020] An embodiment of the present invention will now be explained with reference to the drawings.

[0021] As illustrated in FIGS. 1 to 3, a connector housing 11 of an insulator displacement type waterproof connector 10 is constructed of a synthetic resin-made inner housing 12, or a second housing, having a plurality of terminal accommodation chambers 13 formed integrally therewith, a synthetic resin-made outer housing 15, or a first housing, having this inner housing 12 fitted thereinto, and a synthetic resin-made spacer 21 interposed between the inner housing 12 and the outer housing 15 and having retained thereby female type insulator displacement type terminals 14 that have been accommodated in their corresponding terminal accommodation chambers 13 of the inner housing 12.

[0022] The inner housing 12 as a second housing has a box portion 12athe upper and lower surfaces of which are open on their rear sides thereof, and the respective terminal accommodation chambers 13 are formed in the spaces that are formed between a central horizontal wall 12band upper and lower vertical side walls not illustrated concurrently serving as partitioning walls. The terminals 14 are accommodated within these respective terminal accommodation chambers 13. Further, at the positions, opposing the respective terminal accommodation chambers 13, of the box portion 12aof the inner housing 12, there are formed rectangular insertion through holes 12cthrough which male terminals 41 within a hood portion 40aof a mated side connector 40 illustrated in FIG. 3 are passed. Further, a pair of upper and lower opening portions 12dthat are on a rear side of the box portion 12aof the inner housing 12 form through-holes for permitting insertion therethrough of a pressure body.

[0023] In each of both sides plate portions of a rear portion of the box portion 14aof the female type terminal 14 there are formed a pair of insulator displacing blades 14b, 14b, or insulator displacing portions, by the side plate portions being bent. The insulator displacing blades 14b, 14beach have a blade and a slot portion shown in FIG. 4A.

[0024] The outer housing 15 as a first housing is constituted by a substantially square-cylindrical inner wall portion 15a, a substantially square-cylindrical outer wall portion 15bthat surrounds the inner wall portion 15a, and a bottom wall portion (a wall portion) 15cthat connects together rear portions of the inner and outer wall portions 15aand 15band is thereby made into a double-walled box which is open on its frontal surface side. The bottom wall portion 15cis thick-walled at the center. At the positions, opposing the respective terminal accommodation chambers 13, on the frontal side of the thick-walled portion there are respectively formed large-in-diameter and circular-in-section rubber plug accommodation recessed portions 17 into which waterproof rubber plugs 16 are accommodated by forced insertion or the like. On the other hand, in a rear side part of the thick-walled portion there are respectively formed small-in-diameter and circular-in-section electric wire insertion through holes 18 through which insulated electric wires 30 are passed so that these insertion through holes 18 may communicate with their corresponding rubber plug accommodation recessed portions 17. It is to be noted that the waterproof rubber plug 16 is made into a substantially circular-cylindrical body whose inner and outer peripheral surfaces are each in the form of concavities and convexities. Further, the rubber plug 16 has an electric wire through-hole 16athrough which the insulated electric wire 30 is internally passed.

[0025] Also, at the positions, opposing a pair of the insulator displacing blades 14b, 14bof the terminal 14 accommodated in each terminal accommodation chamber 13 of the inner housing 12, of the corresponding inner and outer wall portions 15a, 15bof the outer housing 15, there are respectively formed rectangular through-holes 19 for insertion of a pressure body. Further, at a large-depth portion on an outer surface side of the inner wall portion 15aof the outer housing 15, there is integrally protectively formed a V-shaped packing reception portion 15dfor receiving therein an annular rubber-made waterproof packing 20.

[0026] The spacer 21 is constituted by a substantially square-cylindrical trunk portion 21athat is fitted into the inner wall portion 15aof the outer housing 15, a substantially square-cylindrical flange portion 21bthat is integrally so formed as to be bent rearward from a frontal end of the trunk portion 21aand that is fitted onto an outer surface side of the inner wall portion 15aof the outer housing 15, and a bottom wall portion (a wall portion) 21cof the trunk portion 21a. The spacer 21 is thereby made into a box whose frontal surface side is open.

