# Patent

## Title
Connector and connector assembly provided therewith

## Abstract

A connector (L1) has a one-piece rubber plug (39) with wire insertion holes (45) to collectively seal wires (W) drawn out from the rear end surface of an inner housing (22) by inserting the wires into the corresponding wire insertion holes (45). The connector (L1) has wall surfaces (23, 41) for sandwiching the one-piece rubber plug (39) from front and rear in an inserting direction of the wires (W). Positioning pins (48) project substantially parallel with axial directions of the wire insertion holes (45) from the wall surface (41) on the side of the inner housing (22) toward the one-piece rubber plug (39) and to be inserted and press-fit into positioning holes 51 arranged near the wire insertion holes (45). Narrowed portions (51A) having a small hole diameter are formed at axial intermediate positions of the positioning holes (51).

## Background
BACKGROUND
1. Field of the Invention
The invention relates to a connector and to a connector assembly provided therewith.
2. Description of the Related Art
US Patent Application Publication No. 2002/0052142 discloses a waterproof connector with a one-piece rubber plug for collectively sealing a plurality of wires. A rubber plug accommodating portion is formed in a rear part of the housing and the one-piece rubber plug is accommodated therein. Wire insertion holes penetrate the one-piece rubber plug and communicate with cavities of the housing. An inner lip is formed on the inner peripheral surface of each wire insertion hole and contacts the outer peripheral surface of an insulation coating of the wire to provide sealing. However, a sealing force for the wire insulation coating depends solely on a resilient reaction force from the seal lip. Thus, there has been a limit to improved sealing.
The invention was completed in view of the above situation and aims to improve overall operability and enhance sealability for one or more wires.
SUMMARY OF THE INVENTION
The invention relates to a connector with a one-piece resilient plug. The one-piece resilient plug has wire insertion holes and is configured to collectively seal wires drawn out from the rear end surface of a housing by inserting the wires into the corresponding wire insertion holes in a sealed state. The connector includes two wall surfaces for sandwiching the one-piece resilient plug from the front and rear substantially in an inserting direction of the wires. At least one positioning pin projects from one of the wall surfaces toward the one-piece resilient plug and is substantially parallel with axial directions of the wire insertion holes. The positioning pin is inserted and press-fit into at least one positioning hole arranged near the wire insertion holes. At least one narrowed portion is formed at an axial intermediate position of the positioning hole and defines a small hole diameter.
At least one inner lip is formed on the inner peripheral surface of each wire insertion hole and closely contacts an insulation coating of the wire and an axial position of the narrowed portion in the positioning hole is aligned with the top of the inner lip. The axial alignment of the narrowed portion of the positioning hole and the inner lips causes the positioning pins to squeeze the inner lips tightly against the wire to enhance sealing.
Plural positioning holes preferably are arranged at substantially diagonally symmetric positions with respect to each wire insertion hole. Thus sealing forces for the wires are circumferentially uniform while narrowing intervals between the respective wire insertion holes as much as possible.
The one-piece resilient plug is mounted while being positioned with respect to the connector housing by inserting and press-fitting the positioning pin into the positioning hole. On the other hand, a material around the positioning hole is strongly pushed outward at the narrowed portion formed in the positioning hole. That influence reaches surfaces of the wire insertion holes near the positioning hole and press-contact forces applied to insulation coatings of the wires in the wire insertion holes are enhanced to improve sealing.
A slider preferably is accommodated movably along an arrangement direction of the fixed-side connectors in one plural adjacent lever-side connectors. The slider includes a cam groove to be engaged with the cam follower and produces a force multiplying action by displacing a lever on the lever-side connector while the cam groove and the cam follower are engaged.
The slider preferably is movable between a movement start position where the cam follower is received and a movement end position where the connection of the fixed-side connector and the lever-side connector with the mating connector is finished. The slider projects out from the lever-side connector in an arrangement direction of a plurality of mating connectors when the slider is at the movement start position. Thus, the slider does not interfere with the adjacent lever-side connector or fixed-side connector, and a distance between the adjacent connectors can be narrowed.
The connector may include a housing connectable to a mating connector. A lever is mounted displaceably to extend between opposite side surfaces of the housing. A wire cover projects out from the housing while at least partly covering a wire drawing surface of the housing and is configured to correct a wiring direction of wires drawn out from the wire drawing surface. The lever is mounted between side surfaces of the housing located between a connection surface and the wire drawing surface and is displaceable substantially along the connecting direction between the connection surface and the wire drawing surface.
The wire cover preferably includes a base that is mountable on the housing and open toward the wire drawing surface. A correcting portion rises from the peripheral edge of the base via a constricted portion to narrow an inner space from the base portion. Accordingly, the wires drawn out from the wire drawing surface can be drawn out from the wire cover while being collected in a projecting end space in the wire cover. Thus, a taping operation can be performed easily on a wire drawing part of the wire cover.
The correcting portion of the wire cover may extend and project from the base in a direction substantially parallel to a rotation axis of the lever via the constricted portion.
The lever may comprise two lever plates mounted on the housing and an operating portion coupling ends of the lever plates. The lever is held at an initial position before connection to the mating connector, and the operating portion of the lever is located along an extending direction of the constricted portion near the constricted portion when the lever is at the initial position. Accordingly, the lever will not interfere with the wire cover.
