Waterproof connector

A waterproof connector 10 includes a housing 11, a number of connecting terminals 13 respectively inserted into a number of inserting holes 12 provided at the housing 11, a number of press contact blades respectively provided at end portions of the respective connecting terminals 13 and exposed from the housing, and rear cover 15 attached to the housing 11 to cover the respective press contact blades 14, and a seal member filling layer 17 continuous to the inserting hole 12 and capable of containing a seal member 16 for covering the respective press contact blades 14 is provide at a rear portion 11A of the housing 11.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a waterproof connector, particularly relates to a waterproof connector devised to provide waterproof to a connector for bringing an electric wire into press contact with a press contact blade by breaking a cover of the electric wire by the press contact blade by pressing the electric wire into the press contact blade.

The present invention further relates to a waterproof connector, more in details, relates to a waterproof connector facilitating operation of filling a seal member to a seal member filling layer and capable of waterproofing firmly.

2. Related Art

As shown byFIG. 10(A), generally, an automobile1100is provided with left and right headlamps1102,1103, left and right direction indicator lamps1104,1105and the like at a front bumper1101and is provided with left and right tail lamps1107,1108and the like at a rear bumper1106.

A wire harness is wired to the headlamps1102,1103, the direction indicator lamps1104,1105and the tail lamps1107,1108. As an example of wiring the wire harness, a circuit shown inFIG. 10(B)is known.

That is, in a circuit110shown inFIG. 10(B), connectors1111,1112for the left and right headlamps are connected to lamp cases of the left and right headlamps1102,1103, connectors1113,1114for the left and right direction indicator lamps are connected to lamp cases of the left and right direction indicator lamps1104,1105, and connectors1115,1116for the left and right tail lamps are connected to lamp cases of the left and right tail lamps1107,1108.

At this occasion, a wire harness1118is wired to a portion of the automobile1100which is liable to be influenced by water and therefore, waterproof is requested to the connectors1111through1116and a waterproof connector meeting the request has been proposed, for example, as shown in Japanese Patent 3268945.

According to a waterproof connector1120of the publication, as shown byFIG. 12, a housing1121is constituted by integrating a main body1122and a lid member1123, and inside of the housing1121is inwardly mounted with wire connecting portions1125A of a plurality of connecting terminals1125connected with wire harnesses1124and fit to counter side connecting terminals.

At least one of the main body1122and the lid member1123is provided with partition walls (not illustrated) for partitioning the connecting terminals1125in parallel and an adhering member1127is filled at vicinities of the wire connecting portions1125A to thereby provide waterproof between the main body1122and the lid member1123.

Namely, the waterproof connector described above used in the circuit in which a housing1121is constituted by a main body1122formed with a terminal mounting portion mounted with a connecting terminal1125and a lid member1123, the terminal mounting portion coated with butyl rubber is arranged with the connecting terminal1125and the lid member1125coated with the butyl rubber is covered thereto to waterproof.

Therefore, it seems that the wire harnesses1124can preferably be connected to the left and right headlamps1102,1103and the left and right direction indicator lamps1104,1105provided at the front bumper1101and the left and right tail lamps1107,1108provided at the rear bumper1106of the automobile1100shown inFIG. 10(A)in a waterproof state by using the waterproof connector1120of the publication.

Further, there is also a constitution in which a cover made to be openable and closable to a housing is provided, an ultraviolet ray cured resin is filled to the cover, a connecting terminal is inserted into the housing and thereafter, the cover is closed and a clearance thereof is filled by a gel-like ultraviolet ray cured resin in liquid tight, for example, as shown in Unexamined Japanese Patent Publication Hei. 10-284170.

Further, there is disclosed a constitution in which a housing is formed by a main body having a terminal holding portion formed with a terminal containing groove and a cover covering the terminal holding portion, an adhering seal agent is filled to the terminal holding portion and the cover arranged with a connecting terminal and the cover is covered thereto, the housing is oscillated from outside by an ultrasonic wave to thereby cure the adhering seal agent and weld the terminal holding portion and the cover (refer to, for example, as shown in Unexamined Japanese Patent Publication Hei. 11-121084.

Further, there is also known a constitution in which a pair of jelly containing frames are openably and closably provided opposedly to a connecting terminal fitting portion of a connector housing, a connecting terminal is inserted thereto and thereafter, the connecting terminal fitting portion is closed by the pair of jelly containing frames containing a silicone jelly to thereby waterproof, for example, as shown in Unexamined Japanese Patent Publication Hei. 11-329573.

However, according to the circuit1110shown inFIG. 10(B), the wire harness1118is connected to a main connector1119, the terminal connectors1111through1116connected to the lamp cases are connected to the wire harness1118and therefore, the circuit1110becomes complicated, time and labor for making the circuit1110is taken and in recent years, reduction of a wire harness circuit1130shown inFIG. 11to practice has been desired.

According to the wire harness circuit1130shown inFIG. 11, press contact blades1132are provided to respective connectors1131, and by pressing wire harnesses1133into receiving recess portions of the press contact blades1132, the wire harnesses1133are connected to the press contact blades1132by breaking covers of the wire harnesses1133by the press contact blades1132.

Therefore, the wire harnesses1133can simply be connected to the press contact blades1132and the wire harness circuit1130can be made without taking time and labor.