[0027] And, it is arranged that the box portion 12aof the inner housing 12 is fitted into the interior of the trunk portion 21aof the spacer 21. On the inner surfaces of upper and lower walls of the trunk portion 21aof the spacer 21 there are formed respectively integrally therewith rib-like and terminal draw-off preventing projections not illustrated that respectively retain by engagement rear end edge of the box portion 12aof the inner housing 12 and rear end edges 14cof the box portion 14aof the terminals 14 accommodated in the respective terminal accommodation chambers 13. At the positions, opposing the insulator displacing blades 14bof the terminal 14 accommodated in each of the terminal accommodation chambers 13 of the inner housing 12, of the trunk portion 21aand flange portion 21bof the spacer 21, there are respectively formed rectangular through holes 22 for insertion thereinto of the pressure body. Further, a forward end portion of the flange portion 21bof the spacer 21 is arranged to retain the packing 20 that has been retained by engagement in the packing reception portion 15dof the inner wall portion 15aof the outer housing 15 when the fitting of the spacer 21 into the outer housing 15 has been completed.

[0028] Also, electric wire insertion through holes 23 are respectively formed at the positions, opposing the respective electric wire insertion through holes 18 of the outer housing 15, of the bottom wall portion 21cof the spacer 21. Further, the bottom wall portion 21cof the spacer 21 is arranged to retain the rubber plugs 16 that have been inserted in the respective rubber plug accommodation recessed portions 17 of the bottom wall portion 15cof the outer housing 15 when the fitting into the outer housing 15 has been completed so that the rubber plugs can be freely drawn off or prevented from being drawn off.

[0029] Further, into the respective pressure body insertion through-holes 19 of the outer housing 15, respective pressure body insertion through-holes 22 of the spacer 21 and respective opening portions 12dserving as the pressure body insertion through-holes of the inner housing 12, there are slidably fitted synthetic resin-made block-like pressure bodies 24 that are used to make pressure-contact of the insulated electric wires 30 to their respective pairs of insulator displacing blades 14b, 14bof the respective terminals 14. Namely, the insulated electric wires 30 pass respectively through the electric wire insertion through holes 18 of the outer housing 15, electric wire insertion through holes 16aof the rubber plugs 16 and electric wire insertion through holes 22 of the spacer 21 and are located over their respective pairs of insulator displacing blades 14b, 14bof the terminals 14. The insulated electric wires 30 are displaced and contacted to their respective pairs of insulator displacing blades 14b, 14bof the terminals 14 by the pressure bodies 24 being by-pressure moved by pressing members not illustrated or the like from their temporarily retained positions illustrated in FIG. 1 inside the through holes 19, 22 and opening portions 12dto their regularly retained positions illustrated in FIG. 2. In the temporarily retained position, an upper surface 24aof the pressure body 24 is protruded upward from the flange portion 21bof the spacer 21. In the regularly retained position, the upper surface 24aof the pressure body 24 is located at a level that is lower than the flange portion 21bof the spacer 21. Further, the state of engagement between the outer housing 15 and the spacer 21 is fixedly retained by the pressure body 24 located at the regularly retained position. In this retained position, the terminal 14 is fixedly retained using a corner portion 24con the underside 24bside of the pressure body 24 and the rear end edge 14cof the box portion 14aof the terminal 14.

[0030] In a case where assembling the insulator displacement type waterproof connector 10 of this embodiment, the following procedures are taken beforehand. Namely, the rubber plugs 16 are respectively inserted into, and set in, from the direction in which the connector housing is fitted, the respective rubber plug accommodation recessed portions 17 located inside the bottom wall portion 15cof the outer housing 15 constituting the outer side of the connector housing 11. Then, the packing 20 is inserted into, and set in, the packing reception portion 15dof the inner wall portion 15aof the outer housing 15. In this state, the trunk portion 21aof the spacer 21 is fitted onto the inner wall portion 15aof the outer housing 15 and then the inner housing 12 is fitted into the trunk portion 21aof the spacer 21. Then, the respective pressure bodies 24 are fitted into the pressure body insertion through holes 19, 22 of the outer housing 15 and spacer 21 and respective opening portions 12dof the inner housing 12 and are thereby kept in their provisionally retained states.

