Abstract:
A connector coupling structure includes first and second connectors including housings. A raised portion is formed at a front end side of an inner surface of the second connector housing. When the first and second connectors are coupled, the raised portion contacts an outer surface of the first connector housing, forming a clearance between the outer surface of the first connector housing and an inner surface portion of the second connector housing. An inner case is slidably received in one of the connector housings. A projecting portion is formed on a side of the inner case and a notching piece having a pawl is formed on the one connector housing to be releasably engageable with the projecting portion. When the terminals and terminal-inserting holes of the two connectors are connected with one another, the inner case slides so that the engagement of the pawl and the projecting portion is released.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application is based upon and claims the benefit of priority from Japanese Patent Applications Nos. 2005-122583 and 2005-159882, filed Apr. 20, 2005 and May 31, 2005, respectively, in the Japanese Patent Office, the disclosures of which are incorporated herein in their entirety by reference. 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   Devices, systems, and methods consistent with the present invention relate to a connector coupling structure for coupling connectors which are used to connect a wire harness with accessories, such as audio equipment and vehicular meters, of an automotive vehicle and the like. 
   2. Description of the Related Art 
   In a conventional example of a connector coupling structure, in which audio equipment is mounted on an instrument panel of an automotive vehicle, a wire harness extends from a power supply to the panel, and the distal end of the wire harness is connected to a female connector, which in turn is coupled to a male connector provided on the back side of the audio equipment. A coupling operation of the male connector and the female connector is carried out at a back side of the instrument panel. After a completion of the coupling operation, the next operation, i.e., securing the audio equipment to the instrument panel is carried out. As described, such a conventional structure inevitably involves a two-step operation, and therefore, working efficiency is decreased. Moreover, a problem arises in which the wire harness has a slack due to a margin of the length thereof after installation of the audio equipment whereby abnormal noise is produced. 
   Therefore, structures have been developed in which positional deviation between a male connector and a female connector is absorbed by the connectors themselves in order to increase assemble-ability thereof and to realize an easy and reliable connection between the connectors. One of the structures is formed of a female connector and a male connector. The female connector consists of a housing, a guide for enabling the housing to slide, a first columnar projection provided on the guide, and a second columnar projection provided on the housing. The male connector consists of a housing for the male connector, a lever, terminals for the female connector and terminals for the male connector, both provided on the housing for the male connector, and a guidance groove for guiding the first columnar projection and the second columnar projection. Both housings are coupled by treating the first columnar projection inside the guidance groove as a point of action, by treating the second columnar projection as a power point, and by moving the housing for the female connector in a connection direction with respect to the male connector (see Japanese Patent Application, First Publication No. 2000-215944 (page 4,  FIG. 3 )). 
   The above official publication discloses a male connector which is provided with two U-shaped levers disposed symmetrically with respect to one another, each lever consists of plate portions extending parallel with one another, the plate portions of the each lever are coupled to an upper surface and a lower surface of the male connector at one end side of each of the plate portions and are connected to one another at the opposite end side of the plate portions. With lever grooves formed on each lever along which the first columnar projection and the second columnar projection are guided, both connectors are coupled to one another. The levers which function as a cam are structurally important. In the conventional structure, such a cam or levers are essential parts, and therefore, there become a number of parts to be assembled, thus resulting in increased cost of production. Further, another problem arises in which the degree of freedom in design of modules is low, since such a cam or levers are substantially large. 
   SUMMARY OF THE INVENTION 
   In consideration of the above circumstances, an object of the present invention is to provide a new connector coupling structure which does not have such a conventional lever and which is somewhat down-sized and manufactured at low cost, and enables a three-dimensional alignment in three directions of X, Y and Z axes to increase the degree of freedom in the design of modules. 
