Waterproof connector and method for assembling the same

Abstract: A waterproof connector includes elastic material, seal portion (14) formed on a female connector housing (10) by double molding in such a manner that the seal portion closes openings through which wires (50) are guided, respectively, and covers a flange (12) formed on an outer periphery of the female connector housing (10). The seal (14) portion has a watertight surface at its front side. A male connector housing (30) has hood portions for receiving the female connector housing. The hood portion includes a front end having an abutment surface for abutment against the watertight surface. With this construction, as the male and female connector housings engaged, metal terminals (40,60) are fittingly connected together, and each abutment surface is brought into contact with an associated watertight surface, thereby sealing a gap between the two connector housings (10,30).

Description: This invention relates to a waterproof connector and a method for assembling the same. More particularly, this invention relates to a waterproof connector that is molded in a double manner, using elastic resin. The double manner comprises a one-piece molding including first and second integral sections. Figs. 7 and 8 show a conventional waterproof connector comprising a male connector housing 1 and a female connector housing 2. Each housing has a plurality of metal terminal receiving chambers 3 having a tubular shape. A male metal terminal 5, which has a wire 4 connected thereto, is inserted into each terminal receiving chamber 3 of the male connector housing through one open end thereof, and a female metal terminal 6 is inserted into each terminal receiving chamber 3 of the female connector housing through one open end thereof. The male connector housing 1 has a hood portion 7 for receiving the female connector housing 2, and a ring-shaped rubber seal member 8 is mounted on the outer periphery of the female connector housing 2. The seal member 8 cooperates with an inner peripheral surface of the hood portion 7 to form a watertight seal therebetween when the female connector housing is inserted into the hood portion 7. After the male metal terminals 5 and female metal terminals 6 are inserted into the metal terminal receiving chambers 3, respectively, molten elastic resin 9 is applied to the open ends of the terminal receiving chambers 3 to form an inner molding (double molding) to close the gap. When the male and female connector housings 1 and 2 are connected together, the rubber seal member 8 seals the gap between the male and female connector housings 1 and 2 in a waterproof manner, and the open ends of the metal terminal receiving chambers 3 are sealed by the elastic resin 9. Thus the double molding uses a first molding in which a seal member is molded to the female connector housing and a second molding in which elastic resin seals the open ends of the terminal receiving chambers. In the above conventional waterproof connector, the rubber seal member 8 is required for sealing the gap between the male and female connector housings 1 and 2 in a waterproof manner. Therefore, the number of the component parts is increased and considerable time and labor are required for mounting the conventional seal member. US-A-4,707,045 shows a sealing member or subassembly which is assembled with terminals as integral unit. Then said integral unit is bonded to the inside surface of a housing member. Therefore this known connector needs two assembling steps for providing or inserting the molding in order to have a watertight fit between two connector housings. US-A-5,197,898 discloses a multi-contact electrical connector with a one-piece seal. From this known connector the present invention starts from in the preambles of claims 1 and 14, respectively. The seal or sealing member in case of US-A-5,197,898 is for two purposes, namely for holding the terminals or wires, respectively, in a watertight manner and for sealing the two connector housings in a watertight manner, when said housings are connected. However, the sealing member of US-A-5,197,898 has a rather complicated structure with a plurality of projections or fingers for providing a seal in radial direction and even with an undercut in case of the embodiment according to Fig. 3 of US-A-5,197,898, said undercut housing the fingers. Especially the embodiment according to Fig. 2 of US-A-5,197,898 can be somehow compared with the above discussed Fig. 7 of the present application showing prior art, as in both cases the seal acts in a radial direction. The sealing member acting in a radial direction is a disadvantage of the connector according to US-A-5,197,898, as this makes molding complicated due to the complicated structure of the sealing member with the plurality of circumferencel protections and/or the circumferencel undercut. Moreover, the connector of US-A-5,197,898 needs two assembling steps. Furthermore, the sealing member of US-A-5,197,898 needs an accurately molded or processed surface for contact with the respective counter-surfaces at the connector housings. Such accurate surfaces, however, are different to accomplish due to the complicated shape of the mold, as the sealing member substantially acts in a radial direction, as already outlined above. The present invention has been made in view of the above problems, and an object of the invention is to provide a waterproof connector in which the number of component parts is reduced to reduce the cost, and the mounting operation is simplified. Solution of this object is