Abstract:
The self-locating connector assembly includes a first connector receiving one of internal and external terminals. The assembly includes a second connector receiving the other one of external and internal terminals. The assembly includes a locator for slidably inserting first connector thereinto in an axial direction of the internal and external terminals. Respecting one of the first connector and the second connector are slidably locked with corresponding one of supporting members vertically and horizontally. Before the first and second connectors are mated with each other, the first and second connectors automatically correct a displacement between axes thereof. The first connector includes a recess, the recess including an oblique face for facilitating to mate with the second connector, the recess including at least a pair of parallel faces with an axial dimension and joined to the oblique face. The second connector includes a parallel face corresponding to the recess of the first connector. During mating operation of the first connector and the second connector, parallel faces of the first connector and the second connector automatically corrects the displacement before the internal and external terminals are mated with each other.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a connector assembly adapted for electric connection of electric equipment, and more particularly to a locating connector fixed to a modular instrument loaded on an automobile. 
     The automobile includes an instrumental panel having a meter, audio equipment and an air conditioner or electric equipment housed below the instrumental panel. An instrumental harness (referred to as inst-harness) is arranged in the panel and the electric equipment. A body-harness is arranged in a vehicle body. The inst-harness and the body-harness are interconnected by a self-locating connector. This connector is disclosed in, for example Japanese Patent Application Laid-Open No. 9-259975. 
     A tool is fitted in a rotation operation part of a rotary screw of one connector. Before one connector is pushed into the other connector, highly accurate locating must be carried out for the connectors. However, elastic deformation of the harness connected to the connector generates undue moment and tensile stress. These forces displace an axis of the connector, which makes smooth pushing-in or rotating work by the tool difficult. The displacement applies an abnormal load on a terminal hence bending it. Thus, the displacement necessitates correction of the axis. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a locating connector used for a modular instrument. This connector has high connection workability and connection reliability without any correction of an axis during mating of internal and external terminals. 
     The first aspect of the invention is directed to a self-locating connector assembly. The assembly includes a first connector receiving one of internal and external terminals. The assembly includes a second connector receiving the other one of external and internal terminals. The assembly includes a locator for slidably inserting first connector thereinto in an axial direction of the internal and external terminals. 
     Respecting one of the first connector and the second connector are slidably locked with corresponding one of supporting members vertically and horizontally. Before the first and second connectors are mated with each other, the first and second connectors automatically correct a displacement between axes thereof. The first connector includes a recess, the recess including an oblique face for facilitating to mate with the second connector, the recess including at least a pair of parallel faces with an axial dimension and joined to the oblique face. 
     The second connector includes a parallel face corresponding to the recess of the first connector. During mating operation of the first connector and the second connector, parallel faces of the first connector and the second connector automatically corrects the displacement before the internal and external terminals are mated with each other. 
     Preferably, each of the supporting members is mounted to a vehicle body and a modular instrument. Automatic correction of the displacement is completed, with equipping of modular instrument on the vehicle body completed. 
     Preferably, the first connector includes a worm and a worm wheel. The second connector includes a guide pin. The first connector includes a cam channel for engaging with the guide pin to drive the first connector toward the second connector. Rotating of the worm and worm wheel allows the first connector and the second connector to be mated with each other. 
     Preferably, the first connector includes a guide pin. The second connector includes lock pin. The locator includes a lever rotatably supported thereto. The lever includes a first cam channel for engaging with the lock pin, and second cam channel for engaging with the guide pin. The lever with a handle operation allows the first connector and the second connector to be mated with each other. 
     Preferably, the first connector includes a connector housing. The locator includes a rotation operating part for rotating the worm. The locator includes a rotation stopping mechanism for stopping the worm wheel from rotating over a number of rotations. The mechanism includes a projection mounted to a rotation operating part. The mechanism includes a movable stopper mounted to the connector housing. 
     Preferably, the rotation operating part includes a torque limiter. 
     Preferably, the locator includes a guide plate integral therewith. The guide plate defines a hole in front of an internal terminal of the first connector for passing the internal terminal through the hole. 
     The second aspect of the invention is directed to the self-locating connector assembly. The assembly includes first and second connectors to be mated with each other. The assembly includes a locator receiving a first connector therein for guiding the second connector to be aligned with the first connector. 
     Preferably, the locator includes an end face inclined to an axis. 
