Abstract:
A stopper ( 67 ) of a detector ( 60 ) is lockable to a lock surface ( 17 ) by entering a lock hole ( 18 ) of a lock arm ( 13 ) from a deflection space  15.  A locking protrusion ( 45 ) of a second housing ( 40 ) locks to the lock surface ( 17 ) by entering the lock hole ( 18 ) from a side opposite the deflection space ( 15 ). Thus, the housings ( 10, 40 ) are held together and the stopper ( 67 ) pressed by the locking protrusion ( 45 ) separates from the lock surface ( 17 ) and the detector can move to the detection position. The locking protrusion ( 45 ) has a main body ( 46 ) wider than the lock surface ( 17 ) of a lock projection ( 16 ) and lockable to the lock surface ( 17 ). A pressing protrusion ( 47 ) narrower than the locking main body  46  projects from the locking main body ( 46 ) and enters the lock hole ( 18 ) to press the stopper ( 67 ).

Description:
BACKGROUND 
       [0001]    1. Field of the Invention 
         [0002]    The invention relates to a connector and to an assembling method therefor. 
         [0003]    2. Description of the Related Art 
         [0004]    Japanese Unexamined Patent Publication No. 2015-32506 discloses a connector with a male housing having a receptacle and a female housing that can fit into the receptacle. A detector is mounted in the female housing and is movable between an initial position and a detection position. A lock protrusion is provided on the inner surface of the receptacle. The female housing includes a deflectable lock arm and the lock arm is provided with a lock projection and two couplings that extend back from both sides of the lock projection. The lock arm has a lock hole between the lock projection and the couplings. The front surface of the lock hole (also rear surface of the lock projection) is formed as a lock surface. Further, a resilient arm projects from the detecting member and a protrusion is provided on a tip part of the resilient arm. 
         [0005]    When the detector is at the initial position, the protrusion is inserted into the lock hole from below and locked by the lock surface. Thus, a movement of the detector to the detection position is regulated. Further, when the two housings are connected properly, the lock protrusion is inserted into the lock hole from above (side opposite to the deflection space) and is locked by the lock surface so that the two housings are held in a state where separation is regulated and the protrusion pressed by the lock protrusion is released from locking by the lock surface and retracted into the deflection space to permit a movement of the detector to the detection position. Thus, it can be known that the two housings have been connected properly when the movement of the detector to the detection position is enabled. 
         [0006]    There have been cases where the lock arm hangs down from a normal position and the deflection space for the lock arm becomes narrower than normal due to deterioration over time, distortion during molding or the like. Then, the lock surface also is lowered by the hanging-down of the lock arm. Thus, even if the protrusion is pushed down by the lock protrusion when the two housings are connected properly, the protrusion cannot be separated sufficiently from the lock surface, the detector may interfere with the lock surface or the lower surface of the lock arm while moving toward the detection position and an operation of moving the detector to the detection position may be regulated. 
         [0007]    The invention was completed based on the above situation and aims detection position. 
       SUMMARY 
       [0008]    The invention relates to a connector with a first housing including a deflectable lock arm. A detector is mounted in the first housing and is movable from a first position to a second position. A second housing is connectable to the first housing. The lock arm includes at least one lock projection having a lock surface extending along a direction intersecting a connecting direction of the first and second housings and a lock hole closed at one end by the lock surface. The second housing includes a locking protrusion and the detector includes a stopper. The stopper is arranged to lock to the lock surface by being inserted into the lock hole from the side of a deflection space for the lock arm when the detector is at the first position. Thus, a movement of the detector to the detection position is regulated. The locking protrusion is arranged to lock with the lock surface by being inserted into the lock hole from a side opposite to the deflection space when the first and second housings are connected properly. Thus, the first and second housings are held in a state where separation is regulated and the stopper pressed by the locking protrusion is separated from the lock surface and is retracted into the deflection space to permit the movement of the detector towards or to the second position. The locking protrusion includes a pressing protrusion configured to press the stopper by entering the lock hole when the first and second housings are connected properly. 
         [0009]    The locking protrusion may include a locking main body lockable to the lock surface and a pressing protrusion projecting from a projecting end of the locking main body. 