achieved by what is claimed in claims 1 or 14, respectively. According to a first aspect of the invention, there is provided a waterproof connector comprising: a connector housing having wire openings for metal terminal receiving chambers into which wires with metal terminals are guided; and a mating connector that is to be sealed in a waterproof manner with said connector housing, wherein a gap between said connector housing and said mating connector is sealed in a waterproof manner, said waterproof connector furthermore comprising: a seal that uses elastic material for providing a waterproof seal between said connector housing and said mating connector, with said wires kept in an inserted condition, wherein said seal is provided on the outer periphery of the rear portion of the connector housing and includes first and second integral sections, said first section closing said wire openings and said second section forming a front sealing side on a front side of said molding for abutting against an abutment surface of said mating connector in a watertight manner when said connector housing is fittingly connected to said mating connector, the connector being characterized in that said seal being a one-piece molding which is molded to said connector housing as one piece and forms a seal portion. According to a second aspect of the present invention there is provided a method for assembling a waterproof connector, said method comprising the steps of: providing a connector housing having wire openings for metal terminal receiving chambers and guiding metal terminals with wires extending therefrom into said metal terminal receiving chambers; providing a mating connector that is to be sealed in a waterproof manner with said connector housing, wherein a gap between said connector housing and said mating connector is sealed in a waterproof manner; providing a seal that uses elastic material for providing a waterproof seal between said connector housing and said mating connector, with said wires kept in an inserted condition, said method furthermore comprising the steps of: forming said seal to said connector housing by a single molding step as one piece such as to form a seal portion in the outer periphery of the rear portion of said connector housing including first and second integral sections, said first section closing said wire openings and said second section forming a front sealing side on a front side of said molding; and fitting said connector housing to said mating connector such that said front sealing side is abutted against an abutment surface of said mating connector in a watertight manner. Thus, in case of the present invention the molding inside the connector housing which is made under use of an elastic material for providing a waterproof seal between the two connector housings to be connected is a one-piece-molding forming a seal portion with first and second integral sections, said first and second integral sections are for a different purposes, namely holding the wires in place in a watertight manner and providing a sealing surface for the mating connector. In other words, the molding member is a one-piece-member for simultaneously accomplishing two different functions namely holding the wires and sealing the connector. "Double-molding", "molding in a double manner" or similar expressions, as they are is used in the description to follow, means that in manufacturing the connector according to the present invention, a first molding step is used to mold the female connector housing and then a second molding step is used to mold a sealing member such that it is integrated with the female connector housing with the wires kept in an inserted condition. Accordingly, the sealing member according to the present invention is molded to the (beforehand molded) female connector housing as one piece by one step. The elastic material closes the openings of the metal terminal receiving chambers through which the wires are guided, respectively, and forms the watertight surface that closes the gap between the connector and the mating connector housing. Therefore, when the connector is connected to the mating connector, the watertight surface is held in sealing engagement with the mating connector to provide a waterproof fit. As described above, in the present invention, the seal portion, which closes the openings of the metal terminal receiving chambers, is formed of the elastic material by double molding, and has a watertight surface for contact with abutment surface of the mating connector. Therefore, a similar effect as achieved by the provision of a rubber seal is obtained and the number of the component parts of the waterproof connector is reduced, as well as requiring less time and labor for the mounting operation. Preferred embodiments of the present invention will now be described with reference to the drawings, wherein: Fig. 1 is a cross-sectional view of one preferred embodiment of a waterproof connector of the present invention; Fig. 2 a front-elevational view showing female connector housings; Fig. 3 is a cross-sectional view of the female connector housing; Fig. 4 is a front-elevational view of a frame; Fig. 5 is a front-elevational view of a male connector housing; Fig. 6 is a cross-sectional view of the waterproof connector; Fig. 7 is a cross-sectional view of a conventional waterproof connector; and Fig. 8 is a cross-sectional view of the conventional waterproof connector. Fig. 1 is a cross-sectional view of one preferred embodiment of a waterproof connector of the invention. Four female connector housings 