PATENT ABSTRACT
At least one pair of positioning members are provided on both side faces of a terminal fitting connected to an electric wire. A housing includes a chamber for accommodating the terminal fitting therein, and a pair of guide members engaged with the associated positioning members to guide the terminal fitting inserted into the chamber to a predetermined position. The positioning members are protrusions integrally formed with the both side walls of the terminal fitting. The guide members are a pair of grooves each formed on both side walls of the chamber for receiving the associated protrusions therein.

PATENT DESCRIPTION
BACKGROUND OF THE INVENTION  
         [0001]    This invention relates to a connector, such as a waterproof connector, in which a wire, connected to a terminal received in a chamber in a connector housing, is sealed by a rubber plug.  
           [0002]    [0002]FIG. 10 shows a related connector of the type described. This connector  1  comprises a housing  2  having chambers  3  for respectively receiving terminals  7  each press-clamping a wire  5  and a rubber plug  6 . A cantilever-type elastic arm (so-called lance)  4  for retaining the terminal  7  is integrally formed on and projects upwardly from a bottom wall of the chamber  3 .  
           [0003]    When the terminal  7  is inserted into the chamber  3  in the housing  2  from the rear side thereof, the elastic arm  4  is elastically deformed, and retains the terminal  3  in the chamber  3 . A lower portion of the terminal  7 , retained in the chamber  3  by the elastic arm  4 , is supported by a spacer  8 , inserted into the chamber  3  from the front side thereof.  
           [0004]    In the related connector  1 , the terminal  7  is received in the chamber  3 , and is retained therein by the elastic arm  4 , and besides the terminal  7  is supported by the rattle-preventing spacer  8 . However, since the clearance (Δd) of the terminal  7  is formed as a result of accumulation of dimensional irregularities (tolerances) of three dimensions, that is, a height A of the chamber  3  in the housing  2 , a thickness C of the spacer  8  and a height B of the terminal  7  (Δd=A−C−B), it tends to be enlarged. As a result, there is probability that the durability of the terminal was adversely affected by vibrations and others.  
         SUMMARY OF THE INVENTION  
         [0005]    Therefore, this invention has been made in order to solve the above problem, and an object of the invention is to provide a connector in which the clearance of a terminal is suppressed so as to enhance the durability against vibrations and others.  
           [0006]    In order to achieve the above object, according to the present invention, there is provided a connector comprising:  
           [0007]    a terminal fitting, connected to an electric wire;  
           [0008]    at least one pair of positioning members, provided on both side faces of the terminal fitting; and  
           [0009]    a housing, including a chamber for accommodating the terminal fitting therein, and a pair of guide members engaged with the associated positioning members to guide the terminal fitting inserted into the chamber to a predetermined position.  
           [0010]    In this configuration, the clearance of the terminal fitting within the chamber is suppressed, and the durability against vibrations and others is enhanced. Therefore, wear of that portion of the terminal, disposed in contact with a mating terminal, which would be caused by the clearance, is positively prevented, so that the contact reliability of the terminal is further enhanced.  
           [0011]    Preferably, the positioning members are protrusions integrally formed with the both side walls of the terminal fitting, and the guide members are a pair of grooves each formed on both side walls of the chamber for receiving the associated protrusions therein.  