   In order to achieve the above objects, in accordance with the present invention, a connector coupling structure is provided comprising: a first connector including a housing and a plurality of terminal-inserting holes; a second connector including a housing and a plurality of terminals which are connectable to their respective terminal-inserting holes; a raised portion which is formed at a front end side of an inner surface of the second connector housing, wherein, when the first and second connectors are coupled, the raised portion is in contact with an outer surface of the first connector housing such that a clearance is formed between the outer surface of the first connector housing and an inner surface portion other than the raised portion of the second connector housing; an inner case which is slidably received in one connector housing of the first connector housing and the second connector housing and which includes one of the plurality of terminal-inserting holes and the plurality of terminals; a projecting portion which is formed on a side of the inner case; and a notching piece which is formed on said one connector housing and which includes a pawl releasably engageable with the projecting portion; wherein, when the plurality of terminals and the plurality of terminal-inserting holes are connected with one another, the inner case is slid such that the engagement of the pawl and the projecting portion is released. 
   Preferably, the first connector is a female connector and the second connector is a male connector. 
   Further, preferably, the inner case includes the plurality of terminal-inserting holes and is slidably received in the first connector housing. 
   Still further, preferably, when the housing of the first connector is mounted to a panel through an opening of the panel, the housing includes a housing body portion, which does not pass through the opening of the panel but is engaged with one surface of the panel, and a plurality of spring pieces, which are resiliently deformable so as to pass through the opening and are resiliently engaged with an other surface of the panel. 
   Yet further, preferably, when the housing of the second connector is mounted to a panel through an opening of the panel, the housing includes a housing body portion, which does not pass through the opening of the panel but is engaged with one surface of the panel, and a plurality of spring pieces, which are resiliently deformable so as to pass through the opening and are resiliently engaged with an other surface of the panel. 
   Another object of the present invention is to provide a new connector coupling structure which does not have such a conventional bulky cam member and which is somewhat down-sized and can be manufactured at low cost, and enables an efficient absorption of error in a fitting direction. 
   In order to achieve the above objects, in accordance with the present invention, a connector coupling structure is provided comprising: a first connector including a housing and a plurality of terminal-inserting holes; a second connector including a housing and a plurality of terminals which are connectable to their respective terminal-inserting holes; an inner case which is slidably received in one connector housing of the first connector housing and the second connector housing and which includes one of the plurality of terminal-inserting holes and the plurality of terminals; and a U-shaped spring piece which is provided on a side of the inner case; a rib which is provided on said one connector housing and is releasably engageable with the U-shaped spring piece, wherein, when the rib is engaged with the U-shaped spring piece, sliding movement of the inner case in said one connector housing is stopped; a channel which is provided on a side of the other connector housing of the first and second connector housings and which guides a movement of the rib and the U-shaped spring piece; and a deflection permitting window which is provided partway along the channel and which receives a resiliently deformable portion of the U-shaped spring piece; wherein, when said one connector housing, in which the inner case has been partway received, and said the other connector housing are fitted to each other, the U-shaped spring piece of the inner case comes to a position corresponding to the deflection permitting window in such a manner that the deflection permitting window makes the U-shaped spring piece open to release an engagement of the rib such that a fitting degree of both the connector housings is enlarged. 
   Preferably, the first connector is a female connector and the second connector is a male connector. 
   Further, preferably, the inner case includes the plurality of terminal-inserting holes and is slidably received in the first connector housing. 
   Still further, preferably, when the housing of the first connector is mounted to a panel through an opening of the panel, the housing includes a housing body portion, which does not pass through the opening of the panel but is engaged with one surface of the panel, and a plurality of spring pieces, which are resiliently deformable so as to pass through the opening and are resiliently engaged with an other surface of the panel. 
   Yet further, preferably, when the housing of the second connector is mounted to a panel through an opening of the panel, the housing includes a housing body portion, which does not pass through the opening of the panel but is engaged with one surface of the panel, and a plurality of spring pieces, which are resiliently deformable so as to pass through the opening and are resiliently engaged with an other surface of the panel. 