The connector may comprise a force multiplying mechanism that includes a slider mounted slidably through a side surface of the housing for movement in a direction intersecting a connecting direction. The slider is formed with at least one cam groove engageable with at least one cam follower provided on the mating connector. The connector further includes a lever with an operating portion on one end. The lever is mounted displaceably on the housing while being interlockingly coupled to the slider. The slider is movable with respect to the housing between a movement start position where the cam follower is received into the cam groove with the slider projecting back in a mounting direction thereof and a movement end position reached by inserting the slider deeper into the housing from the movement start position to properly connect the connector with the mating connector. At least one of the slider and the lever includes a lock that holds the slider at the movement start position by being locked to the housing, but is releasable from a locking state to the housing by displacing the lever. The lever has a protecting edge located at substantially the same height as an end of the slider that projects from the housing when the slider is at the movement start position. The protecting edge is at the same position as or behind the projecting end part in the mounting direction of the slider.
The lever preferably is mounted rotatably on the housing via at least one rotary shaft. A distance from the rotary shaft to the protecting edge preferably is shorter than a distance from the rotary shaft to the operating portion.
The lever preferably has two lever plates mounted to straddle opposite side surfaces of the housing adjacent to a surface through which the slider is mounted and the operating portion couples the lever plates. Each lever plate has one of the protecting edges, and the protecting edges sandwich the projecting end of the slider. The protecting edges prevent external matter from interfering with the projecting end of the slider.
The above described connector may be part of a connector assembly with a force multiplying mechanism. The assembly includes a plurality of fixed-side connectors arranged substantially side by side. Each fixed-side connector includes a cam follower. Lever-side connectors are connectable to the respective fixed-side connectors. A lever is mounted displaceably on each lever-side connector and engages the cam follower. The lever can be displaced to produce a force multiplying action for connecting the connectors.
Surfaces of adjacent fixed-side connectors where the cam followers are formed are at an angle and preferably substantially perpendicular to each other. Conventionally, a lever is mounted on a housing to straddle a wire cover, and therefore the lever must have a length necessary to straddle the wire cover. However, the lever of the invention is provided in a space different from a space where the wire cover projects. Thus, the length of the lever can be set independently of the projecting height of the wire cover, and the lever can be miniaturized.
The slider projects out from the housing when at the movement start position. External matter can contact the projecting end part with sufficient force to release the lock so that the slider moves toward the movement end position. However, the projecting edge of the lever is at the same position as or behind the projecting end when the slider is at the initial position. Thus, a pushing force by the external matter acts first on the protecting edge. The distance from the rotary shaft to the protecting edge of the lever is shorter than the distance to the operating portion. Therefore, a force necessary to release the lock is larger when it acts on the protecting edge than when it acts directly on the projecting end of the slider. Thus, the configuration of the invention can alleviate a situation where the slider inadvertently is pushed to the movement end position.
Thus, the connector can prevent the slider from being pushed inadvertently by a simple configuration that a part of the lever is located behind the projecting end part of the slider in the mounting direction under a given condition.
These and other features and of the invention will become more apparent upon reading of the following detailed description of preferred embodiments and accompanying drawings. It should be understood that even though embodiments are separately described, single features thereof may be combined to additional embodiments.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view showing a state before a connector with a force multiplying mechanism according to an embodiment is connected,
FIG. 2 is a side view showing the state after the connector is connected,
FIG. 3 is a front view of a fixed-side connector unit,
FIG. 4 is a rear view of the fixed-side connector unit,
FIG. 5 is a rear view showing a state where an alignment plate is detached in FIG. 4,
FIG. 6 is a bottom view of the fixed-side connector unit,
FIG. 7 is a rear view showing a state where the alignment plate is detached in FIG. 6,
FIG. 8 is a section of the alignment plate,
FIG. 9 is a side view showing a first lever-side connector when a lever is at an initial position,
FIG. 10 is a side view showing the first lever-side connector when the lever is at a connection end position,
FIG. 11 is a front view of the first lever-side connector when the lever is at the connection end position,
FIG. 12 is a section along A-A of FIG. 11,
FIG. 13 is a view of the first lever-side connector of FIG. 11 when viewed in a direction of an arrow P,
FIG. 14 is a front view of an outer housing of the first lever-side connector,
FIG. 15 is a front view of a one-piece rubber plug,
FIG. 16 is a section along C-C of FIG. 15 showing wire insertion holes,
FIG. 17 is a section along D-D of FIG. 15 showing positioning holes,
FIG. 18 is a rear view of an inner housing,
FIG. 19 is an enlarged section showing a fitted state of positioning pins and the positioning holes,
FIG. 20 is a diagram showing the influence of the insertion of the positioning pins into the positioning holes on a sealed state of the wire inserted into the wire insertion hole,
FIG. 21 is a section along E-E of FIG. 11 showing an accommodated state of a slider,
FIG. 22 is a section, corresponding to one along F-F of FIG. 11, showing a coupled state of the lever and the slider when the lever is at the initial position,
FIG. 23 is a section, corresponding to one along F-F of FIG. 11, showing the coupled state of the lever and the slider when the lever is at the connection end position,
FIG. 24 is a front view of a retainer,
FIG. 25 is a rear view of a front mask,
FIG. 26 is a section, corresponding to one along B-B of FIG. 11, showing a state where the retainer is at a partial locking position,
FIG. 27 is a section, corresponding to one along B-B of FIG. 11, showing a state where the retainer is at a full locking position,
FIG. 28 is a section showing the position of the slider when a first fixed-side connector and the first lever-side connector are lightly connected and cam followers enter the entrances of cam grooves,
FIG. 29 is a section showing the position of the slider when the connection is completed,
FIG. 30 is a section showing a state before the first fixed-side connector and the first lever-side connector are connected,
FIG. 31 is a section showing a state when the connection is completed,
FIG. 32 is a rear view when a lever is at a connection end position in a second lever-side connector,
FIG. 33 is a side view when the lever is at an initial position,
FIG. 34 is a front view when the lever is at the connection end position, and
FIG. 35 is a side view when the lever is at the connection end position.



DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A connector with the force multiplying mechanism in accordance with the invention includes a fixed-side connector unit U with first and second fixed connectors F1, F2 arranged substantially side by side on a board 1, as shown in FIGS. 1 and 2. First and second lever connectors L1, L2 connectable to the respective fixed-side connectors F1, F2.
The fixed-side connector unit U includes the board 1 and the first and second fixed connectors F1, F2 mounted on the board 1. As shown in FIG. 3, the first and second fixed connectors F1, F2 are mounted on the board 1 so that their long sides are aligned along an arrangement direction of the fixed connectors F1, F2.
The fixed connectors F1, F2 include substantially rectangular tubular receptacles 2, 3 projecting forward (up in FIG. 1) in a connecting direction CD from the board 1. As shown in FIG. 3, guide projection shafts 4, 5 project unitarily from the back wall of the receptacle 2, 3 toward a connection surface of each fixed connector F1, F2 for guiding connection to the lever connectors L1, L2. Two guide projection shafts 4 are arranged substantially side by side in a longitudinal direction in the first fixed connector F1 and at least one guide projection shaft 5 is arranged substantially in a central part of the second fixed connector F2. Each guide projection shaft 4, 5 has a substantially crisscross cross-section. The guide projection shafts 4, 5 penetrate through the corresponding lever connector L1, L2 to reach a one-piece rubber plug 39 mounted in the lever connector L1, L2 when the fixed connectors F1, F2 and the lever connectors L1, L2 are connected.
Rod-shaped male terminal fittings 6 project in each of the receptacles 2, 3. In this embodiment, more male terminal fittings 6 are mounted in the first fixed-side connector F1 than in the second fixed connector F2, so that the first fixed connector F1 has more poles. Each male terminal fitting 6 is press-fit into the back wall of the corresponding receptacle 2, 3 and is bent down at a substantially right angle.
A protection wall 7 is provided on the rear of the board 1 for partly surrounding groups of the male terminal fittings 6 projecting from the board 1 (see FIGS. 4 and 30). The protection wall 7 is provided in a range from an upper edge part to opposite short sides of the board 1 and protrudes in a projecting direction of the male terminal fittings 6.
As shown in FIG. 4, tips of the male terminal fittings 6 are inserted into positioning holes 9 that penetrate though a long flat alignment plate 8. As shown in FIGS. 6 and 8, arrangement areas of groups of positioning holes 9 are separated to correspond to the fixed connectors F1, F2. As shown in FIG. 8, stepped edges 10 are formed on both longitudinal ends of the alignment plate 8, and a stepped hole 11 penetrates between the arrangement areas of the positioning holes 9 in the alignment plate 8. On the other hand, hooks 12 face each other on lower ends of the side parts of the protection wall 7, as shown in FIG. 5, and the alignment plate 8 is held by hooking the stepped edges 10 on the hooks 12. A vertical intermediate wall 13 projects back at a position between the first and second fixed connectors F1, F2 on the rear surface of the board 1, and an intermediate holding portion 14 in the form of a hook is formed on a lower part of the intermediate wall 13, as shown in FIGS. 5 and 7. The intermediate holding portion 14 is inserted into the stepped hole 11 of the alignment plate 8 to be locked. Thus, the alignment plate 8 is held at an intermediate part to prevent deflection.
Clips 15 project on the lower ends of the opposite side panels of the protection wall 7, as shown in FIG. 5. The clips 15 are inserted into holes (not shown) on the printed circuit board 16 and are locked resiliently, as shown in FIG. 4, for temporary holding the printed board 16 until the male terminal fittings 6 are inserted into through holes (not shown) of the printed circuit board 16 and soldered.
Cam followers 17 project on each of the opposite long side surfaces of the receptacle 2 of the first fixed connector F1 and hence are on the sides that extend along the arrangement direction AD of the fixed-side connectors. The cam followers 17 are in the form of pin shafts and, as shown in FIG. 1, are at height positions near the opening edge of the receptacle 2, but are shifted away from the second fixed-side connector F2 with respect to a center line in the longitudinal direction of the receptacle 2. On the other hand, cam followers 18 of the second fixed connector F2 are formed on opposite outer surfaces of the short sides of the receptacle 3, and hence are on the sides that are substantially perpendicular to the arrangement direction AD of the fixed connectors F1, F2. The cam followers 18 on the second fixed connector F2 are arranged in central parts of the opposite short side surfaces in a height direction HD (see FIG. 3) and are lower than the cam followers 17 on the first fixed connector (see FIG. 1).
A slider 19 is mounted into the first lever connector L1 (see FIGS. 28, 29) and functions as a force multiplying mechanism when engaged with the cam followers 17 of the first fixed connector F1. The first lever connector L1 also has a lever 20 for moving the slider 19 (see FIGS. 9 and 10). As shown in FIG. 12, the first lever connector L1 has an outer housing 21 and an inner housing 22 that is mounted in the outer housing 21.
The outer housing 21 is a substantially rectangular tube that is open toward a front end FS that will face the first fixed-side connector F1, and the interior of the outer housing 21 defines an accommodation space for the inner housing 22. A wire drawing surface 67 is defined at the rear surface of the back wall 23 of the accommodation space of the outer housing 21 and wire insertion holes 24 penetrate through the wire drawing surface 67. Wires W connected to female terminal fittings 25 are drawn out to the outside of the outer housing 21. The back wall 23 also has two escaping holes 69A for allowing the guide projection shafts 4 of the first fixed-side connector F1 to escape.
Slider accommodating chambers 26 are formed at inner surfaces of opposite long sides of the outer housing 21 for accommodating the slider 19, as shown in FIG. 12. The slider accommodation chambers 26 have insertion openings 27 on one short side surface of the outer housing 21, and hence on an outer surface in the arrangement direction AD of the fixed-side connectors, as shown in FIG. 13.
As shown in FIG. 14, entrance openings 28 are formed on a front wall of the outer housing 21 and are at positions to receive the respective cam followers 17 of the first fixed connector F1. The entrance openings 28 communicate with the corresponding slider accommodation chambers 26.