         [0010]    A width direction extends substantially orthogonal to a projecting direction of the lock projection and also orthogonal to the connecting direction of the first and second housings. The locking main body has a larger dimension in the width direction than the lock surface of the lock projection and is lockable to the lock surface. Additionally, the pressing protrusion has a smaller dimension in the width direction than the locking main body. The pressing protrusion of the locking protrusion enters the lock hole from the side opposite to the deflection space and presses the stopper when the first and second housings are connected properly. Thus, the stopper can be separated reliably from the lock surface by being caused to sink deep into the deflection space, and interference of the detector and the lock arm can be reduced or eliminated when the detector moves to the detection position. As a result, the detector can move smoothly to the detection position. Further, the locking main body of the locking protrusion is wider than the lock surface of the lock projection and is lockable to the lock surface. Thus, a sufficient locking margin of the locking main body to the lock surface of the lock projection can be ensured and the state where the separation of the first and second housings is regulated can be held reliably. 
         [0011]    One or more extension parts may protrude from the lock projection toward opposite widthwise sides of the lock projection. The extension parts may be lockable to the lock surface of the lock projection over the substantially entire width when the first and second housings are connected properly. According to this configuration, a sufficient locking margin of the locking main body to the lock surface of the lock projection can be ensured more reliably. 
         [0012]    A width of the lock hole may be substantially equal to that of the lock surface of the lock projection and/or smaller than that of the locking main body of the locking protrusion. 
         [0013]    The first housing may comprise one or more guide walls to project laterally of the lock arm so as to guide the detector on the first housing. 
         [0014]    At least one elongated projection may be provided on the guide wall of the first housing and may extend substantially in the front-back direction so that when the first and second housings are in proper postures, the elongated projection can fit into an elongated projection receiving portion on the second housing. However, if the first and second housings are in postures different from the proper ones, the elongated projection contacts the second housing to prevent an erroneous connection of the first and second housings. 
         [0015]    These and other objects, features and advantages of the invention will become more apparent upon reading the following detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1  is a partial enlarged section of a first housing having a detector held at a standby position and a second housing including a locking protrusion in a connector according to an embodiment of the present invention. 
           [0017]      FIG. 2  is a partial enlarged section showing a state where a lock arm is deflected in the process of connecting the first and second housings 
           [0018]      FIG. 3  is a partial enlarged section showing a state where the first and second housings are connected properly and a locking protrusion is pressing a stopper portion of a detector. 
           [0019]      FIG. 4  is a partial enlarged section showing a state where the detector is at a detection position. 
           [0020]      FIG. 5  is a schematic view showing a state corresponding to  FIG. 3  when viewed from front. 
           [0021]      FIG. 6  is a front view of the first housing. 
           [0022]      FIG. 7  is a plan view of the first housing. 
           [0023]      FIG. 8  is a front view of the second housing. 
           [0024]      FIG. 9  is a section along A-A of  FIG. 8 , 
           [0025]      FIG. 10  is a front view of the detector. 
           [0026]      FIG. 11  is a plan view of the detecting member. 
       
    
    
     DETAILED DESCRIPTION 
       [0027]    An embodiment of the invention is described with reference to  FIGS. 1 to 11 . A connector of this embodiment includes a first housing  10  and a second housing  40  connectable to each other and a detector  60  is mounted in or to the first housing  10  is movably between a standby position and a detection position. Note that, in the following description, sides facing each other when the connection of the first and second housings  10 ,  40  is started are referred to as front sides concerning a front-back direction and a vertical direction is based on  FIGS. 1 to 5, 7 and 9 . 
         [0028]    The second housing  40  is made e.g. of synthetic resin and includes a terminal accommodating portion  41  in the form of a substantially rectangular block and a substantially rectangular tubular receptacle  42  projects forward from the outer periphery of the front end of the terminal accommodating portion  41 , as shown in  FIGS. 8 and 9 . Second cavities  43  (see  FIG. 8 ) are provided in the terminal accommodating portion  41  and unillustrated male terminal fittings are inserted therein so that tabs of the male terminal fittings project into the receptacle  42 . 
         [0029]    As shown in  FIG. 9 , a substantially rectangular recess  44  is recessed slightly backward in a widthwise intermediate part part of the front end of the upper wall of the receptacle  42 . A locking protrusion  45  is provided right behind the recess  44  on the inner surface of the upper wall of the receptacle  42 . As shown in  FIG. 8 , the locking protrusion  45  comprises a locking main body  46  in the form of a flat rectangular block projecting from the inner surface of the receptacle  42  and extending in a width direction. A pressing protrusion  47  projects integrally or unwarily down and in from a central part of the locking main body  46  in the width direction orthogonal to a connecting direction of the first and second housings  10 ,  40  and a projecting direction of the locking protrusion  45  (downward direction). A dimension in the width direction of the pressing protrusion  47  is smaller than about ⅓ of the width of the locking main body  46 . 