By arranging the respective connectors1131of the wire harness circuit to rear face sides of the front bumper1101and the rear bumper1106to connect to the lamp cases of the left and right headlamps1102,1103, the left and right direction indicator lamps1104,1105and the left and right tail lamps1107,1108, the left and right headlamps1102,1103, the left and right direction indicator lamps1104,1105and the left and right tail lamps1107,1108can be connected to a battery of the automobile.

However, the respective connectors1131of the wire harness circuit1130shown inFIG. 11are different from the terminal connectors1111through1116of the circuit1116shown inFIG. 10(B)in structures thereof and therefore, a waterproofing structure used in the connectors1111through1116shown inFIG. 10(B)is not applicable to the respective connectors1131ofFIG. 11as it is.

Therefore, the waterproofing structure constituted by the respective connectors1131of the wire harness circuit1130shown inFIG. 11has not yet been reduced to practice and the respective connectors1131of the wire harness circuit1131which are waterproofed have been desired to be reduced to practice.

That is, all of the waterproof connectors disclosed above are constituted by a structure in which a connecting terminal (for example, male terminal) is fixedly attached to a terminal of an electric wire and fit to a connecting terminal (for example, female terminal) of a counter connector to thereby electrically connect to each other. In contact thereto, the connector used in the wire harness circuit130needs to be attachable in a state in which a waterproof connector is connected to a middle portion of each electric wire and each electric wire passes the waterproof connector, that is, in a through state. A waterproof connector attachable with each electric wire in the through state in this way has not been reduced to practice.

Further, according to the waterproof connectors of the prior art disclosed above, waterproof is carried out by injecting a seal member of butyl rubber, an ultraviolet ray cured resin, an adhering seal agent or silicone jelly or the like and thereafter covering the cover or the like and therefore, the seal member is extruded by the cover and there is a drawback of bringing about leakage, extrusion or the like of the seal member. Further, since a position of injecting the seal member is unclear, depending on an operator, a dispersion in a position of coating or an amount of injecting the seal member is liable to be produced and there is a concern that a waterproof function differs for respective products and a product value is deteriorated by extrusion of the seal member such that when the amount of injecting the seal member is small, the seal member is not distributed to a portion which needs to fill and the waterproof function becomes deficient and when the amount of injecting the seal member is large, the outlook is deteriorated by extruding the seal member.

Further, in order to prevent the seal member from being hung, until the seal member is cured, the wire harness cannot be transported to a successive step to handle and there poses a problem that an operational efficiency is poor. Further, a cover is mounted at a final step of integrating steps and therefore, in the meantime, movement of the electric wire, the connecting terminal and a connecting portion thereof is not restricted and when an external force is operated to the electric wire or the like, the electric wire is shifted from a predetermined position or connection of the connecting portion becomes unstable and there is a concern of effecting an adverse influence on the function of the wire harness.

SUMMARY OF THE INVENTION

Therefore, a first object of the invention relates to resolving the above-described problem and is to provide a waterproof connector in which a waterproofing measure can be provided to a press contact connector of a type of bringing an electric wire into press contact with the press contact blade.

A second object thereof to provide a waterproof connector attachable with an electric wire in a through state by bringing the electric wire into press contact with a press contact blade and capable of waterproofing electric wire firmly by simple operation.

The above-described object of the invention is achieved by a waterproof connector provided in comprising a housing, a number of connecting terminals respectively inserted into a number of inserting holes provided at the housing, a number of press contact blades respectively provided at end portions of the respective connecting terminals and exposed from the housing, and a rear cover attached to the housing to cover the respective press contact blades wherein a seal member filling layer continuous to the inserting hole and capable of containing a seal member for covering the respective press contact blades is provided at at least one of the housing and the rear cover.

According to the waterproof connector having the above-described constitution, the seal member filling member capable of containing the seal member for covering the respective press contact blades is provided at at least one of the housing and the rear cover. Therefore, the respective press contact blades can be protected by covering the respective press contact blades by the seal member by filling the seal member into the seal member filling layer.

Further, the above-described object of the invention is achieved by the waterproof connector provided in that the seal member filling layer is provided at the housing and a planer shape of the seal member filling layer is formed to be larger than a shape of an opening of the inserting hole and the seal member is filled up to the inserting hole.

According to the waterproof connector having the above-described constitution, by making the planar shape of the seal member filling layer larger than the shape of the opening of the inserting hole, a stepped difference portion is formed at a boundary between the seal member filling layer and the inserting hole.

Therefore, when the seal member is filled only to the seal member filling layer, in the case of exerting a drawing force to the respective contact blades, there is a concern of stripping the seal member off the stepped difference portion. Hence, the seal member is prevented from being stripped off the stepped difference portion by filling the seal member up to the inserting hole.

Further, the above-described object of the invention is achieved by the waterproof connector provided in that the seal member filling layer is provided on a front side of a rear end of the housing and respective electric wires can be bent by bringing the respective electric wires into press contact with the respective press contact blades to connect in the seal member filling layer.

According to the waterproof connector having the above-described constitution, the respective press contact blades and the respective electric wires can firmly be immersed into the seal member by bringing the respective electric wires into press contact with the respective press contact blades in the seal member filling layer and bending the respective electric wires.

