Packing protection cap and connector

An electrical connector includes a connector body and a seal protection cap. The connector body includes a cap housing, a body, and a fitting section provided with a seal. The seal protection cap includes a front face plate and a protection section. The front face plate is provided with an opening in order to allow a continuity check from a front face of the fitting section. The protection section extends cylindrically from a peripheral edge of the front face plate along a side face of the fitting section so as to cover the seal. The seal protection cap is applied to the fitting section of the connector body so as to cover the seal.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing date under 35 U.S.C. §119(a)-(d) of Japanese Patent Application number 2008-118848 filed Apr. 30, 2008.

FIELD OF THE INVENTION

The present invention relates to a seal protection cap for protecting a fitting portion of an electrical connector to be fitted to a mating connector and for protecting a seal provided on the fitting portion, and to an electrical connector including the seal protection cap.

BACKGROUND

An electrical connector having a fitting portion to be fitted to a mating connector and a seal provided on the fitting portion is readily known. In the case where such a connector is used for an airbag system for an automobile, for example, the fitting portion and the seal of this connector are often protected with a seal protection cap in order to ensure safety and reliability until the connector is mated with the mating connector.

For example, Japanese Patent Application Publication No. 08-64298 proposes a waterproof electrical connector including a seal that is provided inside a fitting concave section to be fitted to a fitting section of a mating connector while the seal is partially exposed on an outer periphery of the fitting concave section. In this connector, the exposed portion of the seal is covered with a protection cover that is put on the outer periphery of the fitting concave section.

Meanwhile, Japanese Patent Application Publication No. 2001-267004 proposes a cap-shaped dust cover to be fitted onto an outer periphery of a connector so as to cover a front face of a fitting portion of the connector. In this application, a seal protection section is formed in an extending manner on an opening end of a peripheral wall of the dust cover so as to cover a seal exposed on a rear-end outer periphery of the connector.

However, when putting the protection cover on the outer periphery of the fitting concave section as proposed in Japanese Patent Application Publication No. 08-64298, the portion of the seal that is exposed on the outer periphery of the fitting concave section is protected by the protection cover, whereas a front end side of the seal provided inside the fitting concave section is not protected by the protection cover. Therefore, an insufficient protection of the seal results.

Meanwhile, again, according to Japanese Patent Application Publication No. 2001-267004, the seal exposed on the rear-end outer periphery of the connector is covered with the seal protection section that extends on the opening end of the peripheral wall of the cap-shaped dust cover to be fitted to the outer periphery of the connector. In this application, the front face of the connector, in a fitting direction in which the connector is fitted to the mating connector, is covered with the dust cover. Thus, it is impossible to carry out a visual inspection of the connector or a continuity check of a contact after putting the dust cover on the connector. Therefore, this connector has a problem of poor workability in its manufacturing process.

SUMMARY

In view of the foregoing problems, the present invention provides a seal protection cap to protect a fitting portion as well as a seal, while improving workability. The present invention also provides a connector having the seal protection cap.

The seal protection cap for a connector body, according to the present invention, includes a connector body having a fitting section and a seal. The fitting section, which is fitted to a fitting concave section of a mating connector, has a contact hole formed in a front face thereof in a fitting direction, in which the fitting section is fitted to the fitting concave section. The contact hole extends far enough to reach a contact disposed inside the fitting section. The seal surrounds a side face of the fitting section. The seal protection cap includes a front face plate and a protection section. The front face plate, which spreads to face the front face, includes an opening to allow inspection from the front face. The protection section extends cylindrically from a peripheral edge of the front face plate along the side face of the fitting section so as to cover the seal.

Since the seal protection cap of the present invention includes the front face plate provided with the opening, it is possible to carry out a continuity check while touching contacts disposed inside the connector body with the seal protection cap kept on the connector body. Therefore, workability can be improved.

According to the present invention, it is possible to provide a seal protection cap capable of protecting a fitting portion as well as a seal and improving workability at the same time, and to provide a connector including the seal protection cap.

DETAILED DESCRIPTION OF THE EMBODIMENT(S)

A connector1shown inFIG. 1toFIG. 3Bis a connector to be connected, via wires20, to a mating connector (not shown) that is provided on an ignition device of a vehicle airbag system (also not shown). The connector1includes a connector body1_1and a seal protection cap1_2.

The connector body1_1includes a body50, a fitting section112, and a seal60as shown inFIG. 3B.

The body50corresponds to an example made of an insulative material such as a resin-made head section. This body50is arranged at a rear portion of the fitting section112in a fitting direction in which the fitting section112is fitted to the mating connector. The body50seals portions around the wires20extending from the rear portion. The body50is integrally molded with the fitting section112as well as insulation on the wires20, by use of a mold to be described later. A material such as polyamide-based hot-melt or polyester-based hot-melt may be used for the body50but it should be understood by those skilled in the art that other insulative materials would be suitable for the body50. Therefore, the materials of the body50are not limited only to those mentioned above. It is possible to employ any other materials as long as such materials allow the body50to be formed by means of a mold, at a low pressure in a short period of time, thereby obtaining the body50integral with the fitting section112and the insulation coatings of the wires20. Moreover, this material is expected to have affinity for the materials of the fitting section112and the insulation of the wires20while preventing adhesion to the mold.