           [0012]    In this configuration, the clearance of the terminal in the chamber is suppressed easily and positively with this simple construction, and the connector of a high reliability can be produced at low costs. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]    The above objects and advantages of the present invention will become more apparent by describing in detail preferred exemplary embodiments thereof with reference to the accompanying drawings, wherein like reference numerals designate like or corresponding parts throughout the several views, and wherein:  
         [0014]    [0014]FIG. 1 is a vertical cross-sectional view of one preferred embodiment of a connector of the invention, showing a condition before this connector is assembled;  
         [0015]    [0015]FIG. 2 is a vertical cross-sectional view of the connector, showing a condition in which an inner housing is provisionally fitted in an outer housing, with terminals not yet inserted;  
         [0016]    [0016]FIG. 3 is a vertical cross-sectional view of the connector in the above provisionally-fitted condition, showing a condition during the insertion of the terminals;  
         [0017]    [0017]FIG. 4 is a vertical cross-sectional view of the connector in the provisionally-fitted condition, showing a condition in which the terminals are primarily retained;  
         [0018]    [0018]FIG. 5 is a vertical cross-sectional view of the connector in a completely-assembled condition in which the inner housing is completely fitted in the outer housing;  
         [0019]    [0019]FIG. 6 is a front-elevational view of the connector in its completely-assembled condition;  
         [0020]    [0020]FIG. 7 is a perspective view of the terminal to be received in a chamber in the inner housing, according to a first embodiment of the invention;  
         [0021]    [0021]FIG. 8 is a cross-sectional view of the terminal of FIG. 7 in its received condition;  
         [0022]    [0022]FIG. 9 is a perspective view of a terminal to be received in the chamber, according to a second embodiment of the invention;  
         [0023]    [0023]FIG. 10 is a cross-sectional view of a related connector; and  
         [0024]    [0024]FIG. 11 is a cross-sectional view showing a terminal in its received condition, which is used in the related connector. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0025]    One preferred embodiment of the present invention will now be described with reference to the drawings.  
         [0026]    As shown in FIGS.  1  to  6 , a connector housing  11  of the connector  10  comprises the inner housing  12 , made of a synthetic resin, and the outer housing  21  of a synthetic resin to be fitted with the inner housing  12 . The inner housing  12  has a pair of right and left chambers  13  formed integrally therewith for respectively receiving terminals  32  each press-clamping a wire  30  and a rubber plug  31 . The outer housing  21  has a pair of right and left insertion paths  23  of a substantially cylindrical shape each formed integrally therewith for receiving the wire  30 , the rubber plug  21  and the terminal  32 . A waterproof packing  20  is provided between the inner housing  12  and the outer housing  21 .  
         [0027]    The inner housing  12  includes an inner peripheral wall portion  14  of a substantially square shape (having an open rear end) for fitting in an inner peripheral wall portion  24  of the outer housing  21 , an outer peripheral wall portion  15  of a substantially square shape, which extends rearwardly in surrounding relation to the inner peripheral wall portion  14 , and can be fitted on the inner peripheral wall portion  24  of the outer housing  21 , and a front wall portion  16  from which the inner and outer peripheral wall portions  14  and  15  extend rearwardly. Within the inner peripheral wall portion  14 , the pair of right and left chambers  13  are formed respectively on opposite sides of a partition wall  14   a  serving also as a central side wall of the inner peripheral wall portion  14 .  
         [0028]    Cantilevered flexible retainers  17  each for retaining the terminal  32  received in the chamber  13  are formed integrally on an inner face of an upper portion of the inner peripheral wall portion  14  of the inner housing  12 , and are opposed to the chambers  13 , respectively, the flexible retainers  17  extending from the front portion to the rear end. A retaining projection  17   a  for retaining engagement with a retained portion  33   a  of the terminal  32  is formed integrally on a lower face of a free end of each flexible retainer  17 , and a cancellation projection  17   b  is formed integrally on a rear portion of the flexible retainer  17  near to the free end thereof. A flexure-allowing space  18  is formed between each flexible retainer  17  and an upper wall of the inner peripheral wall portion  14 . A recessed groove  14   c  serving as a positioning guide portion, is formed in each of opposed side walls  14   a  and  14   b  of each chamber  13  in the inner peripheral wall portion  14 , and extends horizontally, the groove  14   c  being disposed substantially centrally of the height of the wall  14   a,    14   b.    