Further, the above-described object of the invention is achieved by the waterproof connector provided in that the seal member filling layer is provided by a wall surrounding the respective press contact blades and end portions of the respective electric wires can be contained between an inner side face of the housing and the wall.

According to the waterproof connector having the above-described constitution, end portions of the respective electric wires can be immersed into the seal member by containing the end portions of the respective electric wires between the inner side face of the housing and the wall.

Further, the above-described object of the invention is achieved by the waterproof connector provided in that the respective press contact blades are oriented to open to the rear cover.

According to the waterproof connector having the above-described constitution, the respective press contact blades can be directed to an opening of the seal member filling layer by opening the respective press contact blades to the rear cover. Therefore, middle portions of the electric wires can simply be brought into press contact with the press contact blades from the opening of the seal member filling layer without taking time and labor.

In this way, the waterproof connector can be connected to the middle portions of the respective electric wires and the respective electric wires can be attached thereto in a state of passing the respective electric wires to the waterproof connector, that is, a through state.

In order to achieve a second object, a waterproof connector according to the invention is provided in a waterproof connector comprising a housing provided with a number of inserting holes, a number of connecting terminals one end of each of which is formed with a press contact blade and other end of each of which is formed with an electric contact portion and which are inserted into the inserting holes, and a rear cover mounted to the housing for covering the respective press contact blades:

wherein the housing is provided with a seal member filling layer capable of containing a seal member for covering the respective press contact blades, the rear cover is mounted to the housing to close an opening portion of the seal member filling layer, and the seal member filling layer is provided with a seal member injecting hole for filling the seal member to the seal member sealing layer.

According to the waterproof connector having the above-described constitution, the housing provided with the inserting hole for inserting the connecting terminal formed with the press contact blade is formed with the seal member filling layer capable of containing the seal member for covering the press contact blade, the rear cover formed with the seal member injecting hole is mounted to the housing, the opening portion of the seal member filling layer is closed and therefore, the electric wire can be wired in a through state by pressing the electric wire to the press contact blade of the connecting terminal arranged at inside of the seal member filling layer to be brought into press contact therewith. Further, after closing the opening portion of the seal member filling layer by the rear cover, the seal member can be filled from the seal member injecting hole into the seal member filling layer. Thereby, the press contact blade wired with the electric wire in the through state is covered by the seal member to subject to a waterproof treatment, the press contact blade and the press contact portion can firmly be protected and reliability of a state of brining the electric wire into press contact with the connecting terminal (press contact blade) can be promoted.

Further, control of an amount of filling the seal member is facilitated, the seal member can be prevented from being leaked or extruded from the seal member filling layer and a stable waterproof function can be achieved by eliminating a dispersion in the waterproof function. Further, after curing the seal member, the rear cover is bonded with the seal member and is difficult to be stripped off and therefore, the reliability of the press contact is promoted by protecting the portion of bringing the electric wire into press contact with the connecting terminal (press contact blade) and the press contact portion can firmly be sealed.

Further, the rear cover is arranged to the opening portion of the seal member filling layer to close the opening portion and therefore, the rear cover protects the seal member filled in the seal member filling layer and the seal member can be prevented from being scattered. Thereby, even before the seal member is completely cured, the waterproof connector can be transported to a successive step to carry out operation and an operational efficiency can be promoted.

Further, the rear cover is mounted to the housing immediately after bringing the electric wire into press contact with the connecting terminal (press contact blade) and therefore, even when a force is operated to the electric wire from outside before filling the seal member, the press contact portion can be protected and highly reliable wiring can be carried out.

Further, according to a third aspect of the present invention, a waterproof connector according to the invention is provided in a waterproof connector comprising a housing provided with a number of inserting holes, a number of connecting terminals one end of each of which is formed with a press contact blade and other end of each of which is formed with an electric contact portion and which are inserted into the inserting holes, and a rear cover mounted to the housing for covering the respective press contact blades:

wherein the housing is provided with a seal member filling layer capable of containing a seal member for covering the respective press contact blades, the rear cover comprises a main body portion formed with an opening hole and mounted to the housing, and a lid member fitted to the opening hole for closing the opening hole, and the seal member is made to be able to fill from the opening hole to the seal member filling layer.

According to the waterproof connector having the above-described constitution, the rear cover mounted to the opening portion of the seal member filling layer is constituted by the main body portion formed with the opening hole and the lid member fixed to the opening hole for closing the opening hole, the seal member is made to be able to fill from the opening hole to the seal member filling layer and therefore, after brining the electric wire into press contact with the press contact blade of the connecting terminal, the main body portion of the rear cover is immediately mounted to the housing to fix the electric wire and the press contact portion can be protected against a force from outside. Further, after optically observing a state in the seal member filling layer (press contact state of the electric wire or the like) from the opening hole of the rear cover to confirm to be normal, the seal member can be filled from the opening hole and highly reliable operation can be carried out. Further, after filling the seal member, the opening hole is closed by the lid member and therefore, an effect similar to that described above can be achieved.

Further, according to a fourth aspect of the present invention, the waterproof connector according to the invention is the waterproof connector described in the third aspect of the present invention, provided in that the lid member of the rear cover is provided with a seal member injecting hole for filling the seal member to the seal member filling layer.