The fitting section112is fitted to a fitting concave section (not shown) of the mating connector. This fitting section112includes an outer peripheral surface1123provided with a lock1121. The lock1121plays a role in preventing detachment of the mating connector when the fitting section112is inserted to a predetermined position of the fitting concave section of the mating connector. Moreover, as shown inFIG. 3B, this fitting section112includes contact holes1125formed on a front face1122in the fitting direction, which are configured to reach contacts arranged inside the fitting section112, as will be described later.

As shown inFIG. 3B, the seal60is arranged so as to surround a side face of the fitting section112. This seal60is formed, for example, by insert-molding of silicone rubber onto an outer peripheral surface1123of the fitting section112formed in advance. The silicone rubber adheres to the fitting section112in the course of the insert-molding process and thereby forms the seal60that is integrated with the fitting section112. Here, the seal60may also be formed simultaneously and integrally with the fitting section112by means of a two shot molding process wherein different color material may optionally be used for each component. The seal60has an annular shape so as to surround part of the outer peripheral surface1123, and a lip61is formed on the outermost periphery of the seal60. The lip61protrudes from the outer peripheral surface1123so that an outside diameter of the seal60is larger than an inside diameter of the fitting concave section of the mating connector. That is, the seal60is formed so as to be in intimate and elastic contact with an inner wall of the fitting concave section of the mating connector when the fitting section112is inserted to the fitting concave section.

Meanwhile, as shown inFIG. 2andFIG. 3A, the seal protection cap1_2includes a front face plate1_21and a protection section1_22. The front face plate1_21is spread to face the front face1122of the fitting section112and includes an opening1_21ain order to allow an inspection from the front face1122. The protection section1_22is a member that extends from a peripheral edge of the front face plate1_21cylindrically along the side face of the fitting section112, so as to cover the seal60.

Moreover, the seal protection cap1_2, in the embodiment shown, is made of highly-transparent polypropylene so as to allow the connector body1_1to be visible through the seal protection cap1_2. However, the material of the seal protection cap1_2is not limited only to polypropylene. The seal protection cap of the present invention only needs to be made of a transparent material that allows the connector body to be visible through this seal protection cap.

The configuration of the connector1will be described further in detail with reference toFIG. 4.

A contact containing chamber1124is formed in the fitting section112of the connector1shown inFIG. 1. Contacts30and a ferrite core40are housed in this contact containing chamber1124. The contacts30are connected to ends of the wires29, and the ferrite core40has an oblong and hollow shape for noise absorption. Meanwhile, the contact holes1125for connecting the contact containing chamber1124to the outside, which are also illustrated inFIG. 3, are formed in the front face1122of the fitting section112. When the connector1is mated with the mating connector, male contacts (not shown) of the mating connector are inserted to the contact containing chamber1124through the contact holes1125and touch the contacts30.

As shown inFIG. 4, each of the contacts30is a female contact to be mated with the male contact of the mating connector, which is formed by stamping, forming and plating operations. The contact30has a substantially L-shape and includes a contact section31to be in contact with the male contact of the mating connector, and a wire connecting section32to be connected to the end of the wire20. The wire connecting section32includes a core-wire pressure-bonding section321for pressure-bonding a core wire of the wire20, and an insulation-coating pressure-bonding section322for pressure-bonding the insulation coating of the wire20.

Moreover, a cap housing120for covering an upper portion of the fitting section112is provided between the body50and the fitting section112of the connector body1_1. This cap housing120includes a wire-end cladding section1210for cladding a wire-end container section1110of the fitting section112.

This wire-end cladding section1210includes a claw member1212that comes between the end of the wire20to be housed in the wire-end container section1110and an electric-wire locking portion1112. This claw member1212prevents the cap housing120from falling from the upper portion of the fitting section112. Moreover, this claw member1212prevents the wire-end cladding section1210from being lifted up when an upward (upward inFIG. 4) force is applied to the wires20.

Further, the wire-end container section1110includes a through hole1113, which is formed in a position where the core-wire pressure-bonding section321of the wire connecting section32is exposed in the state prior to forming of the body50and when the wire connecting sections32of the contacts30and the wires20are housed in the wire-end container section1110.

Meanwhile, the body50is poured in from the through hole1113formed on the wire-end container section1110and is filled in a portion around the end of each of the wires20inclusive of the core-wire pressure-bonding section321of the wire connecting section32housed in the wire-end container section1110. In a conventional connector, since this filling is not performed, there is a risk of water entering the surroundings of the ends of the wires inclusive of the core-wire pressure-bonding sections of the wire connecting sections when the body is removed from an insulation housing. However, according to the connector1of the present invention, the waterproof property of the connector1is maintained by the body50, which is poured in from the through hole1113, filling around the ends of the wires20that are housed in the wire-end container section1110.