         [0030]    As shown in  FIG. 1 , the front of the locking protrusion  45  forms a tapered guiding surface  48  inclined back toward a lower projecting end. Further, the rear of the locking protrusion  45  defines an overhanging locking surface  49  inclined slightly back toward the lower projecting end. The guiding surface  48  and the locking surface  49  are formed continuously from the locking main body  46  to the pressing protrusion  47  without any step. 
         [0031]    The first housing  10  is made of synthetic resin and includes a housing main body  11  in the form of a substantially rectangular block, as shown in  FIGS. 6 and 7 . First cavities  12  are provided in the housing main body  11  at positions corresponding to the second cavities  43 , as shown in  FIG. 6 , and unillustrated female terminal fittings are insertable therein. The male and female terminal fittings are connected electrically when the first and second housings  10 ,  40  are connected properly. 
         [0032]    As shown in  FIG. 6 , a lock arm  13  projects in a widthwise intermediate part of the upper surface of the housing main body  11 . As shown in  FIG. 1 , the lock arm  13  includes an arm main body  14  that is cantilevered back after standing up from a front end part of the upper surface of the housing main body  11 . The arm main body  14  is deflectable and deformable in the vertical direction that intersects the connecting direction, with the standing front end part as a support. A deflection space  15  is formed between the arm main body  14  and the upper surface of the housing main body  11 . 
         [0033]    As shown in  FIG. 1 , a lock projection  16  projects out and up in an intermediate part in an extending direction (front-back direction). The rear surface of the lock projection  16  defines a lock surface  17  that is arranged to stand substantially vertically, but a lower end part is inclined slightly backward. 
         [0034]    A rearwardly open lock hole  18  extends in the front-back direction on the arm main body  14 , as shown in  FIGS. 4 and 7 . The front end of the lock hole  18  is closed by the lock surface  17  of the lock projection  16 . As shown in  FIG. 7 , a width of the lock hole  18  is equal to the width of the lock surface  17  of the lock projection  16  and smaller than the width of the locking main body  46  of the locking protrusion  45 . Further, as shown in  FIG. 1 , the arm main body  14  is provided with an insertion recess  19  below the lock projection  16 . The insertion recess  19  communicates with the lock hole  18  and is open on the lower surface of the arm main body  14 . A later-described stopper  67  of the detector  60  is insertable into the insertion recess  19 . 
         [0035]    Further, an unlocking portion  21  is provided at a position on a rear end part of the arm main body  14  to cover a rear end part of the lock hole  18  from above and is slightly higher than the lock projection  16  in the vertical direction. The lock hole  18  penetrates through the arm main body  14  in the vertical direction between the unlocking portion  21  and the lock projection  16 . 
         [0036]    The locking protrusion  45  of the second housing  40  faces the lock surface  17  of the lock projection  16  when the first and second housings  10 ,  40  are connected properly, as shown in  FIGS. 3 and 4 . Thus, the first and second housings  10 ,  40  are held in a state where separation is regulated. On the other hand, at the time of separating the first and second housings  10 ,  40 , the unlocking portion  21  is pressed from above after the detector  60  is pulled back to the standby position. The arm main body  14  then is pushed resiliently down and toward the deflection space  15  so that the lock projection  16  is separated from the locking protrusion  45  and the first and second housings  10 ,  40  enter a separable state. As shown in  FIG. 7 , guide walls  22  project laterally at opposite widthwise sides of a rear end part of the lock arm  13  on the upper surface of the housing main body  11 . The guide walls  22  have parts extending back from the rear end of the lock arm  13  and are arranged on a rear end part of the upper surface of the housing main body  11 . The detector  60  is mounted by being inserted between the guide walls  22  into the deflection space  15  for the lock arm  13  and is movable in the front-back direction along the inner surfaces of the guide walls  22  between the standby position and the detection position. Although not shown in detail, holding structures are provided on the inner surfaces of the guide walls  22  for holding the detector  60  at the standby position and the detection position (such as holding portions  23  of  FIG. 6 ). 
         [0037]    Further, as shown in  FIG. 6 , two inversion preventing portions  24  are provided while being bent inward above opposite widthwise end parts of the unlocking portion  21  on upper end parts of the guide walls  22 . The inversion preventing portions  24  function to contact with the opposite widthwise end parts of the unlocking portion  21  when the lock arm  13  is going to be deformed in a direction opposite to a proper direction, thereby regulating any further deflection of the lock arm  13 . Note that, as shown in  FIG. 6 , stepped recesses  25  are recessed slightly on the opposite widthwise end parts of the unlocking portion  21  and contact the inversion preventing portions  24 . 