According to the waterproof connector having the above-described constitution, the rear cover is constituted by the main body portion and the lid member, the lid member is provided with the seal member injecting hole for filling the seal member and therefore, the seal member can be filled from the seal member injecting hole provided at the lid member into the seal member filling layer by mounting the rear cover to the housing in which the electric wire is brought into press contact with the connecting terminal and closing the opening hole of the rear cover by the lid member. Thereby, the seal member can be filled to an entire region of the seal member filling layer and waterproof can firmly be carried out by filling the seal member into the closed seal member filling layer.

Further, according to a fifth aspect of the present invention, the waterproof connector according to the invention is the waterproof connector according to any one of the second aspect through the fourth aspect, provided in that the seal member is foamed urethane.

According to the waterproof connector having the above-described constitution, the seal member is constituted by foamed urethane and therefore, the waterproof function can be promoted by firmly filling foamed urethane to an entire region of the seal member filling layer by filling foamed urethane into the seal member filling layer the opening portion of which is closed by the rear cover to foam.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A detailed explanation will be given of a waterproof connector according to an embodiment of the invention in reference to the attached drawings as follows.

First Embodiment

As shown byFIG. 1throughFIG. 3, a waterproof connector10of the first embodiment is provided with a housing11, a number of connecting terminals13respectively inserted into a number of inserting holes12provided at the housing11, a number of press contact blades14respectively provided at end portions of the respective connecting terminals13and exposed from the housing, and a rear cover15attached to the housing11to cover the respective press contact blades14and a seal member filling layer17(refer toFIG. 3) capable of containing a seal member16(refer toFIG. 6throughFIG. 9) continuous to the inserting holes12and covering the respective press contact blades14is provided at a rear portion11A of the housing11.

The housing11is formed substantially in a rectangular parallelepiped by an insulating resin, the plurality of inserting holes12are provided at inside thereof, the rear portion11A is formed to be able to attach the rear cover15, a front portion11B is formed with an inner cylinder portion19, the inner cylinder portion19is fit with a packing21for waterproof and attached with a front cover22(refer toFIG. 6throughFIG. 9).

In addition thereto, as shown byFIG. 3, the housing11is formed with the seal member filling layer17, that is, a containing recess portion capable of containing a flat electric wire23(seal member filling layer17) at the rear portion11A and the press contact blade14is exposed to the seal member filling layer17.

The connecting terminal13is a conductive member formed substantially in a cylindrical shape to be able to insert into the inserting hole12. A connecting portion24is extended from the end portion of the connecting terminal13and an end portion of the connecting portion24is provided with a pair of the press contact blades14.

By inserting the connecting terminal13into the inserting hole12, the press contact blade14is exposed to a side of the rear portion11A of the housing11, that is, the seal member filling layer (refer toFIG. 3).

The pairs of press contact blades14are formed with receiving recess portions14A into which respective electric wires23A of the flat electric wire23are pressed. By pressing the electric wire23A into the receiving recess portion14A, a cover of the electric wire23A is broken by the press contact blade14and the electric wire23A is brought into press contact with the press contact blade14.

The respective press contact blades14are oriented such that the receiving recess portions14A are opened to the rear cover15. Therefore, the respective press contact blades14can be directed to an opening of the seal member filling layer17.

Thereby, a middle portion of the electric wire23A can simply be pressed from the opening of the seal member filling layer17into the receiving recess portion14A of the press contact blade14and therefore, the electric wire23A can simply be brought into press contact with the press contact blade14without taking time and labor.

In this way, the waterproof connector10can be connected to middle portions of the respective electric wires23A and the respective electric wires23A can be attached thereto in a state of passing the waterproof connector10, that is, in a through state.

As shown byFIG. 4throughFIG. 5, by bringing the respective electric wires23A of the flat electric wire23into press contact with the press contact blades14, the flat electric wire23can be contained in the seal member filling layer17of the housing rear portion11A. By filling the seal member16(refer toFIG. 6throughFIG. 9) into the seal member filling layer17under the state, the seal member16can be stored at inside of the seal member filling layer17and the respective electric wires23A brought into press contact with the press contact blades14can be immersed into the seal member16.

The flat electric wire23is an electric wire formed in a shape of a ribbon by bundling the plurality of electric wires23A in a strip-like shape.

Here, arrangement of the flat electric wire23(respective electric wires23A) in the through state signifies a state in which the flat electric wire23is extended from both sides of the seal member filling layer17, that is, a state in which the flat electric wire23passes the seal member16.

As shown byFIG. 6throughFIG. 7, the seal member filling layer17is provided at the housing11and a planar shape of the seal member filling layer17is formed to be larger than the shape of the opening of the inserting hole12. Further, the seal member16filled in the seal member filling layer17is filled up to the inserting hole12.

An explanation will be given here of reason of filling the seal member16from the seal member filling layer17to the inserting hole12.

That is, by making the planer shape of the seal member filling layer17formed at the housing11larger than the shape of the opening of the inserting hole12, a stepped difference portion26is formed at a boundary between the seal member filling layer17and the inserting hole12.

Therefore, when the seal member16is filled only to the seal member filling layer17, in the case in which the respective press contact blades14are operated with a drawing force in an arrow mark direction, the seal member16is exerted with a force of stripping off the stepped difference portion26and there is a concern on stripping the seal member16off the stepped difference portion26.

Hence, the seal member16is filled to a middle of the inserting hole12, that is, to a side of a rear end12A of the inserting hole12.

