JPH08250200A - Electric connector with gel-form seal and its preparation - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an electric connector with a gel-like seal and a method for manufacturing the same, in which wire terminating assembly can be facilitated and excellent sealing can be achieved. SOLUTION: An electric connector 2 comprises a terminal block 4 having an IDC contact 10, an outside shell 8, and a gel-like seal member 6. A wire 66 is inserted into a terminated portion of the contact 10 via an opening 40 at the rear end of the outside shell 8 and the seal member 6. The outside shell 8 and the terminal block 4 compress the seal member 6, and a conductor 70 of the wire 66 is terminated at the contact 10, to be thus completely sealed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electrical connector, and more particularly to a waterproof electrical connector with a gel seal and a method for manufacturing the same.

[0002]

2. Description of the Related Art Impurities such as splashes of water, dust, and oil enter the electric connector to corrode internal electric contacts or deteriorate electrical characteristics of the electric connector. May need to be used. In recent electrical connectors, there is also provided a waterproof (sealed) structure that prevents deterioration of electrical contacts and the like due to intrusion of such impurities.

In the conventional waterproofing technique, a wire (electric wire) is provided at a position where the wire is drawn into a connector housing, and a grommet (waterproof plug) -like structure for each wire or a plurality of openings through which a plurality of wires are inserted are collectively formed. It has a seal structure. Both of these sealing techniques rely on the elasticity of the material to adhere to both the wire and the connector housing. A problem with these sealing techniques is that they may come out of the wire side or connector housing side due to aging of the seal or if excessive force is applied to the wire. If this happens, impurities and vapors will penetrate into the connector housing, and even if these impurities do not reach the electrical contacts directly, if the seal is repeatedly displaced, it will gradually reach the electrical contacts by pumping. It will be. Therefore, continuous improvements in structure and materials are needed to ensure that the seal is retained or secured.

One improved sealing concept is the use of gel-like sealing members in electrical connector assemblies. An example of this type of seal is disclosed in U.S. Pat. No. 4,662,692. This US patent is hereby incorporated by reference. This patent discloses an electric connector with a terminal block portion in which a contact (terminal) is inserted in a terminal insertion passage. This terminal block has a contact insertion surface complementary to the front fitting surface. The gel material is arranged in a continuous shape over the entire rear surface. Next, the gel is pressed through and inserted into the cavity. The gel is self-healing and is pierceable by the contact and can then act to close the through hole to provide a tight seal around the wire terminated to the contact. This gel material is also described in detail in this patent specification.

One of the problems with this gel is that since it is oily, the gel sometimes adheres to the contact penetrating therethrough when the contact or the like touches it. As a result, gel remains as a film on the contact surface, and especially when the contact has a complicated shape (other than a simple pin shape), for example, in the case of a receptacle (female type) contact, when the gel penetrates, the sealing material is The part will invade into the contact. One concern with such contamination of the contacts by the seal material is that they may adversely affect the electrical connection of the contacts, either immediately or during extended use. Another concern is that in the case of complex geometries, such as contacts with sharp edges, the gel may be severely damaged or displaced during contact penetration, making proper sealing no longer possible. is there.

US Pat. No. 4,875,870, incorporated herein by reference, discloses various improvements to the above-described conventional seal structure. First, the gel layer includes a plurality of openings into which contacts are inserted and the wires extend outward from the rear. This improves the damage of the gel when inserting pins or wires. The gel is then provided with a foam support to reinforce the mechanical strength of the gel, minimize damage to the gel during insertion of contact pins, and further minimize gel penetration. Thirdly, a connector including a holding member for holding the gel in a compressed state is disclosed. The retaining member has a first position, holds the gel in place, and compresses the gel to cause the gel material to flow around the wire and connector housing to provide a sufficient seal over the useful life of the connector. It has 2 positions to assure. This alleviated some of the problems mentioned above, but the contact still needed to penetrate the gel and could form a coating on the contact surface. Therefore, it is difficult to use a contact having a complicated shape because the contact may be pressed into the opening to cause damage.