10 (see Figs. 2 and 3) having a generally tubular shape are received in a juxtaposed manner and held in a frame 20 (see Fig. 4). A male connector housing 30 (see Fig. 5) having an integral construction has four convex portions that face the four female connector housings 10, held by the frame 20, respectively. The female connector housings 10 shown in Figs. 2 and 3 have a tubular and generally rectangular cross-sectional shape. Two (upper and lower) rows of juxtaposed metal terminal receiving chambers 11 having a tubular shape are formed in the female connector housing 10. The metal terminal receiving chamber 11 has opposite open ends disposed respectively at the opposite ends of the female connector housing 10. When a female metal terminal 40 is inserted into the metal terminal receiving chamber 11 through the rear end thereof, the female metal terminal 40 is held in the metal terminal receiving chamber 11, with a wire 50 (connected to the female metal terminal 40) extending from the metal terminal receiving chamber 11. A flange 12 is formed on the entire outer periphery of the female connector housing 10 at the rear end portion thereof, and a positioning projection 13 is formed on a central portion of each of the upper and lower portions of the flange. The female metal terminals 40 are attached and, in this condition, elastic resin is molded in a double manner to form a seal portion 14 on the outer periphery of the rear end portion of the female connector housing. The seal portion 14 closes the rear open ends of the metal terminal receiving chambers 11 and covers the flange 12 in a manner that also covers a front side thereof. In such a configuration, the seal portion 14 increases the outer diameter of the female connector housing 10. The front surface of the seal portion is flat and serves as a watertight surface 14a. In this embodiment, although elastic resin is used as the elastic material, any other suitable material such as rubber can be used in so far as it achieves a waterproof effect. In this embodiment, the seal portion can be provided around the sealed portion in a manner that also covers a fitting surface and thus the seal portion can be modified in any shape in accordance with the surface of contact of the male connector housing 30. The projections 13 project from the seal portion 14. Housing receiving holes 21 having a tubular shape are formed in the frame 20 and correspond in shape with the associated female connector housings 10, respectively. Each housing receiving hole 21 has a pair of notches 22 formed in central portions of the upper and lower walls of the frame 20. The notches 22 are open to the rear side of the frame 20 so that each female connector housing 10 can be inserted into the associated housing receiving hole 21 from the rear side. The notch 22 is generally equal in width to the projection 13. The projections 13 of each female connector housing 10 are brought into registry with the notches 22 of the associated housing receiving hole 21, respectively. Then, the female connector housing 10 is inserted into the housing receiving hole 21, so that the female connector housing 10 can be guided to be disposed centrally in the housing receiving hole 21. Elastic engagement pawls 23 are formed on the inner peripheral surface of the housing receiving hole 21 adjacent to the rear end of the frame 20 and project into the housing receiving hole 21. Each engagement pawl 23 projects inward of the inner peripheral surface of the housing receiving hole 21 progressively from the rear side of the frame toward the front side thereof. As the female connector housing 10 is inserted into the housing receiving hole 21, the engagement pawl 23 flexes outward of the inner peripheral surface to slidingly contact the outer periphery of the seal portion 14. When the female connector housing is inserted until the projections 13 engage the inner ends of the notches 22, respectively, the seal portion 14 passes the engagement pawls 23 so that the engagement pawls 23 are restored outward of the inner peripheral surface to engage the rear surface of the seal portion 14. A stepped portion 14b is formed at the rear surface of the seal portion 14 and is engagable with the engagement pawls 23. The step portion 14b covers the rear side of the flange 12 and causes the flange 12 to bear the load. In this embodiment, although the female connector housings 10 are adapted to be supported by the frame 20, it is not always necessary to provide separate female connector housings, and the female connector housings can be formed integrally with the frame. Each male connector housing 30 supports male metal terminals 60 in a projected manner, the terminals being arranged to be aligned respectively with the female metal terminals 40 received in the female connector housings 10. Four hood portions 31 having a tubular shape surround the corresponding male metal terminals 60 and are formed on the male connector housing 30. Each hood portion 31 is sized to receive an associated female connector housing 10. The front end of the hood portion 31 projects only at its outer peripheral portion to provide an annular portion. The annular portion has an inner diameter that engages the outer peripheral surface of the seal portion 14. A generally flat abutment surface 31a, disposed inward of the annular portion, is adapted to engage the watertight surface 14a of the seal portion 14. An annular projection 31a1 is formed on the abutment surface 31a and extends toward the watertight surface 14a. In this embodiment, although the front or distal end of the hood