         [0038]    An elongated projection  26  is provided on the upper surface of the housing main body  11  on one of the opposite widthwise sides of the guide walls  22  and extends in the front-back direction. The elongated projection  26  can fit into elongated projection receiving portion  51  (see  FIG. 8 ) on the inner surface of the upper wall of the receptacle  42  when the first and second housings  10 ,  40  are in proper postures. On the other hand, if the first and second housings  10 ,  40  are in an improper posture, the elongated projection  26  contacts the opening edge of the receptacle  42  to avoid a situation where the first and second housings  10 ,  40  are connected erroneously. 
         [0039]    The detector  60  is made of synthetic resin and includes, as shown in  FIGS. 10 and 11 , a thick base  61  extending along the width direction, a resilient arm  62  cantilevered forward from a widthwise central part of the base  61  and two holding pieces  63  that project forward from opposite widthwise ends of the base  61 . The detector  60  is slidable forward from the standby position to the detection position relative to the first housing  10 . 
         [0040]    As shown in  FIGS. 10 and 11 , a rib-like operating portion  64  projects on the upper end of the base  61  and extends along the width direction. The detector  60  can be moved by pressing or gripping the operating portion  64  from behind. Two guide protrusions  65  are provided on lower edge parts of opposite widthwise end surfaces of the base  61 . The detector  60  is guided by fitting the guide protrusions  65  into guide grooves  28  (see  FIG. 4 ) on the inner surfaces of the guide walls  22 . 
         [0041]    As shown in  FIG. 10 , the holding pieces  63  are in the form of flat plates substantially along the vertical direction. As shown in  FIG. 11 , holding projections  66  project out on front end parts of the holding pieces  63 . After the holding pieces  63  are deflected in the width direction, the holding projections  66  are lockable to the holding structures such as the holding portions  23  of the guide walls  22 . 
         [0042]    As shown in  FIG. 1 , the resilient arm  62  is inclined up toward the front from the front end of the base  61  and is vertically deflectable and deformable with a position coupled to the front end of the base  61  as a support. The stopper  67  projects on a front end part of the resilient arm  62 . The front surface of the stopper  67  defines a stopper surface  68  inclined slightly forward toward an upper side. An auxiliary projection  69  extends in the front-back direction in a widthwise central part on the upper surface of the stopper  67 . The auxiliary projection  69  has a sharp top  71  on the upper end, and front and rear side surfaces before and behind the top  71  are inclined down to form a triangular cross-sectional shape. 
         [0043]    A receiving piece  72  protrudes forward on the resilient arm  28  before the stopper  67 . When the lock arm  13  is deflected into the deflection space  15 , the receiving piece  72  contacts the inner upper surface of the insertion recess  19  of the lock arm  13  and the resilient arm  62  follows the deflection of the lock arm  13 . 
         [0044]    The detector  60  is inserted between the guide walls  22  of the first housing  10  from behind and is held at the initial position (see  FIG. 1 ). When the detector  60  reaches the initial position, the stopper  67  of the resilient arm  62  is inserted into the lock hole  18  from below (side of the deflection space  15 ) and the stopper surface  68  of the stopper  67  faces the lock surface  17  of the lock projection  16  from behind and is lockable to the stopper surface  17 . In this way, a movement of the detector  60  to the detection position is regulated. Further, at the standby position, the base  61  is placed on the upper surface of the housing main body  11 , the receiving piece  72  is inserted in the insertion recess  19  and the auxiliary projection  69  projects up from the upper surface of the arm main body  14 . 
         [0045]    Subsequently, the first housing  10  is fitted into the receptacle  42  of the second housing  40 . 
         [0046]    As shown in  FIG. 2 , in the process of connecting the first and second housings  10 ,  40 , the pressing protrusion  47  of the locking protrusion  45  of the second housing  40  contacts the lock projection  16  of the lock arm  13  and the lock arm  13  is deflected in and down. Further, as the lock arm  13  is deflected and deformed, the receiving piece  72  is pressed by the inner upper surface of the insertion recess  19  and the resilient arm  62  is deflected in and down. 
         [0047]    As shown in  FIG. 3 , when the first and second housings  10 ,  40  are connected properly, the lock projection  16  passes over the locking protrusion  45 , the lock arm  13  resiliently returns, the locking protrusion  45  is inserted into the lock hole  18  from above (side opposite to the deflection space  15 ) and the locking surface  49  of the locking protrusion  45  faces and is lockable to the lock surface  17  of the lock projection  16 . In this way, the first and second housings  10 ,  40  are held in the state where the separation is regulated. 