[0007] International Patent Application No. 92/05603, which is hereby incorporated by reference, discloses a remedy for the above-mentioned drawbacks. This prior art technique places a sealing gel between at least two limiting components, and the connector further includes pressure means to provide resilience to absorb the displacement of the sealing gel. This patent also mentions improvements in the sealing gel, ensuring a reliable seal. However, in reality, it includes some of the problems described above.

What is needed to make the sealing technique using a gel more effective is that it can be used to seal the contacts of complex shapes used in many applications today, and that conductors or The goal is to ensure that the wire does not come into contact with the contact, or that no gel coating forms at the electrical interconnection points along the contact such that the contact comes into contact with the mating terminal.

All of this must be incorporated into a commercially available package. A typical electrical connector has many electrical contacts, each receiving a wire. The electrical connector can be supplied to the end user (end user), and it is preferable and effective that all parts (components) such as the housing, the secondary locking member and the seal are already incorporated as an integral unit. The wire harness, typically with the contacts attached, is manufactured separately from the connector housing. It is well known to apply a conventional seal to the wire before terminating the contact, but it is not practical because of the inability to keep the gel together. That is, the gel is liable to deform and the wire may penetrate into the seal or the gel may disperse during or after assembly with the wire and contacts. Therefore, what is needed is a structure that is pre-packaged until it reaches the end user, which results in a gel-like seal, with no foreign matter adhering to the surface and the gel being unobtrusive during assembly.

In order to satisfy this need and in EP 0102156 cited therein, a contact structure of particular interest is disclosed. The electrical contact is a pressure contact (I) consisting of a pair of weak and generally opposing walls.
DC) part is included. This weakly formed portion falls inward when the body is displaced axially. The wire can be inserted into the contact and when this weakened portion is collapsed, the edge cuts through the wire's insulation and contacts the conductor inside. This patent further includes a rear sealing means captured between the main housing and the seal holder. The contact is placed in the cavity of the terminal block, and the wire is inserted from the rear through the seal member in the terminal block and between the collapsible walls. When the wire is properly placed, the front of the contact is displaced causing the wall to collapse, cutting the wire's insulation and making contact with the conductor inside.

US Pat. No. 5,356,3, incorporated herein by reference.
No. 02 discloses another electrical connector assembly that uses the contacts described above. In this connector assembly, the receptacle type terminal is held in the terminal block by the cover. The cover includes an opening therethrough and is inserted therethrough into the collapsible portion of the contact. A pusher member is formed around the opening, and after the wire is inserted, a tool applies a force to the pusher member to move it, causing the contact wall to collapse and contact the conductor of the wire.

Another contact and connector arrangement of interest is disclosed in EP 0554810. This electrical connector includes a terminal block portion, and a contact having an IDC (pressure contact) structure opening rearward is arranged. A wire positioning block is matable with the terminal block and includes a wire groove (channel). When the inserted wire includes a portion that traverses the IDC portion of the contact and the mating connector halves mate with each other, I
The DC portion cuts through the wire insulation to form an electrical connection with the inner conductor.

Finally, another example of a connector system of interest is disclosed in French Patent No. 9410257.
In this case, an integral housing is provided, the contact is located in the first position of the housing, and when the contact is moved to the second position, the IDC slot cuts through the insulation,
Contact with wire conductors.

Common to the contacts and connector system of interest, as described above, is that the wire is inserted into the connector housing and the housing is preloaded with contacts and terminated there.
This is of particular interest in the case of the sealing technique using the gel described above. If an electrical connector of this kind incorporates a gel seal around the wire at the rear of the connector housing, this electrical connector can be realized without the problems mentioned above with respect to the gel seal.

The electrical connector having the contacts therein and the gel-like seal at the terminal receiving end of the terminal block can be delivered to the user in an at least partially assembled state. The wire is insertable from the terminal receiving end of the connector into the termination of the contact. When the wire has an insulating jacket around the conductor, the gel seal coating and foreign matter are located outside the insulating jacket. Once inside the connector housing, the wire is terminated in the IDC termination area of the contact, with the insulation removed and the conductor exposed. Eliminating the insulation also eliminates coatings and debris on it, providing good interconnection with the conductors. There is concern that foreign matter in the electrical interconnect may degrade the electrical interconnect.