portion 31 is adapted to abut against the seal portion 14, the seal portion may be provided at the front end portion of the female connector housing 10, in which case the seal portion 14 abuts against the inner end wall of the hood portion 31. Although the front end of the hood portion 31 projects only at its outer peripheral portion, only the abutment surface 31a may be provided at the front end. However, by providing such a projected outer peripheral portion, the abutment surface 31a is less liable to be damaged. A pair of projections 32 is formed respectively on the upper and lower surfaces of the male connector housing 30. The projections are disposed centrally of the width of the housing. Engaging levers 24 are provided on the frame 20 and are adapted to be engaged respectively with the projections 32 so as to draw the projections. A cover 70 is attached to the rear end of the frame 20 and leads the wires 50 out in a collective manner. An assembling method and the operation of this embodiment of the above construction will now be described. With respect to the female connector housing 10, the wires 50 are clamped and connected to the female metal terminals 40, respectively, and the metal terminals are inserted into the metal terminal receiving chambers 11, respectively. After the female metal terminals 40 are thus inserted into all the metal terminal receiving chambers 11, respectively, the double molding is formed by the use of elastic resin, with the wires 50 held in a led-out condition. The elastic resin forms a seal portion 14 that closes the rear open ends of the metal terminal receiving chambers 11 and covers the flange 12. The female connector housing 10 is inserted into the housing receiving hole 21 in the frame 20 from the rear side thereof. As the connector housing is inserted with the projections 13 received respectively in the notches 22 in the frame 20, the outer peripheral surface of the seal portion 14 is brought into engagement with the engagement pawls 23 to flex the pawls outward. When the projections 13 abut against the inner ends of the notches 22, respectively, the seal portion 14 passes the engagement pawls 23 so that the engagement pawls 23 are restored to engage the step portion 14b formed at the rear side of the seal portion 14. In this condition, the projections 13 are held against the inner ends of the notches 22, thereby preventing a forward movement of the female connector housing. Also, the engagement pawls 23 are engaged with the rear surface of the seal portion 14, thereby preventing a rearward movement of the female connector housing, so that the female connector housing is held in a fixed condition. The male metal terminals 60 are attached to the male connector housing. The hood portions 31 are inserted respectively into the housing receiving holes 21 from the front side of the frame 20. During the inserting operation, the projections 32 are engaged respectively in spiral grooves formed respectively in the engagement levers 24, and the engagement levers 24 are turned to draw the projections 32 into the spiral grooves, respectively, so that the male connector housing 30 is moved toward the frame 20. As the hood portions 31 are inserted respectively into the housing receiving holes 21, the male metal terminals 60 are inserted respectively into the front open ends of the metal terminal receiving chambers 11 of the female connector housings 10. Then, male metal terminals 60 are fitted in and connected to the female metal terminals 40, respectively. When the engagement levers 24 are fully turned, the front end of each of the hood portions 31 is held against the seal portion 14. The outer peripheral portion of the seal portion 14 is received in the annular portion formed at the front end of the hood portion 31, and the watertight surface 14a defined by the front surface of the seal portion 14 is held against the abutment surface 31a of the hood portion 31. At this time, the annular projection 31a1, formed on the abutment surface 31a, bites into the watertight surface 14a of the elastic resin, thus enhancing the waterproof effect. The elastic material, such as elastic resin, is thus molded on the female connector housing 10 in a double manner to form the seal portion 14 which closes the open ends through which the wires 50 are guided. Seal portion 14 covers the flange 12, which is formed on the outer periphery of the female connector housing 10, and has a watertight surface 14a at its front side. The hood portions 31 for respectively receiving the female connector housings 10 are formed on the male connector housing 30. The abutment surface 31a is formed at the front end of each hood portion 31 so as to abut against the watertight surface 14a. Therefore, the two surfaces 14a and 31a are opposed to each other and are moved toward each other so that the male metal terminals are fittingly connected to the female metal terminals. Each abutment surface 31a abuts against the associated watertight surface 14a, thereby sealing the gap between the two connector housings 10 and 30 in a waterproof manner. Although the above embodiment is directed to the so-called lever-type connector having the engagement levers 24, the invention can be applied to a connector of the ordinary type. The invention has been described with reference to preferred embodiments thereof, which are intended to be illustrative, not limiting. Various modifications will be apparent to those of ordinary skill in the art and are intended to be encompassed within the scope of the invention, as set forth in the appended claims.