   The above and still further objects, features and advantages of the present invention will become apparent upon consideration of the following detailed description of specific embodiments thereof, particularly when taken in conjunction with the accompanying drawings wherein like reference numerals in the various figures are utilized to designate like components. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above features and advantages of the invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which: 
       FIG. 1  is a perspective view illustrating a panel before coupling connectors, as viewed from a back side of the panel, according to a first embodiment of the present invention. 
       FIG. 2  is a perspective view illustrating the panel before coupling the connectors, as viewed from a front side of the panel. 
       FIG. 3  is a perspective view illustrating a coupling state. 
       FIG. 4  is a cross sectional view diagrammatically illustrating the connectors before coupling thereof. 
       FIG. 5  is a cross sectional view diagrammatically illustrating a state at the beginning of insertion of one housing into another housing. 
       FIG. 6  is a cross sectional view diagrammatically illustrating the middle of the insertion. 
       FIG. 7  is a cross sectional view diagrammatically illustrating a cancellation of a provisional securement. 
       FIG. 8  is a cross sectional view diagrammatically illustrating a coupling state. 
       FIG. 9  is a perspective view illustrating a panel before coupling the connectors, as viewed from a back side of the panel, according to a second embodiment of the present invention. 
       FIG. 10  is a perspective view illustrating the panel before coupling the connectors, as viewed from a front side of the panel. 
       FIG. 11  is a cross sectional view diagrammatically illustrating the connectors before coupling thereof. 
       FIG. 12  is a cross sectional view diagrammatically illustrating a state at the beginning of insertion of one housing into another housing. 
       FIG. 13  is a cross sectional view diagrammatically illustrating the middle of the insertion. 
       FIG. 14  is a cross sectional view diagrammatically illustrating a cancellation of a provisional securement. 
       FIG. 15  is a cross sectional view diagrammatically illustrating a coupling state. 
       FIG. 16  is a side cross sectional view illustrating deformation permitting windows and U-shaped spring pieces. 
       FIG. 17  is a side cross sectional view, which is similar to  FIG. 16 , illustrating the cancellation of the provisional securement implemented by the U-shaped spring pieces. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Exemplary embodiments of the invention will now be described below with reference to the attached Figures. The described exemplary embodiments are intended to assist the understanding of the invention, and are not intended to limit the scope of the invention in any way. 
   First Embodiment 
   Hereinafter, a first embodiment according to the present invention will be exemplarily described with reference to  FIGS. 1 through 8 . 
     FIG. 1  is a view illustrating a securement state of a female connector  4  with respect to a panel  1 , such as an instrument panel or the like, to which one connector is to be secured, when viewed from the back of the panel  1 . The panel  1  is formed with an opening  2 , in which the female connector  4  is mounted. A catching wall  3  is formed along the periphery of the opening  2  at a panel back side. This catching wall  3  is comprised of a portion that is formed in such a manner as to protrude from a back surface of the panel  1 , and of a peripheral wall that is flush with the opening  2 . On a back surface of the female connector  4  is formed a plurality of spring pieces  5 , each of which has a tip  5 A that is an outwardly rounded bulging portion. Each of the tips  5 A (or rounded bulging portions) of the spring pieces  5  is brought into resilient contact with the aforesaid catching wall  3  whereby the female connector  4  is secured to the panel  1 . The tips  5 A of the spring pieces  5  bulge in such a manner as to protrude outwardly from outlines by which the back surface of the female connector  4  is defined. Under a state in which the tips  5 A of the spring pieces  5  are in resilient contact with the catching wall  3 , positioning control of the female connector  4  in X and Y axial directions is possible. When a housing  40  of the female connector  4  is molded from a resin material, the aforesaid spring pieces  5  are also integrally formed with the housing  40 . The spring pieces  5  are provided on a rectangular-shaped back surface of the female connector  4 , one at each short side (or each of upper and lower sides) of the rectangular shape and two at each long side (or each of left and right sides) of the rectangular shape. 