Accordingly, it is an object of the present invention to provide a sealed electrical connector which uses a sealing gel which does not contaminate the seal with foreign matter or the like at the electrical interconnections.

[0017]

According to the electrical connector with a gel seal of the present invention, the housing has a two-body structure including a terminal block which is axially movable relative to each other and which can be latched, and a substantially cylindrical outer shell. In the meantime, a flat gel seal member is arranged. A wire is inserted into the contact through the seal member, and the terminal block and the outer shell are moved to each other to press-connect the contact to the wire.

According to the method of manufacturing an electric connector with a gel seal of the present invention, the contact is inserted and fixed in the contact passage of the terminal block, the gel seal member is arranged between the outer shell and the terminal block, and this seal member is used. It is characterized in that the wire is inserted through the contact, the outer shell is pressed to compress the sealing member, the wire is pressure-connected to the contact, and the electric connector is satisfactorily sealed.

[0019]

BEST MODE FOR CARRYING OUT THE INVENTION A preferred embodiment of the electrical connector with a gel-like seal of the present invention and a method for manufacturing the same will be described below in detail with reference to the accompanying drawings.

First, FIG. 1 is a vertical cross-sectional view of an electric connector with gel seal (hereinafter simply referred to as an electric connector or connector) 2 according to the present invention. The electrical connector 2 includes a terminal block portion 4, a gel-like sealing member 6, an outer shell 8 and an electrical contact 10. A seal member 12 is provided on the outer periphery of the terminal block 4 to form a shroud of a mating connector (not shown) and a tight seal (a portion for preventing entry of contaminants such as water, steam and dust).

The terminal block 4 includes a fitting surface 14, a projection 16 extends rearward from the fitting surface 14, and a seal 12 is arranged on the outer periphery thereof. A contact receiving passage 18 is formed in the terminal block 4, and the contact 10 is arranged therein. A corresponding mating terminal receiving opening 20 is formed on the mating surface 14, and a terminal (not shown) of the mating connector is inserted into the mating surface 14 to make electrical contact with the contact 10. The opposite side of the fitting surface 14 is a terminal insertion surface 22, and the terminal receiving passage 18 is opened in this surface 22. Mating surface 14
There is a body 24 of the terminal block 4 between the terminal receiving surface 22 and the terminal receiving surface 22. A first latch barb 26 is formed opposite to the outer surface of the body 24 to hold the terminal block 4 at the first (preload) position of the outer shell 8 as shown in FIG. Similarly, a pair of second latches 28 are formed on the body 24 on the side of the fitting surface 14 of the terminal block 4.
These latches 28 cooperate with the outer shell 8 to define a fully engaged position as described below with reference to FIG.

The gel seal 6 comprises a gel material 30 sandwiched between a pair of support members 32 or supported by a matrix well known by the references cited herein.
The gel-like seal 6 has an opening penetrating the support member 32, and if necessary, the gel is filled with the gel in the terminal receiving passage 1 of the terminal block 4.
It may correspond to 8. Here, the foam-shaped support member 3
However, other configurations may be used. The configuration of the gel seal 6 is fully disclosed in the above-mentioned patent publications and the like.

The outer shell 8 includes a peripheral shroud 34 defining an opening 36 in which the terminal block 4 and a mating connector are received. A rear plate 38 is arranged behind the seal 6, and a wire receiving opening 40 and a gel-like seal 6 sheet 41 are formed in the rear plate 38. The wire receiving opening 40 communicates with the terminal receiving passage 18 of the terminal block 4 when the connector 2 is assembled, as best shown in FIG.

A holding member 42 is formed in the outer shell 8 and engages with the latches 26, 28 of the terminal block 4 to provide a first (preload or temporary assembly) position and a second position between the terminal block 4 and the outer shell 8. Hold in the (complete mating) position. The holding member 42 of this embodiment is provided with the opening 3 in front of the rear plate 38.
6 is an arm extending inside. The holding member 42 is substantially U-shaped, and has a closed end 44 near the front end of the holding member 42.
The U-shaped base acts as a catch to engage the latches 26, 28 to maintain the latch engagement between the outer shell 8 and the terminal block 4 and to facilitate assembly.