     Preferably, the first connector is displacable within the locator. The locator includes a cam mechanism for approaching the first and second connectors to each other. The cam mechanism includes a base rotatably supported on the first connector about an axis and defining a cam. The cam mechanism includes a follower mounted to a second connector for being guided by the cam to approach the axis, as the base is rotated. 
     Preferably, the cam approaches the axis, as the cam travels from a starting point to a terminal point. 
    
    
     BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS 
     FIG. 1 is a perspective view illustrating a connector according to a first embodiment of the present invention. 
     FIG. 2A is a side sectional view of the connector connected to a modular instrument in FIG.  1 . 
     FIG. 2B is a front view of the connector. 
     FIG. 3A is a front view of a connector connected to a vehicle body of FIG.  1 . 
     FIG. 3B is a side view of the connector. 
     FIGS. 4A to  4 C are illustrative views of mating operations of the connectors of FIGS.  1  and  3 A: FIG. 4A illustrates a case before loading on the modular instrument (front faces of internal and external connectors are placed oppositely to each other), FIG. 4B a case of loading in a temporarily held state on the modular instrument, and FIG. 4C completion of connector mating. 
     FIGS. 5A to  5 C are operation illustrative views of an engagement gear and a stopper of FIG.  2 A: FIG. 5A illustrates a case before connector mating, FIG. 5B a case after the connector mating, and FIG. 5C an arrow A view of FIG.  5 A. 
     FIG. 6 is a perspective view illustrating a harness cover of a structure other than the structure of FIG.  1 . 
     FIG. 7 is a plan sectional view of the harness cover of FIG.  6 . 
     FIGS. 8A to  8 D illustrate the other torque limiter used for the connector of FIG.  1 : FIG. 8A is a sectional view during transmission of rotation, FIG. 8B a sectional view during nontransmission of rotation, FIG. 8C a sectional view along VIIIA—VIIIA of FIG. 8A, and FIG. 8D a sectional view along VIIID—VIIID of FIG.  8 B. 
     FIGS. 9A to  9 C illustrate a connector connected to a modular instrument according to a second embodiment of the present invention: FIG. 9A is a side sectional view of the connector, FIG. 9B a front view of the connector, and FIG. 9C a front view of the connector of FIG.  9 A. 
     FIGS. 10A and 10B illustrate a connector connected to a vehicle body according to the second embodiment of the present invention: FIG. 10A is a front view of the connector, and FIG. 10B a side view of the connector. 
     FIG. 11 is an illustrative view of a mating operation of the connectors of FIGS. 10A and 10B. 
     FIG. 12 is an illustrative view of mating completion of the connector of FIGS.  10 A and  10 B. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Embodiments of the present invention will hereby be described with reference to the drawings 
     (First Embodiment) 
     In FIG.  1  and FIGS. 2A and 2B, connector  20  is incorporated in a modular instrument. The modular instrument includes components of an instrument panel, a meter, audio equipment and an air conditioner. Connector  20  is attached to the inside of locator  27  so as to slide in an axial direction of a terminal (hereinafter referred to as “axial direction”). 
     Connector  20  includes housing  200 . Locator  27  and the housing have ends  271  and  200   a  opposite connector  10  (FIGS.  3 A and  3 B). The ends have oblique faces  205 ,  206  inclined with respect to an axis line L 20 . Oblique faces  205 ,  206  facilitate mating with connector  10 . Connected to oblique faces  205 ,  206 , a pair of upper-lower and left-right parallel faces  208 ,  209  are extended in the axial direction. These parallel faces  208 ,  209  constitute recess  203  (hereinafter, in the drawings, a “Z direction” is a longitudinal direction and an “X direction” is a transverse direction). 
     Housing  200  receives a plurality of internal terminals (not illustrated). Housing  200  has a face opposite connector  10 , which has recess  204  for receiving an auxiliary locating pin  101 . 
     Connector  20  includes rotatable guide  25  having circular-arc cam channel  251 . 
     Cam channel  251  has open end or starting point  251   a  and terminal end  251   b  (see FIG.  4 C). Guide  25  has a rotational center, which is made eccentric from the circular-arc center of cam channel  251  toward terminal end  251   b.  Accordingly, each position of cam channel  251  approaches the rotational center from open end  251   a  toward terminal end  251   b.    