As shown inFIG. 4, the connector1of the present invention includes a connector body1_1and a seal protection cap1_2. The connector body1_1includes a cap housing120, the body50, and the fitting section112which is provided with the seal60. The seal protection cap1_2has a front face plate1_21provided with an opening1_21athat allows inspection from the front face1122of the fitting section112to be fitted to the fitting concave section of the mating connector. For this reason, it is possible to carry out a continuity check by touching the contacts30disposed inside the connector body1_1when the seal protection cap1_2is on the connector body1_1. Moreover, through the opening1_21a, it is also possible to check whether the contacts30and the ferrite core40are disposed inside the connector body1_1. It is therefore possible to improve workability. Further, as shown inFIG. 3A, this seal protection cap1_2includes the protection section1_22, which extends cylindrically from the peripheral edge of the front face plate1_21along the side face of the fitting section112, so as to cover the seal60. In this way, it is possible to protect the fitting section112and the seal60reliably.

Moreover, the seal protection cap1_2is made of transparent polypropylene. Accordingly, it is possible to check the presence and external appearance of the seal60that surrounds the side face of the fitting section112with the seal protection cap1_2kept on the connector body1_1. In this way, workability can be further improved.

In addition, when manufacturing this connector1, as will be described later, it is possible to carry out a forming operation to form the body50on the connector body1_1(a connector body portion) with the seal protection cap1_2kept on the connector body1_1. Therefore, this connector1is excellent in forming operability.

Next, a method of manufacturing the connector1will be described.

First, as shown inFIG. 5andFIG. 6, the seal protection cap1_2is put on the fitting section112with the seal60attached thereto. Next, the ferrite core40and the contacts30connected to the wires20, which are not illustrated inFIG. 5andFIG. 6, are inserted into the fitting section112from above.

FIG. 7is a view showing how the cap housing120is fitted to the fitting section112having the seal protection cap1_2thereon and the contacts30housed therein, the contacts having been connected to the ferrite core40and the wires20.

FIG. 7shows the fitting section112provided with the seal protection cap1_2put thereon, the ferrite core40housed inside the fitting section112, and the two contacts30connected to the two wires20housed to be surrounded by the ferrite core40. The cap housing120is fitted to the fitting section112, thereby making the connector body1_1without the body50. Here, the connector body1_1without the body50will be hereinafter referred to as the connector body portion for the convenience of explanation.

Further, as described below, the body50is formed on the upper portion of the cap housing120by using a mold including lower mold sections and an upper mold section.

A first lower mold section71and a second lower mold section72of the mold are shown inFIG. 8toFIG. 11. The first lower mold section71is provided with a hole71a in which a insulative material for forming the body50is poured by way of the upper mold section to be described later. Meanwhile, as shown inFIG. 9andFIG. 11, the seal60is attached to the side face of the fitting section112. The seal protection cap1_2is put so as to cover this seal60.

First, the first and second lower mold sections71and72are arranged away from each other by a predetermined distance, and then the fitting section112with the cap housing120and the seal protection cap1_2attached thereto is placed on these first and second lower mold sections71and72. Subsequently, these first and second lower mold sections are joined to each other and an upper mold section to be described later is further put thereon so as to close the mold.

An upper mold section70of the mold is shown inFIG. 12toFIG. 14. The upper mold section70is provided with a hole70ain which the insulative material for forming the body50is poured. As shown inFIG. 13andFIG. 15, this hole70acommunicates with the hole71aprovided on the first lower mold section71. The insulative material is poured into an inner space defined by the first and second lower mold sections71and72and the upper mold section70by way of these holes70aand71a. Meanwhile, as shown inFIG. 12, support pins70band70cfor supporting the cap housing120are respectively fitted into holes70dand70eprovided on an upper face of the upper mold section70.

Here, as shown inFIG. 12toFIG. 15, the upper mold section70is put on the first and second lower mold sections71and72so as to close the mold. Subsequently, the insulative material is poured into the mold as described below.

An insulative material A is poured from the hole70aprovided on the upper face of the upper mold section70as shown inFIG. 16. The insulative material A poured from the hole70apasses through a reservoir portion70fprovided on a lower surface of the upper mold section70and through the hole71aprovided on the upper surface of the lower mold section71, and then flows rightward inFIG. 16. The flowing insulative material A thus poured is filled in the upper portion of the cap housing120and a portion around the ends of the wires20. In this way, the body50is formed so as to be integrated with the insulation of the wires20. Then, the upper mold section70is detached from the first and second lower mold sections71and72.

As shown inFIG. 18andFIG. 19, the upper mold section70is detached upward from the first and second lower mold sections71and72.FIG. 18andFIG. 19show the body50that is formed on the upper portion of the cap housing120and around the ends of the wires20. Moreover, the formed connector1is taken out by separating the first lower mold section71from the second lower mold section72, as described below.

The first lower mold section71is separated from the second lower mold section72as shown inFIG. 20toFIG. 23, leaving the molded connector1in a state of being mounted on the second mold section72. Subsequently, the formed connector1is taken out of the second lower mold section72. In this way, the connector1of this embodiment is manufactured.