The contact 10 is of the type disclosed in the above mentioned EP 0102156. The contact 10 is aligned with the terminal insertion opening 20 and includes a mating terminal receiving portion 46 formed of a pair of forwardly extending resilient arms 48. The mating terminal is inserted into the terminal block 4 and comes into contact with the internal contact 10. The terminal receiving portion 46 extends from the body portion 50 and includes the stopper 52 to establish the insertion position of the conductive member, that is, the wire 66. On the opposite side of the body 50 from the terminal receiving portion 46 is a conductor connection having a pair of collapsible sidewalls 56 formed with an insulator cut edge 58. In this particular embodiment, the sidewalls 56 project outwardly from the terminal block 4 over the terminal insertion surface 22 to the terminal end 60.

Next, description will be made with reference to FIG. The electric connector 2 has the terminal block 4 and the outer body 8 in the first position, and is in a state of being sent to the end user. In this provisionally assembled state, the contact 10 remains in the terminal block 4, and the shoulder 62 of the body portion 50 is in contact with the shoulder 64 of the terminal block 4. The terminal block 4 is arranged in the outer shell 8, and the catch portion 44 of the holding member 42 engages with the first latch 26 and abuts on the second latch 28. In this first position, there is a great resistance to pulling out the terminal block 4 from the outer shell 8, and also when the terminal block 4 is further inserted, by the holding arm 42 and the catch 44,
There is some resistance. The rear surface 22 of the terminal block 4 is near the gel seal 6 seated in the seal receiving cavity 41. The arm 56 of the conductor connecting portion 54 extends rearward through the gel seal 6 and is in contact with the inner surface of the rear plate 38. The gel seal 6 blocks the wire insertion opening 40, but is aligned with the opening if the gel seal 6 is formed.

Next, description will be made with reference to FIG. The insulation coated wire 66 is inserted from the rear end into the connector 2 in the temporarily assembled state shown in FIG. The wire 66 has a front end 72 that is inserted into the wire insertion opening 40 of the outer shell 8. This wire 66
Is inserted into the conductor connecting portion 54 by penetrating the gel-like sealing member 6, and is continuously inserted until the front end 72 contacts the stopper 52.

In this position, the notched edge 58 of the contact 10 is located along the side of the insulated wire 66. Once the wire 66 passes through the sealing gel 30 and is held stationary, the self-healing property of the gel 30 surrounds and seals around the insulator 68. When the insulated wire 66 passes through the gel 30 and leaves a gel coating, the gel adheres along the ends 72 of the wire 66 or the surface of the insulating coating 68.

Next, the termination will be described with reference to FIG. When the wire 66 is inserted, pressing the connector 2 in the direction of arrow A causes relative movement between the terminal block 4 and the outer shell 8. As a result, the collapsing wall 56 of the contact 10 collapses or collapses inward and cuts the insulating coating 68 to reach the conductor 70. A sharp edge 58 along this wall 68 penetrates the insulating coating 68 and eliminates it. This eliminates not only the insulating coating, but also the coating of the gel seal 6 which may have adhered to its outer surface. As a result, a reliable electrical interconnection is established. When the wall 56 collapses, that is, falls down, the above-described catch 44 of the holding member 42 gets over the second latch 28. When the latch 28 is captured by the catch 44, it prevents the terminal block 4 from coming off the outer shell 8. Furthermore, in this position, the rear surface 22 of the terminal block 4 abuts the gel-like sealing member 6 and applies a compressive force thereto, which further strengthens the sealing of the insulated wire 66.

Next, another embodiment of the electrical connector with a gel-like seal according to the present invention will be described with reference to FIGS. This embodiment is very similar to the embodiment of Figures 1 to 4 described above. Therefore, corresponding elements are given the same reference numerals to avoid repeating the detailed description. First, referring to FIG. 5, the electrical connector 200 includes a terminal block 4, a gel-like sealing member 6, an outer shell 8 and a contact member 210 therein. The contact member 210 is disposed in the contact passage 212,
Receptacle end 2 for receiving a mating contact (not shown)
14 and a wire connection end 216 connected to the insulated wire 60 by the IDC technique. The wire connection end 216 is flat, has a water drop shaped slot, and the wide portion is configured to receive the wire, and the narrow portion includes the cutting edge to cut the insulating coating of the wire 66. Then, the inner conductor 70 is pressed and connected. Details of this point are disclosed in the above-mentioned French patent application 94 10 257 or European patent application 0554810.