As shown in FIG. 13, the slider 19 has two arms 19A that project from a coupling 19B. The arms 19A are accommodated slidably in the slider accommodation chambers 26. Specifically, sides of the arms 19A that face one another are recessed to form cam grooves 29 corresponding to the cam followers 17 of the first fixed connector F1 (see FIG. 21). The cam grooves 29 guide the first fixed connector F1 and the first lever connector L1 to a connected state while being engaged with the corresponding cam followers 17 and produce a force multiplying action as the slider 19 is slid.
As shown in FIGS. 28 and 29, a deflectable locking claw 30 is formed on an upper edge near a free end of each arm 19A of the slider 19. On the other hand, first and second locking recesses 31, 32 are formed at spaced apart positions in a moving direction of the slider 19 in each slider accommodation chamber 26 of the outer housing 21. The locking claws 30 lock in the first locking recesses 31 (FIG. 28) to hold the slider 19 at a start position projecting out from the outer housing 21 in the arrangement direction AD of the first and second fixed connectors F1, F2. The entrances of the cam grooves 29 of the slider 19 communicate with the corresponding entrance openings 28 when the slider 19 is at the start position and can receive the cam followers 17 of the first fixed connector F1. Rear end surfaces of the locking claws 30 in an inserting direction of the slider 19 are inclined steeply and engage surfaces of the first locking recesses 31 to hold the slider 19 in the outer housing 21. On the other hand, front surfaces of the locking claw 30 are inclined more moderately. A specified pushing force applied to the slider 19 will release the locking claw 30 from the locked state in the first locking recesses 31 so that the slider 19 can move forward in a pushing direction. However, front surfaces of the locking claws 30 are sufficiently steep to avoid being released inadvertently from the locked state in the first locking recesses 31 unless a greater specified pushing force is applied to the slider 19.
The locking claws 30 are locked in the second locking recesses 32 (see FIG. 29) and the coupling 19B contacts a side wall surface of the outer housing 21 when the slider 19 is an end position. By this time, the cam followers 17 have reached the ends of the cam grooves 29 and the connection of the first fixed-side connector F1 and the first lever connector L1 has been completed. Note that a locking state of the locking claws 30 and the second locking recesses 32 can be released by applying a strong force to the slider 19 in a pulling direction.
As shown in FIG. 14, opposite side parts of the surface of the outer housing 21 formed with the insertion openings 27 for the slider are cut near the connection surface and rotary shafts 34 used to mount the lever 20 project in a short side direction.
The lever 20 is rotatable about the rotary shafts 34 between an initial position IP (FIG. 1) and a connection end position CEP (FIG. 2). The lever 20 has two lever plates 20A that straddle opposite long sides of the outer housing 21 and an operating portion 20B that couples ends of the lever plates 20A. The rotary shafts 34 are inserted into free ends of the lever plates 20A so that the entire lever 20 is rotatable about the rotary shafts 34. As shown in FIGS. 21 to 23, surfaces of the lever plates 20A that face one another are recessed to form linking grooves 33 in the form of long holes. Connection pins 35 on the outer surfaces of the arms 19A of the slider 19 near the coupling 19B fit into the linking grooves 33 so that the slider 19 can be slid in tandem with a rotational of the lever 20.
As shown in FIG. 1, step-like stopper edges 36 protrude out on the opposite long side surfaces of the outer housing 21 for preventing any further rotation of the lever 20 at the connection end position CEP. Specifically, the opposite long side surfaces of the outer housing 21 are so formed that lower areas below the stopper edges 36 protrude out. Each stopper edge 36 extends horizontally along the arrangement direction AD of the fixed connectors from an end part facing the second fixed connector F2 and then curves arcuately down toward the rotary shaft 34.
Inner surfaces of both lever plates 20A of the lever 20 have step-like contact edges 37 that conform to the shape of the stopper edges 36, as shown in FIGS. 22 and 23, and lower areas below the contact edges 37 protrude out. The contact edges 37 contact the stopper edges 36 to prevent rotation of the lever 20 at the connection end position CEP. Note that, as shown in FIG. 23, the outer surfaces of the operating portion 20B of the lever 20 and the outer short side surfaces of the outer housing 21 are substantially flush with each other when the lever is at the connection end position.
The coupling 19B of the slider 19 projects out from the outer housing 21 when the lever 20 is at the initial position IP and the slider 19 is at the movement start position MSP, as shown in FIG. 21. At this time, projecting edges 38 of the side edges of the lever plates 20A of the lever 20 corresponding to a projecting end part of the slider 19 in the shown height direction HD are at substantially the same position as or behind the projecting end part of the slider 19 in a mounting direction of the slider 19. Thus, external matter that approaches the projecting end part of the slider 19 from behind in the mounting direction of the slider 19 is more likely to contact the protecting edges 38 of the lever 20 than the projection end part of the slider 19. Further, as is also clear from FIG. 21, a distance from the rotary shafts 34 of the lever 20 to the protecting edges 38 is sufficiently shorter than a distance to the operating portion 20B of the lever 20 when viewed in a viewing direction of FIG. 21. Thus, a pushing force applied to the protecting edges 38 to release the locking claws 30 from the locked state is considerably larger as compared with the case where the operating portion 20B is operated. Therefore, the locking claws 30 are less likely to be released from the locked state when a pushing force is applied to the protecting edges 38 than when the same pushing force is applied directly to the slider 19.