Thereby, when the respective press contact blades14are operated with the drawing force in the arrow mark direction, the seal member16and the rear end12A of the inserting hole12are only exerted with a shear force and therefore, the seal member16can be prevented from stripping off the rear end12A of the inserting holes12.

Further, as has been explained in reference toFIG. 4throughFIG. 5, the seal member filling layer17is provided on a front side of a rear end11C of the housing11and at inside of the seal member filling layer17, the respective electric wires23A can be bent along the seal member filling layer17by pressing the respective electric wires23A into the receiving recess portions14A of the respective press contact blades in a state of being brought into press contact to connect therewith.

In this way, by bringing the respective electric wires23A into press contact with the respective press contact blades14at inside of the seal member filling layer17to connect and bending the respective electric wires23A along the seal member filling layer17, when the seal member16is filled into the seal member filling layer17, the respective electric wires23A can firmly be immersed into the seal member16.

Further, by providing the rear cover15, the seal member16can be protected by the rear cover15and the seal member16can be prevented from being scattered by the rear cover15.

Here, as the seal member16, UV hardened rubber, RTV silicone (one solution, two solutions types), foamed urethane, hot melt or the like correspond thereto.

As shown byFIG. 8throughFIG. 9, the seal member filling layer17is provided by a wall27surrounding the respective press contact blades14and end portions29of the respective flat electric wires23can be contained between an inner side face28of the housing11and the wall27.

By containing the end portions29of the respective flat electric wires23between the inner side face28and the wall27, the end portions29of the respective flat electric wires23can firmly be immersed into the seal member16.

As has been explained above, according to the water proof connector10, the housing11is provided with the seal member filling layer17capable of containing the seal member16covering the press contact blades14.

Thereby, by covering the respective press contact blades14by the seal member16by filling the seal member16into the seal member filling layer17, the waterproof can be promoted by protecting the respective press contact blades14and the flat electric wires23against invasion of water.

In addition thereto, by covering the respective press contact blades14by the seal member16by filling the seal member16into the seal member filling layer17, insulating performance of the respective press contact blades14and the flat electric wires23can be promoted and locking performance of the flat electric wires23can be promoted.

Further, although an explanation has been given of the example of providing the seal member filling layer17at the housing11in the above-described embodiment, the embodiment is not limited thereto but the seal member filling layer17can also be provided at the rear cover15, further, the seal member filling layer17can also be provided at both of the housing11and the rear cover15.

Further, although an explanation has been given of the example of protecting the seal member16by the rear cover15and preventing the seal member16from being scattered by the rear cover15, the rear cover15can also be dispensed with by selecting physical properties of the seal member16.

Second Embodiment

As shown byFIG. 13throughFIG. 15, a waterproof connector110of a second embodiment of the present invention is provided with a housing111, a connecting terminal113, a rear cover115, a packing121, and a front cover122. The housing111is formed substantially in a rectangular parallelepiped by an insulating synthetic resin and is provided with a number of inserting holes112at inside thereof. A rear portion111A is formed to be able to attach the rear cover115and a front portion111B is formed with an inner cylinder portion111a,and the inner cylinder portion is fit with the packing121for waterproof and is attached with the front cover122(refer toFIG. 19,FIG. 20). Further, as shown byFIG. 15, the rear portion111A is formed with a seal member filling layer117, that is, a containing recess portion capable of containing a flat electric wire123.

As shown byFIG. 13andFIG. 15, the connecting terminal113is a conductive member formed substantially in a cylindrical shape by a conductive material of a metal or the like, a connecting portion113cis extended from an electric contact portion113aformed at a front end and a pair of press contact blades113bare formed at an end portion of the connecting portion113c. Further, a locking portion113eis formed at a rear end of the electric contact portion113a. The connecting terminals113can be inserted into a number of the inserting holes112provided at the housing111and when inserted, the press contact blade113bis exposed to the seal member filling layer117at the rear portion11A of the housing11. The pair of press contact blades13bare formed in a bifurcated shape and are formed with a receiving recess portion for pressing the flat electric wire123to be brought into press contact therewith. By pressing the flat electric wire123to the receiving recess portion, the press contact blade113bbreaks a cover of the flat electric wire123to be brought into contact with a core wire and the press contact blades113b(connecting terminal113) and the flat electric wire123are electrically connected.

As shown byFIG. 15andFIG. 16, according to the connecting terminal113inserted to the inserting hole112of the housing111, since the press contact blade113bis disposed to direct to an opening portion of the seal member filling layer117, a middle portion of the flat electric wire123can be bent substantially in a channel-like shape in line with the seal member filling layer117and inserted from the opening portion of the seal member filling layer117and pressed to the press contact blade113bto thereby simply brought into press contact therewith. Thereby, the flat electric wire123can be attached thereto in the state of passing the waterproof connector110, that is, the through state.

As shown byFIG. 13andFIG. 18, the rear cover115is formed by an insulating synthetic resin and a pair of locking arms115bare provided to project to the front side from both side ends of a main body115ain a flat plate shape. The main body115ais provided with a seal member injecting hole115cand is formed with a fixing groove115dsubstantially in a semicircular shape for containing the flat electric wire123and a rib115eat a rear face thereof.