     Connector  20  includes worm wheel  21  integrated with guide  25 . Worm wheel  21  is fixed to shaft  211 . Shaft  211  coincides with the rotational center. Both ends of shaft  211  are rotatably supported on housing main body  200 . Worm wheel  21  is engaged with worm  26  fixed to the end of rotation operation part  23 . 
     Locator  27  is fixed to frame-shaped connector bracket  24  as a support member of the modular instrument so as to slide in the transverse direction. Locator  27  includes end  271  inserted into bracket  24 . Locator  27  includes flexible part  272  in a rear end. Flexible part  272  has locking pawl  273  and locating part  274 , which fix locator  27  to bracket  24 . 
     Resin harness cover  28  is fixed to housing  200 . Cover  28  has hole  282 , and it is locked with a projection on housing  200 . 
     In FIGS. 3A and 3B, connector  10  is connected to a vehicle body. Connector  10  includes housing  100  having external terminal  103  received therein. Connector  10  has auxiliary locating pin  101  and lock pin  102  for mating of connectors  10 ,  20 . Connector  10  is fixed to bracket  11  as a support member of the vehicle body so as to slide up and down. 
     Connector  10  includes locking pawl  104  for attachment to bracket  11  of the vehicle body. Connector  10  includes auxiliary locating pin  101 , which has oblique face  105  inclined with respect to an axis line (L 10 ) for locating during mating with connector  10  ( 20 ). 
     Connector  10  includes flanges  107  at the top and bottom. Flanges  107  have gaps therebetween. Connector  10  includes bridges  109  on the both sides. 
     In FIG. 4A, before the modular instrument is loaded (attached) on the vehicle body, connectors  10 ,  20  are located, with the front faces thereof opposed each other. In this state, oblique face  105  of locating pin  101  is abutted on oblique face  205  of connector  20  and locator  27 . 
     Next, in FIG. 4B, the modular instrument is pushed to the final position of the vehicle body. This pushing permits oblique face  105  of pin  101  to move along oblique face  205  of connector  20 . This movement aligns connector  10  in a longitudinal direction with respect to bracket  11 . Housing  100  is fitted in recess  203 . Further, the pushing of the modular instrument into the vehicle body side starts mating of pin  101  in recess  204 . 
     The side faces of connector  10  are fitted along oblique faces  206  of connector  20  and locator  27  in a transverse direction. Pin  102  enters the open end of groove  251  of guide  25 . Flanges  107  abut against the ends  271  of locator  27 . In this position, bracket  11  is abutted on the members of the modular instrument, and housing  100  and locator  27  are positionally restrained (not illustrated). In this position, the attaching of the modular instrument to the vehicle body is completed. The modular instrument is fixed to the vehicle body by appropriate means such as bolts or the like. 
     In FIG. 4B, rotation operation part  23  is rotated in a direction indicated at an insertion port of a socket wrench N of harness cover  28 . The wrench N rotates worm  26 . The worm  26  rotates worm wheel  21 . In FIG. 4C, guide  25  is rotated integrally with worm wheel  21 . Cam channel  251  guides pin  102  to its terminal end  102   b.  The ends  200   a  of connector housing  20  pass gaps  107   a  between flanges  107 . A relative distance between pin  102  and worm wheel  21  is shortened. Thus, connector  10  is pulled towards connector  20 , whereby connectors  10 ,  20  are completely mated together. 
     In FIG. 4B, the external and internal terminals in connectors  10 ,  20  are in a state before a start of mating. In a state where housing  100  is fitted in recess  203  of housing  200 , the axial parallel faces with predetermined dimensions are mated to each other. A force by elastic deformation of the harness or tensile stress applies no undue moment on the external terminal. When an undue force is applied to connectors  10 ,  20  for alignment during loading on the modular instrument, no undue moment is applied to the internal and external terminals, and thus no terminal contact failures occur. 
     In FIG. 5A, L-shaped stopper  22  has a bottom surface, and cylindrical guide pin  222  is projected from this part. Pin  222  is engaged with stopper guide groove  221  of worm wheel  21 . 
     Operation part  23  is rotated in order to engage connectors  10 ,  20  of FIG. 5A with each other. This rotation rotates worm wheel  21  left (M direction). Stopper  22  is guided towards the outside in a diameter direction of worm wheel  21  by groove  221  to project from housing  200 . Stopper  22  is abutted on upper projection  232  of operation part  23 . This abutment stops the rotation of operation part  23 . 