As shown in FIG. 12, the resilient or one-piece rubber plug 39 is to be mounted on a rear surface side of the inner housing 22. A rubber plug accommodating portion 40 for accommodating the one-piece rubber plug 39 is formed in a rear part of the inner housing 22. The rubber plug accommodating portion 40 is formed inside a rectangular tubular part extending back from the peripheral edge of the rear end surface of the inner housing 22. As shown in FIG. 18, two lock projections 43 for the outer housing 21 are formed on a tip part of each of the upper and lower surfaces of a peripheral wall 42 of the inner housing 22. An interval between the lock projections 43 arranged on an upper side is narrower than that between the lock projections 43 on a lower side. On the other hand, as shown in FIGS. 26 and 27, the back wall 23 of the outer housing 21 is formed with lock receiving edges 44 corresponding to the respective lock projections 43. The lock projections 43 and the lock receiving edges 44 will not correspond due to an interval difference and interfere with each other if the inner housing 22 is attempted to be mounted into the outer housing 21 in an improper orientation e.g. a vertically inverted posture a proper posture so that the housings cannot be assembled.
The partition wall 41 of the inner housing 22 partitions between the rubber plug accommodating portion 40 and a terminal accommodating portion 46 for accommodating the female terminal fittings 25. Rear ends of cavities 47 for accommodating the female terminal fittings 25 are open on the partition wall 41 and communicate with wire insertion holes 45 of the one-piece rubber plug 39 and the wire insertion holes 24 of the back wall 23 of the outer housing 21. Two escaping holes 69B penetrate the partition wall 41 for allowing the guide projection shafts 4 of the first fixed connector F1 to escape. As shown in FIG. 12, the one-piece rubber plug 39 is to be mounted substantially in contact with the rear surface of the partition wall 41 and held by being sandwiched between the inner housing 22 and the back wall 23 of the outer housing 21 when the inner housing 22 is mounted into the outer housing 21.
FIG. 18 shows the inner housing 22 when viewed from the side of the rubber plug accommodating portion 40. As shown in FIGS. 18 and 19, positioning pins 48 are arranged on a rear surface side of the partition wall 41 along a central part in the height direction HD. Specifically, as shown in FIG. 18, arrangement areas of the wire insertion holes 45 formed in the partition wall 41 are divided in three rows e.g. according to the size of the female terminal fittings 25 to be inserted, and the positioning pins 48 are arranged at diagonal positions around the respective wire insertion holes 45 in the middle row in the middle arrangement area. Each positioning pin 48 is substantially cylindrical.
The one-piece rubber plug 39 is accommodated in the rubber plug accommodating portion 40 and three outer lips 49 are formed on the outer peripheral surface so that the one-piece rubber plug 39 can closely contact the inner peripheral surface of a peripheral wall of the rubber plug accommodating portion 40 in a sealed state. As shown in FIGS. 15 and 16, the wire insertion holes 45 penetrate the one-piece rubber plug 39. Two inner lips 50 are formed in each wire insertion hole 45 and contact the outer peripheral surface of an insulation coating of the wire W in a sealed state. Further, both front and rear surfaces of the one-piece rubber plug 39 are recessed to form positioning holes 51 at positions corresponding to the respective positioning pins 48 on the same axes. The positioning holes 51 are arranged at diagonal positions around the wire insertion holes 45 in the middle row and are located in a middle area of the one-piece rubber plug 39. Each positioning hole 51 has a diameter so that the positioning pin 48 can be press-fit therein and have a depth slightly longer than the entire length of the positioning pin 48. Further, as shown in FIG. 17, each positioning hole 51 has a narrowed portion 51A with a small diameter at a position near the back end. In this embodiment, as shown in FIG. 19, the narrowed portion 51A is formed at an axial position substantially aligned with an inner lip 50 in the wire insertion hole 45 of the one-piece rubber plug 39.
As shown in FIG. 12, forwardly open cavities 47 are formed in the terminal accommodating portion 46 of the inner housing 22 and receive the female terminal fittings. A deflectable locking lance 52 is formed in a front part of the interior of each cavity 47 and can resiliently lock the female terminal fitting 25.
As shown in FIG. 12, a front mask 53 is mounted on the front end surface of the terminal accommodating portion 46. The front mask 53 includes a part that communicates with the cavities 47 and accommodates front ends of the female terminal fittings 25 so that front ends of the female terminal fittings 25 contact stop walls 54 of the front mask 53. Each front stop wall 54 has a tab insertion hole 55 that receives the male terminal fitting 6 and a jig insertion hole 55A is formed adjacent to and below the table insertion hole 55. Further, as shown in FIGS. 11 and 25, the front mask 53 is formed with two escaping holes 69C for allowing the guide projection shafts 4 of the first fixed-side connector F1 to escape. Further, as shown in FIG. 25, left and right separate pressing pieces 56 extend toward a seal ring 57 on the upper edge of the surface of the front mask 53 facing the inner housing 22. The tips of the pressing pieces 56 rise up or out directly before the seal ring 57 to prevent the detachment of the seal ring 57. Left and right lock claws 58 are provided on a lower part of the seal ring 57. As shown in FIGS. 26 and 27, the lock claws 58 are locked in lock recesses 59 formed at corresponding positions of the lower surface of the terminal accommodating portion 46 of the inner housing 22 so that the front mask 53 can be mounted on the inner housing 22.
As shown in FIG. 12, a connection space S is between the outer peripheral surface of the terminal accommodating portion 46 and the inner surface of the outer housing 1 for receiving the first fixed connector F1. Further, the seal ring 57 is to be mounted on the outer peripheral surface of a back part of the terminal accommodating portion 46. The seal ring 57 can seal between the inner surface of the receptacle 2 of the first fixed connector F1 and the first lever connector L1.
A retainer insertion hole 60 is formed in the side surface of the terminal accommodating portion 46 of the inner housing 22 and a retainer 61 is movably mounted into the retainer insertion hole 60 (see FIG. 24). The retainer 61 is a substantially flat plate and has locking holes 64 corresponding to the respective cavities 47 and two escaping holes 69D for allowing the guide projection shafts 4 of the first fixed connector F1 to escape. A first locking claw 62 and a second locking claw 63 project on each opposite side edge of the retainer 61 in a longitudinal direction while being arranged substantially side by side in an inserting direction of the retainer 61. Although not shown in detail, the locking claws 62, 63 are engaged successively releasably with lock receiving portions formed in the retainer insertion hole 60 to hold the retainer 61 at a partial locking position (FIG. 26) and a full locking position (FIG. 27) with respect to the inner housing 22. When the retainer 61 is at the partial locking position, the female terminal fittings 25 are freely insertable into and withdrawable from the respective cavities 47. When the retainer 61 is at the full locking position, the female terminal fittings 25 are locked by the retainer 61 as well as by the locking lances 52 to be retained doubly.
