Connector and a connector assembly

Two kinds of female terminal fittings (13a, 13b) are accommodated in a housing (10) and have connecting portions (22a, 22b) of different lengths. These terminal fittings (13a, 13b) are inserted into cavities (26a, 26b) of the housing (10) so that front ends of the terminal fittings (13a, 13b) are displaced along forward and backward directions so that rear ends of the connecting portions (22a, 22b) align along an inserting direction of a retainer (33). Thus, the retainer (33) can lock the respective terminal fittings (13a, 13b) substantially simultaneously.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a connector and to a connector assembly.

2. Description of the Related Art

A connector includes a housing and terminal fittings that are mounted in the housing. Each terminal fitting has a connecting portion configured for connection with a mating terminal fitting. Female terminal fittings in such a connector have tubular connecting portions for the connection with male terminal fittings. The front ends of the connecting portions of the terminal fittings are aligned as a prerequisite. A retainer normally is mounted in the housing and engages the rear ends of the connecting portions of the respective terminal fittings to retain the terminal fittings in the housing.

Japanese Unexamined Patent Publication No. 2000-182709 discloses a connector with large and small terminal fittings provided in a mixed manner in conformity with permissible current values. However, the tubular connecting portions have different volumes and different lengths along forward and backward directions depending upon the size of the terminal fittings. Thus, the rear ends of the connecting portions are not aligned with respect to forward and backward directions, and may interfere with a side-mounted retainer. The large and small terminal fittings can be arranged in the housing to avoid the interference with the retainer. Specifically, the shorter terminal fittings can be arranged at an entrance side with respect to an inserting direction of the retainer, and longer terminal fittings can be arranged at a back side with respect to the inserting direction of the retainer. However, connectors with terminal fittings of different lengths along forward and backward directions are deprived of a degree of freedom in designing the arrangement of the terminal fittings.

The present invention was developed in view of the above problem and an object thereof is to provide a connector in which terminal fittings whose connecting portions have different lengths along forward and backward directions are arranged in a mixed manner and with a higher degree of freedom in the arrangement of terminal fittings in a connector housing.

SUMMARY OF THE INVENTION

The invention relates to a connector with a housing having cavities arranged along a width direction. The connector has a plurality of different kinds of terminal fittings that are insertable into the cavities. Each terminal fitting has a connecting portion that is connectable with a mating terminal fitting. The connecting portions of the different kinds of terminal fittings have different lengths along forward and backward directions. A retainer is mountable into the housing along an arranging direction of the cavities for simultaneously engaging locks on the connecting portions of the respective terminal fittings that have been mounted properly in the housing and for retaining the respective terminal fittings in the cavities. The locks of the properly mounted terminal fittings substantially align along an insertion direction of the retainer into the housing. Thus, the retainer can engage the locks regardless of the arrangement of the terminal fittings even though the connecting portions have different lengths. Accordingly, a degree of freedom in arranging the terminal fittings is improved.

Projected positions of the terminal fittings from the front end surface of the housing preferably differ depending on the lengths of the connecting portions along forward and backward directions. The locks are defined by the rear ends of the connecting portions and substantially align with respect to an inserting direction of the terminal fittings. Thus, the construction is simpler than a case where the locks are at intermediate positions of the connecting portions.

The retainer preferably can be positioned at a first position, where the insertion and withdrawal of the terminal fittings to and from the respective cavities is permitted, and a second position, where the terminal fittings are locked in the respective cavities.

A front holder preferably is mountable on the housing to define abutments for at least part of the cavities against which the properly inserted terminal fittings can abut.

An area of a front surface of the front holder corresponding to the cavities projecting from the front surface of the front holder is displaced along forward and backward directions.

The retainer preferably comprises a plurality of locking portions for locking the respective terminal fittings in the respective cavities.

The locking portions have a substantially cranked shape. A free length of the locking portions at one side is shorter than that of the locking portions at the other side along an inserting direction of the retainer. Additionally, the locking portions at one side are thicker than the locking portions at other side.

The invention also is directed to a connector assembly comprising the above-described connector and a mating connector. The terminal fittings are retained in the housing with front ends of the terminal fittings of one kind located slightly behind the front ends of the terminal fittings of the other kind. The displacement of the terminal fittings corresponds to a displacement between the leading ends of mating terminal fittings of the mating connector.