     Four rotations of operation part  23  complete the engagement of connectors  10 ,  20  with each other. Stopper  22  starts projecting when the last fourth rotation is started. Stopper  22  projection is completed when the rotation comes to an end. 
     The rotation stop of operation part  23  eliminates an excessive force applied on worm  26  and worm wheel  21  to prevent damage of the respective portions  26  and  21 . Operation part  23  includes destruction part  231  small in section. Destruction part  231  prevents damage of a dual structure. 
     In FIGS. 6 and 7, harness cover  28 B has a structure different from that of the first embodiment. Harness cover  28 B includes integrally formed clamp  28 B 1 . Clamp  28 B 1  holds and fixes harness  28 B 2 , whereby the harness cover is streamlined. 
     A terminal of harness  28 B 2  has a terminal fixed by caulking. This terminal is connected to the internal terminal received in connector  20 . 
     In FIG. 8A, relief nut  233  is fixed to a tip of operation part  23 . 
     The end of operation part  23  includes relief nut  233  having rectangular hole  233   a.  Hole  233   a  has four flexible bars  234  set at its four corners. Bar  234  has a roughly rectangular sectional shape. 
     When the torque wrench N applies small rotation torque to the nut  233 , the rotation torque is transmitted to worm  26 . Rotation torque exceeding a predetermined value bends bar-shaped part  234  inward, and the nut  233  runs idly. Nontransmission of rotation torque of the predetermined value or higher applies no excessive forces on worm  26  and worm wheel  21 , and prevents damage of the respective portions. 
     (Second Embodiment) 
     A second embodiment includes a lever in place of operation part  23 . Other parts are similar to those of the first embodiment. Similar members are denoted by similar reference numerals, and description thereof will be omitted. 
     In FIGS. 9A to  9 C, locator  37  includes rotatably supported lever  39 . Lever  39  includes base board  397  equivalent to guide  25  of the first embodiment. Base board  397  includes operation handle  395 . Base board  397  has cam channel  391  engaged with lock pin  102  of connector  10 . Base board  397  has cam channel  329  engaged with guide pin  394  fixed to housing  300 . Groove  329  and pin  394  move housing  300  toward connector  10  with respect to locator  37 . 
     Lever  39  has center hole  393  at its rotation center. This hole  393  rotatably supports a center pin of locator  37 . Lever  39  has circular-arc cam channel (cut-out)  391  with an angle. Lever  39  has circular-arc cam channels (slots)  392  at the identical angle, which is provided with a pair of ends  392   a,    392   b.  One end  392   a  is located in a peripheral edge of lever  39 . The other end  392   b  is located near hole  393 . Clockwise (P direction) rotation of handle  395  moves pin  394  from end  392   a  to end  392   b  in groove  39 . This moves housing  300  to connector  10  with respect to locator  37 . Internal terminal  301  is received in housing  300 . 
     First, lever  39  elastically deforms base board  397  inside, and inserts it into locator  37 . Then, lever  39  releases the elastic deformation to engage center hole  393  with pin  373 . This engagement locates lever  39  centered on locator  37  as a buffer. Next, housing  300  is inserted from the rear side between both base boards  397  of lever  37 . Pin  394  widens a thin part formed near an outer end of cam channel  392  of base board  397 . Pin  394  is engaged with cam channel  392 . By this engagement, Lever  39  prevents the coming-off of housing  300  from locator  37 . 
     Plate tab guide  302  is disposed integrally with locator  37  in the front face of internal terminal  301  of a recess of a modular instrument. Guide  302  defines a hole penetrated by internal terminal  301 . Guide  302  guides internal terminal  301  while connector  40  and connector  30  are mated together. Guide  302  prevents damage of internal terminal  301  in component conveyance. 
     In FIGS. 10A and 10B, connector  40  includes housing  400 . Connector  40  includes auxiliary locating pins  401 ,  406  in the front face of housing  400 . Pin  401  has oblique face  405  inclined with respect to an axis line L 40 . Connector  40  includes flanges  407  at the top and bottom. Flanges  407  include gaps  407   a  between flanges  407 . 
     A mating operating of connectors  30 ,  40  will be described. 