The wire cover 66 corrects a drawing direction of the wires W drawn out from the first lever connector L1. As shown in FIG. 12, the wire cover 66 is mounted to cover the wire drawing surface of the outer housing 21 (rear surface of the back wall 23) and the lever 20 is mounted to straddle the wire cover 66. The wire 66 has a wire drawing opening 68 that opens substantially normal to the wire draw-out direction of the wires from the housing. In this embodiment, the wire drawing opening 68 is set to be open out in the arrangement direction of the first and second fixed connectors F1, F2.
Constituent members of the second lever connector L2 are basically similar to or the same as those of the first lever connector L1. Thus, no repeated description is given. The main differences are that the second lever connector L2 includes no slider, an operating direction of the lever 70 is substantially perpendicular to that of the first lever connector L1 and an opening direction of a wire drawing opening 72 of a wire cover 71 is substantially opposite to that of the first lever-side connector L1. Configurations relating to these differences are described below.
The lever 70 of the second lever connector L2 is mounted to straddle an outer housing 73 of the second lever connector L2 between opposite short side surfaces adjacent to a connection surface K and a wire drawing surface H, as shown in FIG. 33. A rotating direction of the lever 70 is perpendicular to the plane of FIG. 1 and along the opposite surfaces of the second fixed connector F2 where the cam followers 18 are provided. Thus, the rotating direction of the lever 70 of the second lever connector L2 particularly is substantially perpendicular to the rotating direction of the lever 20 of the first lever connector L1.
Inner surfaces of the lever plates 70A of the lever 70 are recessed to form cam grooves 74, as shown in broken line in FIGS. 33 and 35. The cam grooves 74 are engaged with the corresponding cam followers 18 of the second fixed-side connector F2 by the rotation of the lever 70 and guides the connectors F2, L2 to a connected state by a force multiplying action.
The lever 70 of the second lever-side connector L2 is also rotatable between an initial position (FIG. 33) and a connection end position (FIG. 35). Note that a mechanism for holding the lever 70 at the initial position is provided near a rotary shaft 75 of each of the lever plates 70A of the lever 70. The mechanism for holding at the initial position is known, and a detailed structure is not shown. Briefly, the lever plates 70A are provided with resiliently deformable hook-shaped partial holding means, which are configured to be engaged with the outer housing 73 to hold the lever 70 at the initial position, but automatically release a temporarily held state at the initial position by contacting a tip part of the second fixed connector F2 inserted into the second lever connector L2 when the second fixed connector F2 is fit lightly. A deflectable lock arm 76 is formed in the center of the operating portion 70B of the lever 70 and engages a receiving portion 77 (see FIG. 1) on a lower part of a side surface of the outer housing 73 for holding at the connection end position.
The wire cover 71 of the second lever-side connector L2 is to be mounted to cover a wire drawing surface of the outer housing 73 of the second lever connector L2. In this embodiment, the wire drawing opening 72 of the wire cover 71 of the second lever connector L2 is open out in the arrangement direction of the first and second fixed connectors F1, F2, i.e. in a direction substantially opposite to the opening direction of the first lever-side connector L1. Further, the wire drawing opening 72 of the wire cover 71 is widened to form a tape winding portion 78 (see FIG. 1).
The lever 20 of the first lever connector L1 is mounted to straddle the wire cover 66 mounted on the connector L1 as shown in FIG. 1, but the wire cover 71 of the second lever connector L2 is not mounted in such a manner. In other words, the operating direction of the lever 20 is along the drawing direction of the wires W from the wire cover 66 in the first lever connector L1, but the operating direction of the lever 70 and the drawing direction of the wires W are substantially perpendicular to each other in the second lever connector L2. Thus, when the lever 70 is at the initial position shown in FIG. 33 close to the wire cover 71, it may interfere with the wire cover 71. However, the wire cover 71 is formed with a constricted portion 79 along a longitudinal direction of a correcting portion 71A, as shown in FIGS. 33 and 35.
The wire cover 71 of the second lever connector L2 includes a base 71B for mounting on the outer housing 73 and the hollow correcting portion 71A unitarily projecting from the base 71B, extending substantially parallel to a direction of a rotation axis of the lever 70 and configured to correct the drawing direction of the wires W.
As shown in FIGS. 33 and 35, the correcting portion 71A rises substantially straight near the center while opposite sides of a base form curved surfaces of the constricted portion 79. Contrary to this, as shown in FIG. 27, a correcting portion 66A is formed to start rising at a position near a side edge of a base 66B and, then to narrow gradually toward a projecting end in the wire cover 66 of the first lever-side connector L1. In this way, in contrast to the first lever connector L1, the wire cover 71 of the second lever connector L2 is formed so that the correcting portion 71A rises at once via the constricted portion 79 from side edges of the base 71B an inner space of the wire cover 71 is narrowed in an intermediate position. This causes the wires W in the wire cover 71 to be collected and accommodated in an upper space in the wire cover 71. This prevents the wires W in the wire drawing opening 72 from being loosened downward so that a tape winding operation can be performed smoothly on the tape winding portion 78. Further, the formation of the wire cover 71 with the constricted portion 79 contributes to avoiding interference with the operating portion 70B when the lever 70 is at the initial position.