One of the connector and the mating connector may comprise a forcible connection preventing wall that projects from a main body thereof. The forcible connection-preventing wall interferes with the other of the connector and the mating connector in response to an attempt to connect the connector and the mating connector in an improper posture. The forcible connection-preventing wall preferably is on the mating connector and the retainer is formed with an insertion hole to accommodate the forcible connection preventing wall when the retainer locks the terminal fittings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A hybrid male connector according to the invention has a housing1that preferably is made of a synthetic resin. In the following description, a mating side of the connector with a mating connector is referred to as the front. The housing1has a forwardly open tubular receptacle2that projects forward from a main body3, as shown inFIG. 1. The main body3accommodates large and small terminal fittings (not shown) in a mixed manner. The large male terminal fittings are accommodated at upper and lower stages at the left and right sides and the smaller male terminal fittings are accommodated at three stages between the larger male terminal fittings inFIG. 1. Tabs of the male terminal fittings project from the front wall of the main body3and into the receptacle2for protection by the receptacle2. The front wall of the main body3has a middle area4where the small terminal fittings are accommodated and left and right areas5at opposite left and right sides of the middle area4for accommodating the large terminal fittings. Although not shown in detail, steps or slanted surfaces6are set between the middle area4and the left and right areas5so that the middle area4projects more forward than the left and right areas5. Accordingly, the front end positions of tabs t1of the smaller terminal fittings projecting from the middle area4are more forward than the front ends of tabs t2of the larger terminal fittings projecting from the left and right areas5.

A forcible connection preventing wall7projects from the front wall of the main body3in an intermediate part of the middle area4with respect to a height direction HD. The front end of the forcible connection-preventing wall7is substantially aligned with the front end of the receptacle2. The forcible connection-preventing wall7will interfere with a female housing10that is in an improper posture during a connection attempt, thereby avoiding deformation of the tabs. Further, as shown inFIG. 1, upside-down insertion preventing ribs9a.9bare arranged on the outer surfaces of the shorter sides of the receptacle2. The ribs9a,9bare arranged in a rotationally asymmetric way to allow connection only in one rotational orientation. InFIG. 1, one rib9bis arranged substantially along a connecting direction CD in the middle with respect to the height direction HD at one side, whereas two ribs9aare arranged substantially along the height direction HD at the other side. Therefore, upside-down insertion of the female housing10into the male housing1can be avoided.

Cam pins8project in a substantially in the widthwise middle on the outer surface of each longer side of the receptacle2. As described later, the cam pins8assist the connection of the female and male connectors.

The female housing10, as shown inFIG. 2, is made unitarily e.g. of a synthetic resin. The female housing10has female terminal fittings13a,13baccommodated in a terminal-accommodating portion14. An outer tube15substantially surrounds the terminal-accommodating portion14so that a connection space for the male housing1is between the terminal-accommodating portion14and the outer tube15. As shown inFIG. 16, a resilient seal ring16is mounted at a back end of the outer surface of the terminal-accommodating portion14. The seal ring16closely contacts the inner surface of the receptacle2over substantially the entire periphery to provide sealing between the female and male housings10,1.

The outer tube15has a substantially hollow structure, and a slide lever11is accommodated inside for assisting the connecting operation of the male and female connector housings1,10. The opposite shorter sides of the outer tube15are entirely open, and the slide lever11is insertable laterally in an inserting direction at an angle and substantially normal to the connecting direction CD (from right side ofFIG. 4). The slide lever11has an operable portion17to operate (e.g. insert and withdraw) the slide lever11and two opposed lever pieces18extend from the opposite ends of the operable portion17. Thus, the slide lever11is substantially U-shaped.

Two resiliently deformable locking claws19a,19bare formed at one longer side of each lever piece18and are spaced apart along the longitudinal direction of the lever pieces18. The respective locking claws19a,19bare cantilevered with their free ends at a front side with respect to a withdrawing direction of the slide lever11. The locking claws19a,19bare engageable with unillustrated engaging portions formed on the inner wall surfaces of the outer tube15to holding the slide lever11at an initial position and a connection ending position.