As shown byFIG. 18andFIG. 19, the rear cover115is fixed in a state of closing the opening portion of the seal member filling layer117by the main body115aby inserting the pair of engaging arms115bfrom the rear portion111aof the housing111to engage with an engaging projection111cprovided at the housing111.

As shown byFIG. 20, the rib115eof the main body115afixed to the seal member filling layer117is brought into contact with the flat electric wire123contained in the seal member filling layer17by being bent substantially in a channel-like shape to press to thereby prevent the flat electric wire123from separating from the press contact blade113b.

As shown byFIG. 13,FIG. 19andFIG. 20, the packing121is for waterproofing a front side (left direction inFIG. 19) of the housing111and is mounted to fit to the inner cylinder portion111aand achieves a waterproof function by being brought into sliding contact with an inner peripheral face of a counter connector housing, not illustrated. The front cover122is formed by an insulating synthetic resin and is inserted from the front side of the housing121to fix to the housing111to constitute a front end portion of the inserting hole112.

In integrating the above-described waterproof connector110, as shown byFIG. 13,FIG. 14,FIG. 19andFIG. 20, the connecting terminal113is inserted into the inserting hole112from the rear side of the housing111and a locking portion113eprovided at the connecting terminal113is engaged with a lance111bformed at the housing111. At this occasion, as shown byFIG. 15, the press contact blade123bis brought into a state of being exposed to the seal member filling layer117.

Successively, the packing121is fit to the inner cylinder portion111aof the housing111and thereafter, the front cover122is inserted from the front portion111bof the housing111to attach. At this occasion, a locking projection122aformed at the front cover122invades an interval between the lance111band an inner peripheral face of the inner cylinder portion111ato thereby prevent the lance111bfrom being bent in a direction of releasing locking of the connecting terminal113to double-lock. (Refer toFIG. 20).

As shown byFIG. 16andFIG. 20, the middle portion of the flat electric wire123is bent substantially in the channel-like shape in line with the seal member filling layer117and inserted from the opening portion of the seal member filling layer117and pressed to the press contact blade113bto be brought into press contact therewith to thereby attach the flat electric wire113to the connecting terminal113in the through state. Further, as shown byFIG. 18andFIG. 19, the rear cover115is inserted from the rear portion1111A of the housing111and the pair of locking arms15bare engaged with the engaging projections111c. Thereby, the main body115ais fixed in the state of closing the opening portion of the seal member filling layer117.

At this occasion, the rib15eis brought into contact with the flat electric wire123arranged at inside of the seal member filling layer117. Thereby, even when an external force is operated to the flat electric wire123, the flat electric wire123is not separated from the press contact blade113band a state of bringing the flat electric wire123into press contact with the press contact terminal113is maintained before filling a seal member. Therefore, in operation of filling a seal member116, mentioned later, handling of the waterproof connector110attached with the rear cover115is facilitated. Further, after filling the seal member116, even when the seal member116is not cured, operation of a successive step or the like can be carried out.

Further, as shown byFIG. 19andFIG. 20, the seal member116is filled from the seal member injecting hole115cof the rear cover115into the seal member filling layer117to fill a clearance at inside of the seal member filling layer117with the seal member116and the flat electric wire123is immersed in the seal member116along with the press contact portion.FIG. 17shows a state in which the flat electric wire123is wired in the through state and integration of the waterproof connector110filled with the seal member16is finished.

In filling the seal member116, the seal member116is filled from the seal member injecting hole116cof the rear cover115closing the opening portion of the seal member filling layer117and therefore, the seal member is not leaked or extruded and the seal member116can be prevented from being scattered to adhere to a surrounding. Further, a position of filling the seal member116is clear and an amount of filling the seal member116is prescribed by a volume of the seal member filling layer117and therefore, a state of filling the seal member116is not dispersed by an operator. Therefore, dispersion of the waterproof function is prevented and the stable waterproof function can be ensured.

Here, as the seal member116, ultraviolet ray cured rubber, RTV silicone rubber (one solution, two solution type), foamed urethane, hot melt or the like can be used. Foamed urethane is foamed when two solutions are mixed therewith to expand the volume by multiplication of twice through thrice therefore, when foamed urethane is filled in the seal member filling layer117the opening portion of which is closed by the rear cover115, foamed urethane can be filled to corners in the seal member filling layer117and excellent in the waterproof function and can preferably be used.

Next, an explanation will be given of a modified example of the waterproof connector in reference toFIG. 21.FIG. 21is a sectional perspective view showing a state of integrating a waterproof connector of the modified example. As shown byFIG. 21, a waterproof connector120of the modified example differs from the waterproof connector110of the first embodiment in a rear cover121thereof. Specifically, the rear cover121is provided with seal member injecting holes121aat four locations by reducing a hole diameter thereof.

Since the seal member injecting hole121ais small, the seal member116before being cured is difficult to flow out from the seal member filling layer117and the seal member116having a comparatively low viscosity can be used. Therefore, the seal member116can firmly be filled also to the seal member filling layer117having a complicated shape. Further, since the seal member injecting holes121aare provided to disperse, even when the seal member filling layer117is formed in a shape difficult to fill the seal member116, the seal member116can easily be filled thereto by injecting the seal member116from a plurality of locations.

The other portion is similar to that of the waterproof connector110of the first embodiment of the invention and therefore, the same portions are attached with the same notations or corresponding notations and an explanation thereof will be simplified or omitted.