         [0029]    A provisional fitting claw (provisional fitting member)  19   a  is formed integrally on a lower outer face of the inner peripheral wall portion  14  of the inner housing  12  at a rear portion thereof, and this claw  19   a  can be engaged in an engagement hole  27 , formed in the inner peripheral wall portion  24  of the outer housing  21 , to hold the two housings  12  and  21  in a provisionally-fitted condition. A complete fitting claw (complete fitting member)  19   b  is formed integrally on the lower outer face of the inner peripheral wall portion  14  at a front portion thereof, and this claw  19   b  can be engaged in the engagement hole  27  in the outer housing  21  to hold the two housings  12  and  21  in a completely-fitted condition.  
         [0030]    In the above provisionally-fitted condition, when each terminal  32  is inserted into the corresponding insertion path  23  of a substantially cylindrical shape from the rear side thereof, and is received in the corresponding chamber  13 , the terminal  32  is retained by the flexible retainer  17 . In the provisionally-fitted condition, the front wall portion  16  of the inner housing  12  forwardly projects a predetermined distance from the front side of the outer housing  21  (This projection distance is indicated by reference character Y in FIG. 2). The rubber plug  31 , press-clamped by a plug damper  35  formed at a rear end portion of the terminal  32 , serves also as a visual confirmation member. When the connector is shifted from the provisionally-fitted condition to the completely-fitted condition, each rubber plug (visual confirmation member)  31  moves into the corresponding insertion path  23 , and this movement of the rubber plug  31  can be visually confirmed from the rear side of the outer housing  21  (The amount of movement of each rubber plug  31  is indicated by reference character Z in FIG. 4).  
         [0031]    A distal end  15   a  of the outer peripheral wall portion  15  of the inner housing  12  is formed into a tapering shape, so that when the inner housing  12  and the outer housing  21  are completely fitted together, the distal end  15   a  of the outer peripheral wall portion  15  of the inner housing  12  and a packing support portion  28 , formed on the inner peripheral wall portion  24  of the outer housing  21 , hold the waterproof packing  20  therebetween in closely-contacted relation thereto.  
         [0032]    Through holes  16   a  each for passing a mating terminal of a mating connector (not shown) therethrough are formed respectively through those portions of the front wall portion  16  of the inner housing  12  substantially aligned respectively with the chambers  13 . A tapering guide face  16   b  is formed at a front peripheral edge portion of each through hole  16   a.  Jig insertion holes  16   c  each for inserting a bar-like terminal-withdrawing jig (not shown) therethrough are formed through the front wall portion  16  of the inner housing  12 , and are disposed above the through holes  16   a,  respectively.  
         [0033]    When a distal end portion of the terminal-withdrawing jig is inserted into the jig insertion hole  16   c  in the same direction as a mating connector-inserting direction, the distal end portion of this terminal-withdrawing jig is brought into abutting engagement with a slanting face of the cancellation projection  17   b  of the flexible retainer  17  to move the retaining projection  17   a  upward. More specifically, in the provisionally-fitted condition of the inner and outer housings  12  and  21 , the cancellation projection  17   b  of the flexible retainer  17  is pressed by the distal end portion of the terminal-withdrawing jig, inserted through the jig insertion hole  16   c,  so that the retaining projection  17   a  of the flexible retainer  17  is displaced out of engagement with the retained portion  33   a  of the terminal  32  in the flexure-allowing space  18 .  
         [0034]    The waterproof packing  20  is made of rubber, and has an annular shape. Front and rear convex portions  20   a  of a substantially triangular cross-section are formed integrally on the outer peripheral face of the waterproof packing  20 . The front and rear convex portions  20   a  are held between the distal end  15   a  of the outer peripheral wall portion  15  of the inner housing  12  and the packing support portion  28 , formed on the inner peripheral wall portion  24  of the outer housing  21 , in closely-contacted relation thereto.  