Each lever piece18has a cam groove12with an entrance at the longer edge of the lever piece18. The entrances of the cam grooves12align with cam-pin receiving openings20(seeFIG. 2) in the widthwise middle of the front surface of the outer tube15when the slide lever11is at the initial position. Thus, the cam pins8can be introduced into the entrances of the cam grooves12via the cam-pin receiving openings20to fit the male and female housings1,10lightly together. The slide lever11is pushed into the outer tube15from the initial position to guide the cam pins8towards the back ends of the cam grooves12by the cam function of the cam pins8with the cam grooves12. The male and female housings1,10are connected properly when the slide lever11is pushed to the connection ending position.

Bulges21are formed on both lever pieces18near the operable portion17and are used for the withdrawing operation. Upside-down insertion preventing rails42a,42breceive the upside-down preventing ribs9a,9bwhen the male and female housings1,10are connected in proper postures to guide the connecting operation of the male and female housings1,10. The rails42a,42binterfere with the ribs9a,9bif an attempt is made to insert the female housing10in a wrong posture, thereby making the connecting operation impossible and notifying an operator of an erroneous connection.

Large and small female terminal fittings13a,13bare accommodated in the terminal accommodating portion14in conformity with permissible current values (seeFIGS. 5 and 6). The female terminal fittings13a,13bare formed by bending plates made of an electrically conductive material (preferably metal), and include connecting portions22a,22bfor connection with the male tabs t1, t2. The connecting portions22a,22bare substantially rectangular tubes with parts that can be brought resiliently into contact with the male tabs t1, t2. Wire barrels24a,24bto be crimped, bent or folded into connection with cores of the wires are provided behind the connecting portions22a,22b, and insulation barrels23a,23bare arranged behind the wire barrels24a,24b. In this embodiment, sealing rubber plugs25a,25bare mounted at ends of insulation coatings of the wires, and the wire barrels24a,24bare crimped, bent or folded into connection with the insulation coatings of the wires together with the sealing rubber plugs25a,25b.

Lengths of the connecting portions22a,22balong forward and backward directions FBD differ (L1>L2shown inFIGS. 5 and 6) to define terminal fittings13afor power and terminal fittings13be.g. for signal.

Cavities26a,26bfor the female terminal fittings13a,13bare arranged at stages in the terminal accommodating portion14of the female connector housing10. As shown inFIG. 2, two kinds of cavities26a,26bare arranged in a mixed manner at the respective stages and correspond to the differently dimensioned female terminal fittings13a,13b. The cavities at each stage are arranged along the width direction with the heights thereof substantially aligned. Two larger cavities26aare arranged one substantially above the other at each of the left and right sides inFIG. 2for accommodating the larger terminal fittings13afor power. The larger cavities26aare aligned along the height direction HD. The smaller cavities26baccommodate smaller the terminal fittings13bfor signal and are arranged at upper and lower sides of an accommodating recess27for accommodating the forcible connection preventing wall7of the male connector housing1. The smaller cavities26babove the accommodating recess27substantially align in a row along widthwise direction at substantially even intervals, whereas those below the accommodating recess27are arranged substantially along widthwise directions at substantially even intervals at upper and lower stages. The phases of the smaller cavities26at each stage are substantially aligned with respect to the height direction.

The larger and smaller cavities26a,26bpenetrate the female connector housing10along forward and backward directions FBD (seeFIG. 7). A hollow cylindrical sealable tower28a,28bis formed at a rear side of each cavity26a,26b. Sealability is ensured by inserting the sealing rubber plugs25a,25binto the sealable towers28a,28b. On the other hand, a resilient lock29a,29bis formed at a wall surface of the front side of each cavity26a,26bfor engaging an intermediate position of the connecting portion22a,22bof the corresponding female terminal fitting13a,13b. Each lock29a,29bcantilevers forwardly, and can deform vertically towards and away from the respective cavity26a,26b. The locks29acorresponding to the terminal fittings13afor power are formed at the bottom surfaces of the cavities26a, as shown inFIG. 7or8. However, the locks29bcorresponding to the terminal fittings13bfor signal are formed at the opposite ceiling surfaces, as shown inFIG. 9. Each larger cavity26ahas a front wall30afor contacting the front of the terminal fitting13afor power. However, each smaller cavity26bhas no front wall.