[0031] Next, as illustrated in FIG. 1, the insulated electric wires 30 are respectively passed, from the outside, through their corresponding electric wire insertion through holes 16a, 23 of the respective rubber plugs 16 and bottom wall portion 21cof the spacer 21 via their corresponding electric wire insertion through holes 18 of the bottom wall portion 15cof the outer housing 15. As a result, the insulated electric wires 30 are thereby located at a level that is over their corresponding pairs of insulator displacing blades 14b, 14bof the terminals 14. Next, as illustrated in FIG. 2, the respective pressure bodies 24 are press moved by the pressing member not illustrated or the like from their provisionally retained positions to their regularly retained positions, respectively, thereby causing the respective insulated electric wires 30 to be pressure contacted to their corresponding pairs of insulator displacing blades 14b, 14bof the terminals 14. By such regular retentions of the respective pressure bodies 24, the state of engagement between the outer housing 15 and the spacer 21 is fixedly maintained at its relevant portions. Also, at this fixed maintenance time, engaging pawls not illustrated of the box portion 12aof the inner housing 12 are engaged with engaging holes not illustrated of the inner wall portion 15aof the outer housing 15. Further, the terminals 14 are doubly retained by the rib-like and terminal draw-off preventing projections not illustrated of the inner surfaces of the upper and lower walls of the trunk portion 21aof the spacer 21 and the corner portions 24cof the underside 24bsides of the pressure bodies 24. The assembling of the insulator displacement type waterproof connector 10 is thus completed.

[0032] In this way, it is possible to dispose respectively the insulated electric wires 30 over their corresponding pairs of insulator displacing blades 14b, 14bof the terminals 14 accommodated in the respective terminal accommodation chambers 13 of the inner housing in the assembly of the previously assembled outer housing 15, spacer 21 and inner housing 12, thereby easily performing pressure-contact of the respective insulated electric wires 30 to their corresponding pairs of blades 14b, 14bof the respective terminals 14 by depressing their corresponding pressure bodies 24 downwardly. This makes it possible to simplify the assembling process of the insulator displacement type waterproof connector 10 into an electric wire passing-through step and electric wire pressure-contact step and this makes it possible to enhance the assembling efficiency. Further, since the respective terminals 14 are each doubly retained by the spacer 21 and pressure body 24, it is possible to enhance the reliability involved.

[0033] Also, when assembling the insulator displacement type waterproof connector 10, the following merit exists in a case where an assembling operator has forgotten the execution of the pressure-contact step for causing the insulated electric wires 30 to be pressure contacted to their corresponding pairs of insulator displacing blades 14b, 14b. Namely, since as illustrated in FIG. 3 the pressure bodies 24 are kept located at their provisionally retained positions and kept not depressed, a mated side connector 40 cannot be fitted to the insulator displacement type waterproof connector 10. Therefore, it is possible to easily detect that the pressure-contact step has been skipped over. In this way, whether the insulated electric wires 30 have already been pressure contacted or have not yet been so done can be easily detected according to whether or not the respective pressure bodies 24 have been depressed. However, this detection is easily managed by measuring the amount of fall H of a measuring gage 50 as illustrated in FIGS. 4A and 4B, whereby the inconvenience that the insulated electric wires 30 are in the state of non pressure-contact is reliably prevented from occurring. Therefore, it is possible to provide a high quality of insulator displacement type waterproof connector 10 at a low cost.

[0034] Further, the respective rubber plugs 16 are prevented from being drawn off by the bottom wall portion 15cof the outer housing 15 and are thereby reliably prevented from falling away from the connector assembly. Also, the packing 20 is prevented from being drawn off by the oblique forward end of the flange portion 21bof the spacer 21. For these reasons, the respective terminal accommodation chambers 13 of the inner housing 12 and the respective insulated electric wires 30 are reliably sealed by the respective rubber plugs 16 and packing 20 and therefore the waterproofness of the connector housing is enhanced again.