         [0035]    The outer housing  21  includes the pair of insertion paths  23  of a substantially cylindrical shape, integrally formed on and extending rearwardly from a central partition wall  22 , the inner peripheral wall portion  24  of a substantially square shape, which is integrally formed on and extends forwardly from the partition wall  22 , and serves as a insertion path communicating with the insertion paths  23 , and the outer peripheral wall portion  25  of a substantially square shape surrounding the inner peripheral wall portion  24 . Thus, the outer housing  21  has a double-wall construction having open front and rear ends. The rubber plug (waterproof plug)  31 , which is press-clamped to the terminal  32 , and is closely fitted on the wire  30 , is inserted into the insertion path  23  by press-fitting or other means. Namely, in the completely-fitted condition of the connector, the rubber plug  31 , which is fitted on the wire  30 , and is secured to the terminal  32 , is held between the wire  30  and the insertion path  23  of a substantially cylindrical shape in closely-contacted relation thereto.  
         [0036]    Plate-shaped flexure-preventing members  26  are formed integrally on the partition wall  22  of the outer housing  21 , and extend therefrom into the interior of the inner peripheral wall portion  24 , and these flexure-preventing members  26  are opposed respectively to the flexure-allowing spaces  18  for the flexible retainers  17  of the inner housing  12 . In the completely-fitted condition of the inner and outer housings  12  and  21 , each of the flexure-preventing members  26  is inserted in the flexure-allowing space  18  to prevent the flexing (or elastic deformation) of the flexible retainer  17 .  
         [0037]    The engagement hole  27  is formed through the lower wall of the inner peripheral wall portion  24  of the outer housing  21 , and the provisional fitting claw  19   a  and the complete fitting claw  19   b,  formed on the inner peripheral wall portion  14  of the inner housing  12 , can be releasably engaged with this engagement hole  27 . A tapered packing support portion  28  is formed integrally at the proximal end of the inner peripheral wall portion  24  of the outer housing  21  at which the partition wall  22  is provided. The tapered face is so formed as to be along with a surface of the convex portion  20   a  of the annular waterproof packing  20  of rubber.  
         [0038]    Recesses  25   d  for respectively guiding convex portions, formed respectively on opposite sides of the mating connector (not shown), are formed respectively in inner faces of the opposite side walls of the outer peripheral wall portion  25  of the outer housing  21 , each of the recesses  25   d  being disposed substantially centrally of the height of the side wall. A retaining hole  29  is formed through a front portion of the upper wall of the outer peripheral wall portion  25  of the outer housing  21 , and an elastic retaining arm on the mating connector (not shown) is releasably engageable in this retaining hole  29 . In an assembled condition of the inner and outer housings  12  and  21 , a clearance t is formed between the inner peripheral wall portion  14  of the inner housing  12  and the inner peripheral wall portion  24  of the outer housing  21 , as shown in FIG. 5.  
         [0039]    As shown in FIGS. 1, 2,  7  and  8 , the terminal  32  has a female terminal body  33  of a square tubular shape, and convex portions  33   c,  each serving as a positioning member, are integrally formed respectively on opposite side faces of the terminal body  33 , and extend horizontally, each of the convex portions  33   c  being disposed substantially centrally of the height of the side face. The convex portions  33   c  are engaged respectively in the grooves  14   c,  formed respectively in the opposed side walls of the chamber  13 , thereby properly positioning the terminal  32  received in the chamber  13 . When the terminal is thus received in the chamber, the upper edge (retained portion)  33   a  of the rear end of the terminal body  33 , which serves as the retaining portion, is retained by the retaining projection  17   a  of the flexible retainer  17 . A conductor  30   a  of the wire  30  is press-clamped by a conductor damper  34  of the terminal  32 , and the front end portion of the rubber plug  31  is press-clamped by the plug clamper  35  of the terminal  32 .  