As is clear fromFIGS. 7 to 9, areas of the front end surface of the terminal accommodating portion14corresponding to the larger cavities26aare substantially flush with the front end of the outer tube15, but an area corresponding to the smaller cavities26bis retracted back from the front end edge of the outer tube15. The rear ends of the connecting portions22a,22bof the respective terminal fittings13a,13bsubstantially align along width direction when the terminal fittings13a,13bare accommodated to proper depths in the corresponding cavities26a,26b.

A retainer insertion hole32is formed in a side surface the terminal accommodating portion14substantially opposite from the surface where the slide lever11is inserted and before the seal ring16. The retainer insertion hole32extends substantially along the width direction of the terminal-accommodating portion14and substantially normal to the inserting direction of the respective terminal fittings. Thus, the retainer33is insertable into the retainer insertion hole32in an insertion direction ID substantially normal to the forward and backward direction FBD. Upper and lower openings32aare formed in the opposite side surface of the terminal accommodating portion14(seeFIG. 8). Thus, most of the cavities26a,26bare divided into front and rear sections by the retainer insertion hole32, including parts of the locks29a,29bbehind the base ends of the locks29a,29b(seeFIGS. 7 and 8). The locks29aof the larger cavities26aare not divided by the retainer insertion hole32in only the upper and lower cavities26alocated at the back with respect to an inserting direction of the retainer33, as shown inFIG. 9. The strength of the terminal-accommodating portion14would be reduced if a large opening was formed instead of the upper and lower openings32a. However, with such openings32a, deformability differs between the locks29ain the larger cavities26aat the left side inFIG. 2and those in the larger cavities26aat the right side. As a result, inserting forces exerted on the female terminal fittings13aare unbalanced between the left and right larger cavities26a. Accordingly, the free length from the base end of the lock to the locking surface inFIG. 7for the locks29ain the larger cavities26aat the left side is shorter than the length of the locks in the larger cavities26aat the right side and the former locks29aare made thicker than the latter locks29a. In this way, the locks29ain the left and right larger cavities26ahave substantially equal deformability.

As shown inFIG. 13, the retainer33has a frame-shaped portion35and two locking legs34a,34bof different lengths project along the width direction from one shorter side of the frame-shaped portion35. The entire length of the retainer33along the width direction substantially equals the width of the terminal-accommodating portion14. The retainer33has signal terminal locking sections36bfor locking the respective signal terminal fittings13band power terminal locking sections36afor locking the power terminal fittings13a. The signal terminal locking sections36bare oblong openings extending along the width direction to communicate with all the cavities26bat the corresponding stages, and are formed at three stages. Each signal terminal locking section36bhas smaller locking projections37bformed at intervals substantially corresponding to intervals of the cavities26bat the corresponding stage. The smaller locking projections37bare offset from the signal terminal fittings13bwhen the retainer33is at a partial locking position. However, the smaller locking projections37bare engageable with the rear ends22b-RE of the connecting portions22bof the signal terminal fittings13bwhen the retainer33is moved to a full locking position.

There are two kinds of the power terminal locking sections36a, those formed at an end inside the frame-shaped portion35and those formed at the locking legs34a,34b. Those inside the frame-shaped portion35are two upper and lower windows formed substantially in conformity with the larger cavities26aat the left side ofFIG. 2. A larger locking projection37aprojects at one corner of each window. On the other hand, larger locking projections37aare provided at the base ends of both locking legs34a,34bin the power terminal locking sections36aset at the locking legs34a,34b. Thus, the larger and smaller locking projections37a,37bare arranged along the longitudinal direction of the retainer33with the positions substantially aligned with respect to forward and backward directions FBD.

The retainer33is displaceable between the partial locking position where the signal terminal fittings13band the power terminal fittings13aare insertable and withdrawable and the full locking position where the retainer33engages the lockable parts22a-RE,22b-RE of the respective terminal fittings13a,13bto retain them in the cavities26a,26b. Holding portions38are provided on longer sides of the frame-shaped portion35near the locking legs34a,34bfor this displacement. As shown inFIG. 14, the leading ends of the retainer holding portions38are permitted to undergo a narrowing deformation. A partial locking recess39aand a full locking recess39bare formed at two positions on the outer surface of the free end of preferably each forked part. Lock projections40project inward at the walls of the retainer insertion hole32substantially in conformity with the partial and full locking recesses39a,39b. The lock projections40engage resiliently with the partial locking recesses39aand the full locking recesses39bto hold the entire retainer33at the partial locking position (FIG. 14) and the full locking position (FIG. 15).