The second lever connector L2 is connected lightly to the second fixed-side connector F2 along a direction CD shown in FIG. 1 in a state where the lever 70 is at the initial position shown in FIG. 33. Then, the cam followers 18 of the second fixed connector F2 enter the cam grooves 74 of the lever 70 of the second lever connector L2. The lever 70 then is rotated in a counterclockwise direction shown in FIGS. 33 and 36, so that the cam followers 18 displace along the cam grooves 74 and the connection proceeds by a force multiplying action. The second fixed connector F2 and the second lever-side connector L2 reach a properly connected state when the lever 70 reaches the connection end position shown in FIGS. 2 and 35 and is held thereat.
The first lever connector L1 is held at the initial position shown in FIG. 1 prior to connecting the first lever connector L1 to the first fixed connector F1. At this time, the locking claws 30 are locked in the first locking recesses 31 to hold the slider 19 at the start position shown in FIG. 28. The first lever connector L1 then is connected lightly to the first fixed-side connector F1 along a direction CD shown in FIG. 1 so that the cam followers 17 of the first fixed connector F1 enter the corresponding cam grooves 29. The lever 20 then is rotated counterclockwise, as shown in FIG. 28. Thus, the locking state of the locking claws 30 and the first locking recesses 31 is released and the slider 19 is displaced toward the back in the slider accommodation chamber 26 as the lever 20 rotates. Accordingly, the cam followers 17 are displaced along the corresponding cam grooves 29 with a force multiplying action that connects the first fixed connector F1 and the first lever connector L1. The locking claws 30 lock into the second locking recesses 32 when the lever 20 reaches the connection end position shown in FIG. 29 and the slider 19 reaches the movement end position, thereby holding the first fixed connector F1 and the first lever connector L1 in a properly connected state.
The surfaces of the laterally adjacent first and second fixed-side connectors F1, F2 that have the cam followers 17, 18 are substantially perpendicular to each other. Additionally, the rotating directions of the levers 20, 70 of the first and second lever connectors L1, L2 are substantially perpendicular to each other. Thus, the levers 20, 70 will not interfere with each and a distance between the fixed connectors F1, F2 can be shortened. Therefore, the fixed-side connector unit U can be made smaller than the prior art connector with parallel levers.
The slider 19 mounted into the first lever connector L1 projects out from the outer housing 21 at the start position in the arrangement direction of the fixed connectors F1, F2. This also contributes to the shortening of the distance between the both fixed connectors F1, F2.
The wires W are drawn out at opposite outer sides in the arrangement direction of the fixed connectors F1, F2 in the lever connectors L1, L2, thereby further shortening the distance between the fixed connectors F1, F2.
A space where the lever 70 is rotated is different from a space where the wire cover 71 projects. Thus, the length of the lever 70 can be set independently of the projecting height of the wire cover 71, thereby enabling the miniaturization of the lever 70.
The wire cover 71 of the second lever-side connector L2 has the correcting portion 71A that rises from the base 71B via the constricted portion 79 to narrow the inner space in the central part of the wire cover 71. Thus, the wires W are collected in the space above the constricted portion 79 and easily can be taped together with the wire cover 71.
The operating portion 70B of the lever 70 is located along an extending direction of the constricted portion 79 and is near the constricted portion 79 when the lever 70 is at the initial position. Thus, the lever 70 does not interfere with the wire cover 71.
The positioning holes 51 of the one-piece rubber plug 39 have the narrowed portions 51A at axial intermediate positions. Thus, material around the narrowed portions 51A displaces toward the adjacent wire insertion holes 45 when the positioning pins 48 of the inner housing 22 are press-fit so that press-contact forces applied to the insulation coatings of the wires W is increased and sealing is improved.
Axial positions of the narrowed portions 51A in the positioning holes 51 align with the inner lips 50 to further improve sealing with the wire insulation coating.
The positioning holes 51 are arranged at diagonal positions around the respective wire insertion holes 45. Thus sealing forces for the wires W are circumferentially uniform while narrowing intervals between the wire insertion holes 45 as much as possible.
The protecting edges 38 of the first lever connector L1 partly surround the end of the slider 19 projecting from the outer housing 21 at the initial position and are close to the rotary shafts 34. Thus, the slider 19 is not likely to be pushed inadvertently.
The lever 20 has two lever plates 20A for holding the slider 19 therebetween and the rear edges of the lever plates 20A define the protecting edges 38. Thus, external matter is likely to contact the protecting edges 38 instead of with the slider 19, and the slider 19 is not likely to be pushed inadvertently.
The invention is not limited to the above described embodiment. For example, the following embodiments are also included in the scope of the invention.
The slider 19 and the lever 20 are mounted on the first lever connector L1 in the above embodiment. However, only one of them may be mounted. Conversely, both the lever 70 and a slider may be mounted on the second lever connector L2.
The housings of the first and second lever connectors L1, L2 have outer and inner members, but may be a single member. In such a case, the back wall 23 of the housing may be formed separately, and the separately formed back wall 23 may be formed with positioning pins that are inserted into the positioning holes 51 formed in the front and rear surfaces of the one-piece rubber plug 39.
Positioning holes 51 are formed in front and rear surfaces of the one-piece rubber plug 39, but they may be in only the surface facing the inner housing 22.
The retainer 61 is held at the partial locking position and the full locking position in the above embodiment, but the partial locking position may not be provided.
The front mask 53 is mounted on the inner housing 22 from front, but it may be mounted in a direction at an angle to the connecting direction.
The retainer 61 is mounted in the deflecting direction of the lock claws 58 in the above embodiment, but may be mounted at an angle to the deflecting direction.