     In FIG. 11 equivalent to FIG. 4B, the modular instrument is in a temporarily held state where loading (attaching) on a vehicle body is completed. Auxiliary locating pins  401 ,  406  start mating into a recess (not shown) of housing  300 . Lock pin  402  is received in open end  391   a  of cam channel  391 . The ends  371  of locator  37  abut against flanges  407 . 
     Lever  39  of FIG. 11 is rotated around pin  373 . During this rotation, cam channel  391  restrains pin  401  at a position in axial directions (L 20 , L 40 ). In FIG. 12 corresponding to FIG. 4C, pin  394  is guided by groove  392 . The ends  300   a  of connector  300  pass through gaps  407   a  between flanges  407 . Pin  394  approaches pin  393  in the axial direction. Accordingly, connector  30  is moved in the axial direction with respect to locator  37  to approach connector  40 . Engagement between groove  391  and pin  402  allows connector  40  to be stationary in the axial direction with respect to locator  37  during the rotation of lever  39 . Thus, connectors  30 ,  40  are completely mated together to completely mate housing  300  and connector  40  with each other. Pins  401 ,  406  are fitted in a mating hole of guide  302 . Internal terminal  301  is guided by guide  302  to move forward through the hole of guide  302 , and then be mated with the external terminal in connector  40 . 
     In FIG. 11, in connector  40 , the eternal terminal and the internal terminal received in connector  30  are not yet mated together. Housing  400  fits in recess  303  of housing  300 , and parallel faces thereof having predetermined dimensions in the axial direction are mated to each other. No undue moment is applied on the internal and external terminals by a force of harness elastic deformation or tensile stress. Even if undue forces are applied for alignment of connectors  30 ,  40  during loading on the modular instrument, no undue moment is applied on the internal and external terminals. Thus, no terminal contact failures occur. During mating of the external and internal terminals, the internal terminal is guided by guide  302  to move forward through the hole of the guide  302 . Thus, both terminals are smoothly mated. 
     According to the self-locating connector assembly, during mating of the first connector and the second connector, before the internal terminal and the external terminal start to be mated with each other, the first connector and the second connector are mated on the axial parallel faces of a predetermined dimension. The mating corrects a displacement between axes of first and second connectors. Thus, a force by elastic deformation of the harness or tensile stress causes no undue moment on internal and external terminals. When an undue force is applied to the first and second connectors for alignment during equipment on the modular instrument, no undue moment is applied to the internal and external terminals, and thus no terminal contact failures occur. 
     This needs no correction of alignment, thus achieving higher workability and reliability in connection of the connectors. 
     According to the connector assembly, automatic correction of the displacement is completed, with equipping of modular instrument on the vehicle body completed. Next, the terminals starts to be mated with each other. This causes no stress and no damage on the terminals during equipping of a modular instrument on a vehicle body. 
     According the invention, rotating of a rotation operating part worm and worm wheel allows the first connector and the second connector to be mated with each other. This facilitates mating operation of the connectors and allows mating operation in a direction parallel with an axial direction of terminals, thus achieving higher workability and reliability in connection of the connectors. 
     According to the invention, the lever with rotating operation allows the first connector and the second connector to be mated with each other. This needs no tool and allows secure mating operation in a direction parallel with an axial direction of terminals, thus achieving higher workability and reliability in connection of the connectors. 
     According to the invention, the rotation stopping mechanism provided to the rotation operating part prevents rotating of the rotation operating part. This applies no excessive force to the worm and worm wheel, achieving no damage on respective parts. 
     According to the invention, the torque limiter provided to the rotation operating part restricts a rotary force of the rotation operating part. This applies no excessive force to the worm and worm wheel, achieving no damage on respective parts. 
     According to the invention, the guide plate, integral with the locator, defines a hole in front of an internal terminal of the first connector for passing the internal terminal through the hole. During the mating of the first and second connectors, the internal terminal is guided by the guide plates. The guide allows smoothly mating of the internal and external terminals with each other. This achieves higher workability and reliability in connection, and prevents damage on the terminals during conveying of components. 
     The entire contents of Japanese Patent Applications P 2002-65537 (filed on Mar. 11, 2002) are incorporated herein by reference. 
     Although the invention has been described above by reference to certain embodiments of the invention, the invention is not limited to the embodiments described above. Modifications and variations of the embodiments described above will occur to those skilled in the art, in light of the above teachings. The scope of the invention is defined with reference to the following claims.