Third Embodiment

Next, an explanation will be given of a third embodiment of a waterproof connector of the invention in reference toFIG. 22throughFIG. 25.

As shown byFIG. 22andFIG. 23, a waterproof connector130of the third embodiment differs from the waterproof connector110of the second embodiment in a rear cover131thereof. Specifically, the rear cover131is constituted by a main body portion131aand a lid member131band the main body portion131aand the lid member131bare connected by two pieces of connecting portions131cformed in a string-like shape and having an elasticity. The main body portion131ais bored with a large square hole131d. Further, the lid member131bis a member in a flat plate shape having an area larger than that of the square hole131dand is formed with four piece of locking arms131eto project.

As shown byFIG. 24, the rear cover1131is inserted from the rear portion11A of the housing111in which the flat electric wire123is brought into press contact with the press contact blade113bof the connecting terminal113and integrated into the seal member filling layer117and similar to the waterproof connector110of the second embodiment, a pair of locking arms (not illustrated) are engaged with engaging projections (not illustrated) of the housing111. At this occasion, a rib131fis brought into contact with the flat electric wire123arranged at inside of the seal member filling layer117to thereby protect a state of bringing the flat electric wire113into contact with the connecting terminal113before filling the seal member. Therefore, in operation of filling the seal member116, mentioned later, handling of the waterproof connector130attached with the rear cover131is facilitated.

The other portion is similar to that of the waterproof connector110according to the embodiment of the invention and therefore, the same portions attached with the same notations or corresponding notations and an explanation thereof will be simplified or omitted.

The seal member116is filled to the seal member filling layer117from the square hole131dand prior to filling the seal member116, a situation of inside of the seal member filling layer117(for example, a state of wiring the flat electric wire1123, a state of bringing the flat electric wire23into press contact with the connecting terminal113or the like) can be confirmed by optically observing from the square hole131dand further highly reliable integration can be carried out. Further, as shown byFIG. 25, after filling the seal member116from the square hole131d, the connecting portion131cis bent in a U-like shape to thereby move from a position designated by a broken line of the drawing to a position designated by a bold line in an arrow mark A direction and the seal member116is prevented from flowing out from the seal member filling layer117by closing the square hole131dby the lid member131b. Further, after curing the seal member116, the lid member131band the main body portion131aare integrally adhered to each other by the seal member116.

Further, as a modified example of the waterproof connector according to the third embodiment, the lid member131bof the rear cover131shown in the waterproof connector130of the third embodiment may be formed with a seal member injecting hole131gshown by a broken line inFIG. 22throughFIG. 25. In this case, in filling the seal member116to the seal member filling layer117, after covering the lid member131bto close the square hole131dformed at the main body portion131aof the rear cover131, the seal member116is injected from the seal member injecting hole131gto fill the seal member filling layer117with the seal member116. According to the modified example, prior to filling the seal member116, a state in the seal member filling layer117can be confirmed from the square hole131dby opening the lid member31b. Further, the seal member16is filled from the seal member injecting hole131dsmaller than the square hole31dand therefore, the seal member116can firmly be prevented from being extruded. Further, the seal having a low viscosity can be used.

Further, as shown byFIG. 26, the waterproof connectors110,120,130of the invention can not only bring the middle portion of the flat electric wire123into press contact with the connecting terminal113to connect in the through state but also connect an end portion23aof the electric wire123. That is, by containing the end portion123aof the electric wire123between the inner side face111cof the housing111and a wall111dsurrounding the press contact blade113band filling the seal member116, the end portion123aof the electric wire123can firmly be subjected to the waterproof treatment.

Furthers the waterproof connector of the invention is not limited to the above-described constitution of the embodiment but can naturally adopt various modes based on the gist of the invention.

For example, although an explanation has been given of the example of using the flat electric wire23as the electric wire to be brought into press contact therewith in the above-described embodiment, a plurality of covered electric wires can be used by being aligned in parallel.

Further, the invention is not limited to the above-described embodiments and modified examples but can pertinently be modified or improved. Otherwise, a material, a shape, a dimension, a numerical value, a mode, a number, an arranging location of each constituent element of the above-described embodiments and modified examples are arbitrary so far as these can achieve the invention and are not limited.

Although according to the invention, an explanation has been given such that the seal member filling layer is provided at the housing, the invention is not limited thereto but the seal member filling layer can also be provided at the rear cover, further, can be provided to both of the housing and the rear cover. Further, the invention can also be used as a waterproof structure of a connector of a kit cut structure constituting the connector by cutting an inner housing formed in parallel with a plurality of section chambers for containing a connecting terminal by a unit of a desired number of section chambers to insert into an outer housing.

As has been explained above, according to the waterproof connector of the present invention, the seal member filling layer capable of containing the seal member for covering the respective press contact blades is provided at at least one of the housing and the rear cover.

Thereby, waterproof can be promoted by protecting the respective press contact blades against invasion of water by covering the respective press contact blades by the seal member by filling the seal member to the seal member filling layer.

In addition thereto, insulating performance of the respective press contact blades can be promoted and locking performance of the respective press contact blades can be promoted by covering the respective contact blades by the seal member by filling the seal member into the seal member filling layer.