         [0040]    For assembling the connector  10  of this embodiment, the waterproof packing  20  is fitted in the packing support portion  28  of the inner peripheral wall portion  24  of the outer housing  21  forming the outer portion of the connector housing  11 , as shown in FIG. 2. Then, the inner peripheral wall portion  14  of the inner housing  12 , forming the inner portion of the connector housing  11 , is fitted into the inner peripheral wall portion  24  of the outer housing  21 , and the provisional fitting claw  19   a,  formed on the inner peripheral wall portion  14  of the inner housing  12 , is engaged with the engagement hole  27  in the inner peripheral wall portion  24  of the outer housing  21 , thereby provisionally fitting the inner housing  12  in the outer housing  21 . In this provisionally-fitted condition, the front wall portion  16  of the inner housing  12  forwardly projects a distance Y from the outer housing  21 .  
         [0041]    Then, in the provisionally-fitted condition, when each terminal  32 , press-clamping the wire  30  and the rubber plug  31 , is inserted into the insertion path  23  in the outer housing  21 , and is received in the chamber  13  in the inner housing  12  as shown in FIG. 3, the rear upper edge  33   a  of the terminal body  33  of the terminal  32  is retained by the retaining projection  17   a  of the flexible retainer  17  as shown in FIG. 4, so that the terminal  32  is primarily retained by the flexible retainer  17 .  
         [0042]    Here, the rear end portion of the rubber plug  31  is pulled into the insertion path  23  by a distance Z from the rear end face of the outer housing  21 . The distance Z is so selected as to become smaller than the distance Y.  
         [0043]    Then, when the inner peripheral wall portion  14  of the inner housing  12  is further fitted into the inner peripheral wall portion  24  of the outer housing  21  as shown in FIG. 5, the complete fitting claw  19   b,  formed on the inner peripheral wall portion  14  of the inner housing  12 , is retainingly engaged in the engagement hole  27  in the inner peripheral wall portion  24  of the outer housing  21 , and the inner housing  12  is completely fitted in the outer housing  21 , thus completing the assembling of the connector  10 .  
         [0044]    In accordance with the fitting operation of the inner housing  12 , the terminal  32  and the rubber plug  31  are moved backwards within the insertion path  23 . Since the distance Z is so selected as to become the distance Y, the rear end portion of the rubber plug  31  is projected outside from the rear end face of the outer housing  21 , when the inner housing  12  is in the completely-fitted condition.  
         [0045]    When the inner housing  12  is completely fitted into the outer housing  21 , each flexure-preventing member  26  of the outer housing  21  is inserted into the flexure-allowing space  18  for the flexible retainer  17  of the inner housing  12 . As a result, the flexure-preventing member  26  positively prevents the flexible retainer  17 , primarily retaining the terminal  32 , from being elastically deformed away from the terminal  32 . Therefore, the terminal  32  is retained by the retaining projection  17   a  of the flexible retainer  17 , and also is indirectly retained by the flexure-preventing member  26  which prevents the elastic deformation of the flexible retainer  17 . Thus, each terminal is easily and positively retained in a double manner.  
         [0046]    The completion of the double-retaining of each terminal  32  by the flexible retainer  17  of the inner housing  12  and the flexure-preventing member  26  of the outer housing  21  can be easily confirmed from the rearward movement (i.e., the movement over the distance Y in FIG. 2) of the inner housing  12  at the front side of the outer housing  21  at the time of shifting of the inner housing  12  from the provisionally-fitted condition to the completely-fitted condition, and also from the rearward movement (i.e., the movement over a distance Z in FIG. 4) of the rubber plug  31  in the substantially-cylindrical insertion path  23  at the rear portion of the outer housing  21   
         [0047]    Namely, the rearward movement of the inner housing  12  at the front side of the outer housing  21  at the time of shifting of the inner housing  12  from the provisionally-fitted condition to the completely-fitted condition and the rearward movement of the rubber plug  31  (occurring simultaneously with the above rearward movement of the inner housing  12 ) in the substantially-cylindrical insertion path  23  at the rear portion of the outer housing  21  can be confirmed at the front and rear sides of the connector housing  11 , respectively. Therefore, in a wire harness-producing process, the movement of the operator for inspection and confirmation purposes is much less as compared with the related construction, and the efficiency of the operation is much enhanced.  