Claims: A waterproof connector comprising: a connector housing (10) having wire openings for metal terminal receiving chambers (11) into which wires (50) with metal terminals (40) are guided; and a mating connector (30) that is to be sealed in a waterproof manner with said connector housing (10), wherein a gap between said connector housing (10) and said mating connector (30) is sealed in a waterproof manner, said waterproof connector furthermore comprising: a seal that uses elastic material for providing a waterproof seal between said connector housing (10) and said mating connector (30), with said wires (50) kept in an inserted condition, wherein said seal is provided in the outer periphery of the rear portion of the connector housing (10) and includes first and second integral sections, said first section closing said wire openings and said second section forming a front sealing side (14a) on a front side of said seal for abutting against an abutment surface (31a) of said mating connector (30) in a watertight manner when said connector housing (10) is fittingly connected to said mating connector (30), characterized in that said seal being a one-piece molding which is molded to said connector housing (10) as one piece and forms a seal portion (14). The connector according to claim 1, wherein said abutment surface (31a) furthermore comprising an annular projection (31a1) for biting into said front sealing side (14a) of said seal (14), when said connector housing (10) is fittingly connected to said mating connector (30). The connector according to claim 1 or 2, wherein said connector housing (10) is a female connector housing and wherein said mating connector (30) is a male connector housing. The connector according to claim 3, wherein said female connector housing has an upper row and a lower row of a plurality of female metal terminal receiving chambers (11) having a tubular shape, said plurality of female metal terminals (40) being insertable within said plurality of female metal terminal receiving chambers(11); and said male connector housing having a corresponding plurality of male metal terminal receiving chambers, said plurality of male metal terminals (60) being insertable within said plurality of male metal terminal receiving chambers. The connector according to claim 3 or 4, wherein said female connector housing has a flange (12) formed on an outer periphery of said female connector housing, said flange (12) having upper and lower portions, each of said upper and lower portions having a positioning projection (13) formed on a central portion of each of said upper and lower portions. The connector according to claim 5, wherein said second integral section of said seal portion (14) is molded around said flange (12), said second integral section forming a stepped portion (14b) on a rear side of said flange (12) and a flat portion (14a) on a front side of said flange (12), said positioning projections (13) projecting from said second integral section. The connector according to anyone of claims 3 to 6, further comprising: a plurality of said female connector housings having a generally tubular shape, said plurality of female connector housings being disposed and held in a frame (20); and a corresponding plurality of said male connector housings forming an integral structure with said plurality of female connector housings. The connector according to claim 7, wherein said frame (20) has a plurality of housing receiving holes (21) of a tubular shape formed therein, each of said plurality of housing receiving holes (21) has a pair of notches (22) formed in an upper wall and a lower wall of said frame (20), each of said pair of notches (22) being open to a rear side of said frame allowing said plurality of female connector housings to be insertable into a corresponding one of said plurality of housing receiving holes (21); and each of said pair of notches (22) being generally equal in width to said positioning projection (13) allowing said plurality of female connector housings to be centrally disposed in said plurality of housing receiving holes (21). The connector of claim 8, wherein each of said plurality of housing receiving holes (21) has a plurality of engagement pawls (23) formed on an inner peripheral surface of each of said plurality of housing receiving holes (21); and each of said plurality of engagement pawls (23) being adjacent to said rear side of said frame (20) and projecting inwardly of said inner peripheral surface for engaging said stepped portion (14b) of second integral section. The connector according to anyone of claims 3 to 9, wherein each of said plurality of male connector housings has a hood portion (31) of tubular shape and an inner diameter allowing insertion of said female connector housings; said hood portion (31) having a flat abutment surface (31a) for engaging said flat portion (14a) of said second integral section; and said flat abutment surface (31a) having an annular projection projecting outwardly. The connector according to claim 10, wherein said male connector housing has a pair of projections (32) formed on an upper and lower structure surface of said male connector housing, said pair of projections (32) being disposed centrally of a width of said male housing; and said frame (20) having a pair of engaging levers (24), said pair of engaging levers (24) being adapted to engage said pair of projections (23) to form said integral structure. The connector according to anyone of claims 7 to 11, wherein said frame (20) has a cover (70) attached to said rear side. The connector according to anyone of claims 3 to 12, wherein said female connector housing has a tubular shape and a generally rectangular cross-sectional shape. A method for assembling a waterproof connector, said method comprising the steps of: providing a connector housing (10) having wire openings for metal terminal receiving chambers (11) and guiding metal terminals (40) with wires (50) extending therefrom into said metal terminal receiving chambers (11); providing a mating connector (30) that is to be sealed in a waterproof manner with said connector housing (10), wherein a gap between said connector housing (10) and said mating connector (30) is sealed in a waterproof manner; providing a seal that uses elastic material for providing a waterproof seal between said connector housing (10) and said mating connector (30), with said wires (50) kept in an inserted condition, said method furthermore comprising the steps of: forming said seal to said connector housing (10) by a single molding step as one piece such as to form a seal portion (14) in the outer periphery of the rear portion of said connector housing (10) including first and second integral sections, said first section closing said wire openings and said second section forming a front sealing side (14a) on a front side of said seal portion (14); and fitting said connector housing (10) to said mating connector (30) such that said front sealing side (14a) is abutted against an abutment surface (31a) of said mating connector (30) in a watertight manner. The method according to claim 14, further comprising the steps of: providing a flange (12) on an outer periphery of said connector housing (10) with an upper portion and lower portion, said upper portion and said lower portion each having a centrally formed positioning projection (13); molding said seal portion (14) around said flange (12) such that said positioning projections (13) extend to the outside of said seal portion (14); and forming a flat portion (14a) at said seal portion (14) on a front side of said flange (12) and a stepped portion (14b) at said seal portion (14) on a rear side of said flange (12) . The method according to claim 14 or 15, further comprising the provision of said connector housing (10) as a female connector housing and of said mating connector (30) as a male connector housing. The method according to claim 16, comprising the steps of: providing a plurality of said female connector housings that are held in a frame (20), the frame having a corresponding plurality of housing receiving holes (21), wherein said plurality of female connector housings are inserted through a rear side of said frame (20), and furthermore having a corresponding plurality of pairs of notches (22), wherein said plurality of positioning projections (13) are received; and providing a corresponding plurality of male connector housings that form an integral structure. The method of claim 17, further comprising the step of providing a flat abutment surface (31a), with an annular projection projecting outwardly, on a hood portion (31) on said male connector housing for engaging said flat portion (14a) of said second integral section.

Inventors: ITO OSAMU, TANIUCHI OSAMU, ITO, OSAMU, TANIUCHI, OSAMU, ITO, OSAMU, C/O SUMITOMO WIRING SYSTEMS, LTD., TANIUCHI, OSAMU, C/O SUMITOMO WIRING SYSTEMS, LTD.
Applicants: SUMITOMO WIRING SYSTEMS, SUMITOMO WIRING SYSTEMS, LTD.
Application year: 1995
Main classification: H01R13
IPC codes: H01R13