Further, according to the waterproof connector of the present invention, by making the planer shape of the seal member filling layer larger than the shape of the opening of the inserting hole, the stepped difference portion is formed at the boundary between the seal member filling layer and the inserting hole.

Therefore, when the seal member is filled only to the seal member filling layer, in the case of exerting a drawing force to the respective press contact blades, there is a concern of stripping the seal member off the stepped difference portion. Hence, the seal member is prevented from being stripped off the stepped difference portion by filling the seal member up to the inserting hole.

Thereby, waterproof, insulating performance and locking performance of the respective press contact blades can further be promoted.

Further, according to the waterproof connector of the present invention, the respective press contact blades and the respective electric wires can firmly be immersed into the seal member by bringing the respective electric wires into press contact with the respective press contact blades in the seal member filling layer to connect and bending the respective electric wires.

Thereby, waterproof, insulating performance and locking performance of the respective press contact blades and the respective electric wires can further be promoted.

Further, according to the waterproof connector of the present invention, the end portions of the respective electric wires can firmly be immersed into the seal member by containing the end portions of the respective electric wires between the inner side face of the housing and the wall.

Thereby, waterproof, insulating performance and locking performance of the end portions of the respective electric wires can further be promoted.

Further, according to the waterproof connector of the present invention, the respective press contact blades can be directed to the opening of the seal member filling layer by opening the respective press contact blades to the rear cover. Therefore, the middle portion of the electric wires can simply be brought into press contact with the press contact blades from the opening of the seal member filling layer without taking time and labor.

In this way, the waterproof connector can be connected to the middle portions of the respective electric wires and the respective electric wires can be attached thereto in a state of passing the respective electric wires through the waterproof connector, that is, in a through state.

Thereby, operability of integrating the electric wires to the waterproof connector can be promoted.

As has been explained above, according to the waterproof connector of the present invention, the housing provided with the inserting hole for inserting the connecting terminal formed with the press contact blade is formed with the seal member filling layer capable of containing the seal member for covering the press contact blade, the rear cover formed with the seal member injecting hole is mounted to the housing, the opening portion of the seal member filling layer is closed and therefore, the electric wire can be wired in the through state by pressing the electric wire to the press contact blade of the connecting terminal arranged at inside of the seal member filling layer to be brought into press contact therewith. Further, after closing the opening portion of the seal member filling layer by the rear cover, the seal member can be filled from the seal member injecting hole into the seal member filling layer. Thereby, the press contact blade wired with the electric wire in the through state is covered to subject to a waterproof treatment and the press contact blade and the press contact portion can firmly be protected. Further, reliability of a state of bringing the electric wire into press contact with the connecting terminal (press contact blade) can be promoted.

Further, control of an amount of filling the seal member is facilitated, the seal member can be prevented from being leaked or excluded from the seal member filling layer and stable waterproof function can be achieved by eliminating a dispersion in the waterproof function. Further, after curing the seal member, the rear cover is bonded to the seal member and is difficult to be stripped off and therefore, reliability of press contact is promoted by protecting the portion of bringing the electric wire into press contact with the connecting terminal (press contact blade) and the press contact portion can firmly be sealed.

Further, since the opening portion of the seal member filling layer is arranged with the rear cover to close the opening portion and therefore, the rear cover protects the seal member filled in the seal member filling layer and the seal member can be protected from being scattered. Thereby, even before the seal member is completely cured, the seal member can be transported to a successive step to carry out operation and an operational efficiency can be promoted.

Further, the rear cover is mounted to the housing immediately after bringing the electric wire into press contact with the connecting terminal (press contact blade) and therefore, even when a force is operated to the electric wire from outside before filling the seal member, the press contact portion can be protected and highly reliable wiring can be carried out.

Further, according to the waterproof connector of the present invention, the rear cover mounted to the opening portion of the seal member filling layer is constituted by the main body portion formed with the opening hole and the lid member fitted to the opening portion for closing the opening hole, the seal member is made to be able to fill from the opening hole to the seal member filling layer and therefore, after bringing the electric wire into press contact with the press contact blade of the connecting terminal, the main body portion of the rear cover is immediately mounted to the housing to fix the electric wire and the press contact portion can be protected against a force from outside. Further, after optically observing a state in the seal member filling layer (press contact state of the electric wire or the like) from the opening hole of the rear cover to confirm to be normal, the seal member can be filled from the opening hole and highly reliable operation can be carried out. Further, after filling the seal member, the opening hole is closed by the lid member and therefore, an effect similar to that described above can be achieved.

Further, according to the waterproof connector of the present invention, the rear cover is constituted by the main body portion and the lid member, the lid member is provided with the seal member injecting hole for filling the seal member and therefore, the seal member can be filled from the seal member injecting hole provided at the lid member into the seal member filling layer by mounting the rear cover to the housing in which the electric wire is brought into press contact with the connecting terminal and closing the opening hole of the rear cover by the lid member. Thereby, the seal member can be filled to an entire region of the seal member filling layer by filling the seal member into the closed seal member filling layer and waterproof can firmly be carried out.

According to the waterproof connector of the present invention, the seal member is constituted by foamed urethane and therefore, the waterproof function can be promoted by firmly filling foamed urethane to the entire region of the seal member filling layer by filling formed urethane into the seal member filling layer the opening portion of which is closed by the rear cover to foam.