   Further, notching pieces  6  with C-shaped incisions formed thereon are provided, one at each of top and bottom portions of a front side of the housing  40  of the female connector  4 . An inner case  8  with a number of terminal-inserting holes  7 , as more fully discussed hereinafter, is housed in the housing  40  so as to be slidable therein. This inner case  8  is provisionally secured in position by means of pawls  11  that are formed in the notching pieces  6  (details thereof will be described hereinafter). 
   A male connector  9  is fitted in the female connector  4 . In  FIG. 1 , a number of male terminals  10  to be inserted in their respective terminal-inserting holes  7  are not illustrated, and instead, a housing  90  to house those male terminals  10  is only illustrated. This housing  90  is fitted on the aforesaid housing  40  so as to cover thereof. The male connector  9  is provided at a back side of accessories such as vehicular meters. 
     FIG. 2  is a view illustrating the panel  1 , as viewed from a front side thereof. As described, the inner case  8  is provided with the number of terminal-inserting holes  7 , and with a number of female terminals each being inserted in one of the terminal-inserting holes  7  and connected with a wire harness extending from a power supply. By inserting the male terminals  10  of the male connector  9  disposed at the back side of the accessories, in the terminal-inserting holes  7 , the mechanical coupling between the two connectors, i.e., the female connector  4  and the male connector  9  is carried out. Such a coupling state is illustrated in  FIG. 3 . 
   Now, coupling operation of said connectors  4  and  9  will be described hereinafter with reference to  FIG. 4  and subsequent figures. The pawls  11  are provided inside the notching pieces  6 , as described above, and the aforesaid inner case  8  is formed with projecting portions  12 .  FIG. 4  illustrates a state in which the pawls  11  and the projecting portions  12  are engaged with one another. This state is a state in which the inner case  8  is provisionally secured in position in the housing  40  of the female connector  4 . As long as this provisional securement is not released, the inner case  8  does not slide in the housing  40 . Further, raised portions  13 , which are formed at a front end side of an inner surface of the housing  90 , touch an outer surface of the housing  40  with a clearance  14  formed between the inner surface of the housing  90  and the outer surface of the housing  40 . A structure is preferable in which a raised portion  13  is formed along the whole periphery of the inner surface of the housing  90 . However, another structure is sufficient in which raised portions are formed on the inner surface of the housing  90  each at a location which corresponds to a location of one of the corresponding notching pieces  6 . At the time the projecting portions  12  are moved over the pawls  11  of the notching pieces  6 , front end portions of the notching pieces  6  are outwardly resiliently deformed or extended. As such, in order to sufficiently receive such deformations or extensions, there is a need to provide the corresponding clearance  14  formed inside the housing  90 . 
   Referring to  FIGS. 5 and 6 , when the male terminals  10  are inserted in the terminal-inserting holes  7 , an offset in the X and Y directions is controlled by means of the spring pieces  5 , such that the male terminals  10  are inserted in the proper position.  FIG. 5  illustrates a state in which the male terminals  10  are correctly inserted in the terminal-inserting holes  7 . From thence, the male connector  9  is further inserted and advanced with respect to the female connector  4 . A support member  15 , by which the male terminals  10  are supported, then abuts against the inner case  8  at a front surface thereof. At this time, the advancement of the inner case  8  is temporarily stopped due to an engagement of the projecting portions  12  of the inner case  8  with the pawls  11 . When the male terminals  10  are inserted in the terminal-inserting holes  7 , because the inner case  8  is in the provisional securing state as described above, the insertion operation as well as two (X and Y) dimensional adjustment are rendered to be easy. Thereafter, the male connector  9  is further advanced or moved. At this time, as illustrated in  FIG. 7 , the projecting portions  12  of the inner case  8  ride over the pawls  11  of the notching pieces  6  whereby the front end portions of the notching pieces  6  are outwardly resiliently deformed so that they are received in the clearance  14 . The male connector  9  is further advanced or moved until the support member  15  abuts against an end of the housing  40  and thereby stops.  FIG. 8  illustrates a state in which the male connector  9  is advanced or inserted to the full extent with respect to the female connector  4 . The female connector  4  is slid or moved by a length L from a position corresponding to the provisional securing state, as shown in  FIG. 6 , to a position corresponding to a coupling-completion state, as shown in  FIG. 8 . In a case where the connector  9  is inserted so deep in the above position, adjusting thereof is possible by pulling the connector  9 . 