The frame-shaped portion35of the retainer33has an insertion hole41that aligns with the accommodating recess27to receive the forcible connection-preventing wall7when the retainer33is at the full locking position.

The front holder31is made e.g. of a synthetic resin and is a substantially rectangular tube fittable on the outer peripheral surface of the front end of the terminal-accommodating portion14. Front-end portions of the smaller cavities26bare formed in an area of the front surface of the front holder31to enable the signal terminal fittings13bto stop at their front end positions. These front-end portions permit the insertion of the tabs of the male terminal fittings. However, openings are formed in areas of the front surface of the front holder31corresponding to the larger cavities26a, and the front ends of the larger cavities26aproject forward through these openings. The peripheral edge of the front holder31at the rear end contacts the front edge of the seal ring16to prevent the seal ring16from coming out.

Even in a state where the front holder31is mounted, the area of the front surface of the front holder31substantially corresponding to the smaller cavities26band the areas thereof corresponding to the larger cavities26aprojecting from the front surface of the front holder31are displaced along forward and backward directions FBD, and these displacements substantially correspond to those of the front surface of the male housing1. Therefore, the corresponding front end surfaces are held substantially in contact when the male and female housings1,10are connected properly.

The front holder31is mounted and the retainer33is held at the partial locking position prior to insertion of the terminal fittings13a,13binto the female housing10. The signal terminal fittings13bthen are inserted into the smaller cavities26band contact the inner surface of the front wall of the front holder31. Thus, the signal terminal fittings13bare stopped at their front end positions and are locked by the locks29b. Similarly, the power terminal fittings13acontact the inner surface of the front wall of the corresponding larger cavity26a. Accordingly, the power terminal fittings13aare stopped at their front end positions and are locked by the corresponding locks29a. At this time, the rear ends22b-RE of the connecting portions22bof the signal terminal fittings13band the rear ends22a-RE of the connecting portions22aof the power terminal fittings13asubstantially align, i.e. distances from a plane of opening of the outer tube portion15to these rear ends are substantially equal. Accordingly, the retainer33can be displaced from the partial locking position to the full locking position. Thus, the larger and smaller locking projections37a,37bof the locking sections36a,36bof the retainer33simultaneously engage the rear ends of the corresponding connecting portions22a,22b. As a result, all of the terminal fittings13a,13bare locked redundantly by the locks29a,29band the locking projections37a,37b.

As described above, the respective terminal fittings13a,13bare held and retained in the female connector housing10. At this time, the front ends of the signal terminal fittings13bare slightly behind those of the power terminal fittings13a. This displacement corresponds to the displacement between the leading ends of the tabs t1, t2of the larger and smaller terminal fittings of the male connector. Thus, when the male and female housings1,10are connected, all the terminal fittings13a,13bstart contacting the corresponding tabs t1, t2substantially at the same time, and the contact strokes of all the terminal fittings13a,13bare substantially equal.

The positions of the rear ends of the connecting portions22a,22bof the terminal fittings13a,13bsubstantially align in the connector for accommodating the terminal fittings13a,13bwhose connecting portions22a,22bhave different lengths. Thus, even if the arrangement of the larger and smaller terminal fittings13a,13bis changed, the terminal fittings13a,13bcan be locked by the retainer33. Therefore, a degree of freedom in the arrangement of the terminal fittings is improved.

The invention is not limited to the above described and illustrated embodiment. For example, the following embodiments are also embraced by the technical scope of the present invention as defined by the claims. Beside the following embodiments, various changes can be made without departing from the scope and spirit of the present invention as defined by the claims.

Although the present invention is applied to the female connector in the foregoing embodiment, it may be applicable to male connectors.

Parts to be locked by the retainer may not necessarily be the rear ends of the connecting portions. For example, the connecting portions may be locked at their intermediate positions by the retainer.

According to the invention, either one of the locks or the retainer may lock the terminal fittings.

The invention is also applicable to connectors with no front holder.

Even though in the above described preferred embodiment the retainer locks a rear portion of the connection portions as a preferred lockable parts, the invention is applicable also to connectors or terminal fittings in which the retainer locks a different lockable part such as a locking projection, locking step or the like.