         [0048]    Further, as shown in  FIG. 3 , with the first and second housings  10 ,  40  properly connected, the projecting end of the pressing protrusion  47  contacts the top  71  of the auxiliary projection  69  of the stopper  67 , and the stopper  67  is pushed in and down while the resilient arm  62  is deflect. In this way, the stopper  67  is separated from the lock surface  17  of the lock projection  16  to enable a movement of the detector  60  to the detection position. 
         [0049]    Specifically, when the first and second housings  10 ,  40  are connected properly, the pressing protrusion  47  is inserted into the lock hole  18  penetrating through the arm main body  14  as shown in  FIG. 5  and contacts the auxiliary projection  69  of the stopper  67  so that the stopper  67  sinks deep into the deflection space  15  and is displaced lower to a height position to be insertable into the insertion recess  19 . Further, when the first and second housings  10 ,  40  are connected properly, the opposite widthwise end parts of the locking main body  46  are arranged to contact the upper surface of the arm main body  14  and lockable to the lock surface  17  of the lock projection  16  over the entire width. At this time, the opposite widthwise end parts of the locking main body  46  are formed as extensions  53  protruding toward substantially opposite widthwise sides of the lock projection  16 . 
         [0050]    Thereafter, the detector  60  is pushed from behind toward the detection position. In the process of moving the detector  60  toward the detection position, a front oblique part of the auxiliary projection  69  slides in contact with and interferes with the rear end of the lock projection  16 , but the stopper  67  and the lock arm  13  do not interfere with each other significantly. Therefore sliding resistance between the lock arm  13  and the detector  60  can be reduced to be small. As shown in  FIG. 4 , when the detector  60  reaches the detection position, the stopper  67  is separated from the pressing protrusion  47  and fit into the insertion recess  19 . Further, when the detector  60  reaches the detection position, the unlocking portion  21  of the lock arm  13  is inserted into the recess  44  and allowed to escape. 
         [0051]    On the other hand, if the first and second housings  10 ,  40  are left without reaching a proper connection position (incompletely connected state), the stopper  67  is kept in a state lockable to the lock projection  16  of the lock arm  13 . Thus, the detector  60  cannot be pushed to the detection position. Therefore, it can be judged that the first and second housings  10 ,  40  have reached the proper connection position when the detector  60  becomes movable to the detection position. 
         [0052]    As described above, according to this embodiment, the pressing protrusion  47  of the locking protrusion  45  at least partly is inserted deep into the lock hole  18 , whereby the stopper  67  of the detecting member  60  is sufficiently displaced (particularly pushed in and down to be reliably separated from the lock surface  17  of the lock projection  16 . Thus, the detector  60  does not interfere with the lock arm  14  when being pushed to the detection position and can be moved smoothly to the detection position. Particularly, it is effective that, even if the lock arm  13  hangs down due to deterioration over time, a molding failure or the like, a hanging-down amount of the lock arm  13  easily can be compensated for by a projecting amount of the pressing protrusion  47 . 
         [0053]    Further, the locking main body  46  of the locking protrusion  45  is wider than the lock surface  17  of the lock projection  16 . Thus, a sufficient locking margin of the locking main body  46  to the lock surface  17  of the lock projection  16  can be ensured when the first and second housings  10 ,  40  are connected properly. In addition, the locking main body  46  also includes the extensions  53  arranged to be lockable to the lock surface  17  of the lock projection  16  over the entire width and protruding toward the opposite widthwise sides of the lock projection  16 . Thus, the locking margin of the locking main body  46  can be ensured more reliably. 
         [0054]    Other embodiments are briefly described below. 
         [0055]    The detector may be configured to automatically reach the detection position by being biased by at least one biasing member. 
         [0056]    The lock hole may be closed over the entire periphery by being closed also on the rear end. 
         [0057]    The pressing protrusion may not be provided at such a position to be lockable to the lock surface of the lock projection and may not have a locking function. 
         [0058]    The invention is also applicable to a waterproof connector having a sealing structure for sealing between a wire and a housing in a liquid-tight manner. 
       REFERENCE SIGNS 
       [0000]    
       
           10  . . . first housing 
           13  . . . lock arm 
           15  . . . deflection space 
           16  . . . lock projection 
           17  . . . lock surface 
           18  . . . lock hole 
           40  . . . second housing 
           45  . . . locking protrusion 
           46  . . . locking main body 
           47  . . . pressing protrusion 
           53  . . . extension 
           60  . . . detector 
           62  . . . resilient arm 
           67  . . . stopper