         [0048]    When the inner housing  12  and the outer housing  21  are completely fitted together, the slanting face of the distal end  15   a  of the outer peripheral wall portion  15  of the inner housing  12  and the packing support portion  28  hold the waterproof packing  20  therebetween in closely-contacted relation thereto. In this completely-fitted condition, the rubber plug  31 , which is fitted on the wire  30 , and is secured to the terminal  32 , is received in the insertion path  23  in the outer housing  21  in closely-contacted relation thereto. With these effects, the waterproof performance of the assembled connector  10  is much enhanced.  
         [0049]    Thus, in the completely-fitted condition of the inner housing  12  and the outer housing  21 , the convex portions  20   a  and  20   b  of the waterproof packing  20 , made of rubber, are disposed between and held in intimate contact respectively with the slanting surface of the distal end  15   a  of the outer peripheral wall portion  15  of the inner housing  12  and the packing support portion  28  of a V-shaped cross-section formed at the proximal end of the inner peripheral wall portion  24  of the outer housing  21 . Therefore, vibrations, applied to the outer housing  21 , can be absorbed by the waterproof rubber packing  20 .  
         [0050]    As shown in FIG. 8, the convex portions  33   c  are integrally formed respectively on the opposite side surfaces  33   b  of the terminal body  33  of the terminal  32 , and the grooves  14   c  of a channel-shaped cross-section, in which the convex portions  33   c  can be engaged, respectively, are formed respectively in the opposed side walls  14   a  and  14   b  of each chamber  13  (which are to be opposed respectively to the convex portions  33   c ) in the inner housing  12 , and thanks to the provision of the convex portions  33   c  and the grooves  14   c,  the clearance of the terminal  32  in the chamber  13  is reduced. Namely, as shown in FIG. 8, the clearance (Δd′) of the terminal  32  is formed as a result of accumulation of dimensional irregularities (tolerances) of two dimensions, that is, a height A′ from the bottom surface of the chamber  13  to the upper surface of each groove  14   c  and a height B′ from the bottom surface of the terminal body  33  of the terminal  32  to the upper surface of each convex portion  33   c  (Δd′=A′−B′), and therefore the durability against vibrations and others is enhanced. Therefore, wear of that portion of the terminal  32 , disposed in contact with the mating terminal, which would be caused by the clearance, is positively prevented, so that the contact reliability of the terminal  32  is further enhanced.  
         [0051]    The convex portions  33   c  are integrally formed respectively on the opposite side surfaces  33   b  of the terminal body  33 , and the grooves  14   c  of a channel-shaped cross-section are formed respectively in the opposed side walls  14   a  and  14   b  of each chamber  13 , and with these simple configurations, the clearance of the terminal  32  in the chamber  13  is suppressed easily and positively, and the connector  10  of a high reliability can be produced at low costs.  
         [0052]    In the above embodiment, as shown in FIG. 7, the convex portions  33   c  are integrally formed respectively on the opposite side surfaces  33   b  of the terminal body  33  of the terminal  32  by pressing or the like, and extend horizontally over a predetermined span L entirely. However, as shown in FIG. 9, a pair of discrete convex portions  33   c′  may be integrally formed respectively on front and rear portions of each side surface  33   b  of a terminal body  33  of a terminal  32  in such a manner that the span of the two discrete convex portions  33   c′  constitutes both ends of the span L. Although the terminals, each press-clamping the rubber plug at its rear end portion, are used, there may be used the type of terminals to which a rubber plug is not press-clamped, in which case the rubber plug is mounted on the wire.  
         [0053]    Although the present invention has been shown and described with reference to specific preferred embodiments, various changes and modifications will be apparent to those skilled in the art from the teachings herein. Such changes and modifications as are obvious are deemed to come within the spirit, scope and contemplation of the invention as defined in the appended claims.