## Claims

1. A connector with a one-piece resilient plug including wire insertion holes and configured to collectively seal wires drawn out from a rear end surface of a housing by inserting the wire into the wire insertion hole, each of the wire insertion holes having an inner peripheral surface with at least one inner lip that closely contacts an insulation coating of the wire comprising:
two wall surfaces for sandwiching the one-piece resilient plug from front and rear substantially in an inserting direction of the wires; and
at least one positioning pin projecting from one of the wall surfaces toward the one-piece resilient plug and being substantially parallel with an axial direction of the wire insertion holes, the positioning pin being inserted and press-fit into at least one positioning hole arranged near the wire insertion holes;
a narrowed portion being formed at an axial intermediate position of the positioning hole and defining a reduced diameter in the positioning hole, the narrowed portion in the positioning hole being aligned with a top of the inner lip.

2. The connector of claim 1, wherein the positioning hole is one of plural positioning holes, the positioning holes being arranged at substantially diagonally symmetric positions with respect to the wire insertion hole.

3. The connector of claim 1, further comprising a slider accommodated movably in the connector, the slider including a cam groove to be engaged with a cam follower on a mating connector to produce a force multiplying action by displacing a lever provided on the connector while the cam groove and the cam follower are engaged.

4. The connector of claim 3, wherein the slider is movable between a start position where the cam follower is received and an end position where connection of the connector with the mating connector is finished, the slider projecting out from the connector at the start position.

5. The connector of claim 1, wherein the housing is configured for connection a mating connector, a lever being mounted displaceably to extend between opposite side surfaces of the housing; and a wire cover projecting out from the housing while at least partly covering a wire drawing surface formed on a surface facing opposite from a connection surface of the housing and configured to correct a wiring direction of the wires drawn out from the wire drawing surface; the lever being mounted between the opposite side surfaces of the housing and between the connection surface and the wire drawing surface, the lever being displaceable substantially along the connecting direction between the connection surface and the wire drawing surface.

6. The connector of claim 5, wherein the wire cover includes a base mounted on the housing and open toward the wire drawing surface, and a correcting portion that rises from a peripheral edge of the base via a constricted portion to narrow an inner space from the base.

7. A connector according to claim 6, wherein the correcting portion of the wire cover extends and projects from the base in a direction substantially parallel to a rotation axis of the lever via the constricted portion; and the lever comprises two lever plates mounted on the housing and an operating portion coupling the lever plates, the lever being positioned at an initial position before connection to the mating connector, and the operating portion of the lever being located along an extending direction of the constricted portion and near the constricted portion at the initial position.

8. The connector of claim 1, wherein the connector comprises a force multiplying mechanism that produces a force multiplying action for connecting the connector to a mating connector, the force multiplying mechanism comprising a slider mounted through a side surface of the housing and being slidably movable in a direction intersecting a connecting direction, the slider being formed with at least one cam groove engageable with at least one cam follower provided on the mating connector; the force multiplying mechanism further comprising a lever including an operating portion on one end part and displaceably mounted on the connector housing while being interlockingly coupled to the slider; wherein:
the slider is movable with respect to the housing between a start position where the cam follower is received in the cam groove while the slider projects back in a mounting direction thereof and an end position reached by inserting the slider deeper into the housing from the start position to properly connect the connector with the mating connector;
at least one of the slider and the lever includes a lock that holds the slider at the start position by being locked to the housing, but is releasable from a locking state to the housing by displacing the lever;
the lever having at least one protecting edge at substantially a same height position as a projecting end of the slider from the housing when the slider is at the start position, the protecting edge being located substantially at the same position as or behind the projecting end in the mounting direction of the slider.

9. A connector of claim 8, wherein the lever is rotatably mounted on the housing via at least one rotary shaft, and wherein a distance from the rotary shaft to the protecting edge is to be shorter than a distance from the rotary shaft to the operating portion.

10. The connector of claim 9, wherein the lever comprises two lever plates and an operating portion coupling the lever plates, the lever plates being mounted to straddle between opposite side surfaces adjacent to a surface, through which the slider is mounted, and the protecting edge is formed on each of the both lever plates to sandwich the projecting end part of the slider.

11. A connector assembly with a force multiplying mechanism, comprising:
a plurality of fixed connectors arranged substantially side by side on and each of which includes a cam follower, surfaces of the fixed connectors that have the cam followers are substantially perpendicular to each other; and
a plurality of lever connectors each of which includes housing a lever displaceably mounted on the respective housing, the lever connectors being individually connectable to the respective fixed connectors by a force multiplying action produced by displacing the lever while the cam follower and the lever are directly or indirectly engaged, at least one of the lever connectors including a one-piece resilient plug with wire insertion holes configured for receiving wires drawn out from a rear end surface of a housing, the one-piece resilient plug being sandwiched between two wall surfaces of the lever connector from front and rear substantially in an inserting direction of the wires, and positioning pins projecting from one of the wall surfaces toward the one-piece resilient plug and being substantially parallel with an axial direction of the wire insertion holes, the positioning pin being inserted into at least one positioning hole arranged near the wire insertion holes, and a narrowed portion being formed at an axial intermediate position of the positioning hole and defining a reduced diameter in the positioning hole.

12. A connector, comprising:
an inner housing having a rear surface and wires drawn out from the rear surface;
an outer housing with a back wall opposed to the rear surface of the inner housing, the back wall having wire insertion holes for receiving the wires drawn out from the rear surface of the inner housing;
positioning pins projecting from at least one of the rear surface of the inner housing and a surface of the back wall of the outer housing that faces the rear surface of the inner housing; and
a one-piece resilient plug including wire insertion holes through which the respective wires pass so that the one-piece rubber plug collectively seals the wires drawn out from the rear surface of the inner housing, each of the wire insertion holes having an inner peripheral surface with at least one inner lip that closely contacts an insulation coating of the respective wire, the one-piece resilient plug being sandwiched from front and rear substantially in an inserting direction of the wires between the rear end surface of the inner housing and the back wall of the outer housing, positioning holes arranged near the wire insertion holes and extending only part way through the one-piece resilient plug, each of the positioning holes being aligned respectively with the positioning pins and being dimensioned to have the positioning pins press-fit therein, each of the positioning holes having a narrowed portion formed at an axial intermediate position of the respective positioning hole and defining a reduced diameter in the positioning hole, the narrowed portion in the positioning hole being aligned with tops of the inner lips of the wire insertion holes in proximity to the respective positioning holes.