   Second Embodiment 
   Hereinafter, a second embodiment according to the present invention will be described with reference to  FIGS. 9 through 17 . 
     FIG. 9  is a view illustrating a securement state of a female connector  104  with respect to a panel  101 , such as an instrument panel or the like, to which one connector is to be secured, when viewed from back of the panel  101 . The panel  101  is formed with an opening  102 , in which the female connector  104  is mounted. A catching wall  103  is formed along the periphery of the opening  102  at a panel back side. This catching wall  103  is comprised of a portion that is formed in such a manner as to protrude from a back surface of the panel  101 , and of a peripheral wall that is flush with the opening  102 . On a back surface of the female connector  104  is formed a plurality of spring pieces  105 , each of which has a tip  105 A that is an outwardly rounded bulging portion. Each of the tips  105 A (or rounded bulging portions) of the spring pieces  105  is brought into resilient contact with the aforesaid catching wall  103  whereby the female connector  104  is secured to the panel  101 . The tips  105 A of the spring pieces  105  bulge in such a manner as to protrude outwardly from outlines by which the back surface of the female connector  104  is defined. Under a state in which the tips  105 A of the spring pieces  105  are in resilient contact with the catching wall  103 , positioning control of the female connector  104  in X and Y axial directions is possible. When a housing  140  of the female connector  104  is molded from a resin material, the aforesaid spring pieces  105  are also integrally formed with the housing  104 . The spring pieces  105  are provided on a rectangular-shaped back surface of the connector  104 , one at each short side (or each of upper and lower sides) of the rectangular shape and two at each long side (or each of left and right sides) of the rectangular shape. 
   Further, ribs  106  are provided one at a center position of each of top and bottom portions of a front side of the housing  140  of the female connector  104 , each rib extending in a back and forth direction as shown in  FIG. 9 . An inner case  108  with a number of terminal-inserting holes  107 , as more fully discussed hereinafter, is housed in the housing  140  so as to be slidable. U-shaped spring pieces  110  are provided, one at each side of the inner case  108 , to latchingly engage the ribs  106 . The advancement or insertion of the inner case  108  within the housing  140  is temporarily stopped due to a latching engagement of these U-shaped spring pieces  110  with the ribs  106 . Namely, the inner case  108  is provisionally secured in position within the housing  140 . Each of the U-shaped spring pieces  110  has a break consisting of opposed portions, a length between which is shorter than a width of each of the ribs  106 . When a leading end of the rib  106  is pushed through the break or opposed portions of the U-shaped spring piece, a force is necessary for compulsorily widening the break of the U-shaped spring piece  110 . 
   A male connector  109  is fitted in the female connector  104 . In  FIG. 9 , a number of male terminals  112  to be inserted in their respective terminal-inserting holes  107  are not illustrated, and instead, a housing  190  to house those male terminals  112  is only illustrated. This housing  190  is fitted on the aforesaid housing  140  in such a manner as to cover the housing  140 . The male connector  109  is provided at a back side of accessories such as vehicular meters. Channels  111 A are formed, one at each side of the housing  190 . The ribs  106  and the U-shaped spring pieces  110  are inserted in the channels  111 A in such a manner as to slide. The housing  190  is provided with deflection permitting windows  111  which are formed at intermediate positions of the channels  111 A and which enable the break of the U-shaped spring piece  110  to be widened in right and left directions when the inner case  108  is inserted in the channel  111 A so that the rib  106  enters the break of U-shaped spring piece. The deflection permitting windows  111  are structured as follows.  FIGS. 9 and 16  indicate a provisional securing state in which the leading end of the rib  106  abuts against the break of the U-shaped spring piece or a latching engagement of the inner case  108  and the housing  140  is formed. When the U-shaped spring piece  110  occupies a position corresponding to the deflection permitting window  111 , the opposed portions (or break) of the U-shaped spring piece  110  are widened from side to side by a forcible insertion of the rib  106  in the break of the U-shaped spring piece  110 . As seen from the foregoing, the deflection permitting window  111  enables the connectors  104  and  109  to be reliably connected to one another, when the housing  140  is further deeply inserted in the housing  190 . Further, the deflection permitting window  111  contributes to absorption of an in-depth error. 
     FIG. 10  is a view illustrating the panel  101 , as viewed from a front side thereof. As described, the inner case  108  is provided with the number of terminal-inserting holes  107 , and with a number of female terminals each being inserted in one of the terminal-inserting holes and connected with a wire harness extending from a power supply. By inserting the male terminals  112  of the male connector  109  disposed at the back side of the accessories, in the terminal-inserting holes  107 , the mechanical coupling between the two connectors, i.e., the female connector  104  and the male connector  109  is carried out. Additionally, pawls  140 A formed on the housing  140  engage and disengage with respect to unillustrated projections which are provided on the inner case  108 . 
   Now, coupling operation of the connectors  104  and  109  will be described hereinafter with reference to  FIG. 11  and subsequent figures.  FIG. 11  illustrates a state in which the ribs  106  and the U-shaped spring pieces  110  are engaged with one another. This state is a state in which the inner case  108  is provisionally secured in position in the housing  140  of the female connector  104 . As long as this provisional securement is not canceled, the inner case  108  does not slide in the housing  140 . Further, an insertion opening of the housing  190  is formed with a tapered opening  190 A which has a diameter widened, and also formed with a bottom portion  190 B against which the inner case  108  abuts. 
   Referring now to  FIGS. 12 and 13 , when the male terminals  112  (not shown in the drawings) are inserted in the terminal-inserting holes  107 , an offset in the X and Y directions is controlled by means of the spring pieces  105 , such that the male terminals  112  are inserted in the proper position.  FIG. 12  illustrates a state in which the male terminals  112  are correctly inserted in the terminal-inserting holes  107 . From thence, the male connector  109  is further inserted and advanced with respect to the female connector  104 . At this time, the advancement of the inner case  108  is temporarily stopped due to an engagement of the ribs  106  of the housing  140  with the U-shaped spring pieces  110 . When the male terminals  112  are inserted in the terminal-inserting holes  107 , because the inner case  108  is in the provisional securing state as described above, insertion operation as well as two (X and Y) dimensional adjustment are rendered to be easy. Thereafter, the male connector  109  is further advanced or moved. At this time, as illustrated in  FIG. 14 , the U-shaped spring pieces  110  are outwardly resiliently deformed against their spring forces such that they are received in the deflection permitting window  111  in such a manner that they are disengaged from the ribs  106 . The male connector  109  is further advanced or moved so as to present a state as described in  FIG. 15 . In a case where the connector  109  is inserted so deep or in the above-described position, adjusting thereof is possible by pulling the connector  109 . In  FIG. 15 , E indicates an absorbable amount of error in the insertion direction. 
     FIGS. 16 and 17  are cross sectional side views illustrating the relationship between the deflection permitting windows  111  and the U-shaped spring pieces  110 . 
   While the invention has been particularly shown and described with reference to exemplary embodiments thereof, the present invention is not limited to these embodiments. It will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the following claims.