The wire 66 is the wire insertion opening 4 of the seal 8.
0 into the wire receiving area 218. The wire receiving area 218 is biased or sloped 220.
And guides the tip of the wire 66 in the direction intersecting the axis of the contact 210 and to the wide portion of the waterdrop-shaped IDC slot.

Next, description will be made with reference to FIG. Pressing force A
Is applied to the connector 200 to connect the outer shell 8 and the terminal block 4 to each other. In this case, the seal 6 is compressed as described above to enhance the sealing effect. As the terminal block 4 moves backwards, the biasing surface 220 also pushes the insulated wire 66 backwards and into the narrow connecting portion of the water drop IDC slot of the contact 210, cutting the insulating coating and crimping the conductor 70. Connecting. As will be readily understood from this configuration, the wire 66 is supported by the rear plate 38 and electrically connected to the contact 210. When this cutting edge cuts through the insulating coating, dirt (adhesion) of the gel seal on the surface is removed, and the contact 210 is removed.
Will be securely connected to the conductor 70 of the wire 66. Further, the gel-like seal 6 seals the through hole of the wire 66, which is the same as in the case of FIGS. 1 to 4.

The preferred embodiments of the gel-like electrical connector with a seal according to the present invention have been described above in detail. However, these are merely examples of the present invention, and various modifications can be made to each part according to the intended use. Will be understood. Further, the electrical connector 2 of the present invention has contacts arranged in a plurality of rows, and it is also possible to use a single gel seal which is independent for each wire or common to all the contacts. It is also possible to provide a positioning post on the outer shell 8 to hold the seal 6 in place.

[0034]

According to the electrical connector with gel seal of the present invention and the method for manufacturing the same, a gel seal member is used,
It penetrates through this and inserts the wire into the contact, presses the outer shell to press-connect the wire to the contact and compresses the seal, so the hole of the gel seal due to the wire insertion is forcibly and completely blocked, which is effective. Various seals can be realized. Further, even if the temporary sealing gel adheres to the wire surface, the surface is cut at the cutting edge of the contact to electrically connect with the internal conductor, so that highly reliable electrical connection can be realized. Further, it has a remarkable practical effect that the assembly of the electric connector and the termination of the wire, that is, the shielded wire harness can be manufactured very easily.

[Brief description of drawings]

FIG. 1 is an exploded vertical sectional view of a preferred example of an electric connector with a gel-like seal according to the present invention.

2 is a vertical cross-sectional view of the electrical connector of FIG. 1 in a first or temporary assembled state.

3 is a vertical cross-sectional view showing a state in which a wire is inserted in the electric connector of FIG.

FIG. 4 is a longitudinal sectional view showing a second or final assembled state in which the electrical connector of FIG. 1 is terminated into a wire to form a wire harness.

FIG. 5 is a vertical cross-sectional view of another embodiment of the electrical connector with a gel-like seal according to the present invention in a temporarily assembled state.

6 is a vertical cross-sectional view of a final assembled state in which a wire is terminated to the electric connector of FIG.

[Explanation of symbols]

 2,200 gel-like electrical connector with seal 4 terminal block 6 gel-like sealing member 8 outer shell 10,210 contact 26,28,42,44 latch member 66 wire 70 conductor

Claims (2)

[Claims] 1. A seal-type electrical connector having one or more contacts connected to a wire and sealing between a contact portion between a wire insertion portion and a mating contact of the contact, and a terminal block holding the contact. An outer shell arranged outside the terminal block, and a gel-like seal member arranged on the wire insertion portion side of the outer shell, wherein a wire is inserted into the contact through the seal member An electric connector with a gel-like seal, characterized in that the wire is pressure-connected to the contact by moving the terminal block and the outer shell relative to each other. 2. A step of inserting and fixing a contact in a contact passage of a terminal block, a step of disposing a gel seal member at a rear end portion of the terminal block, and an outer shell on the outer side of the seal member and the terminal block. A step of arranging, a step of penetrating the seal member and inserting a wire into the contact, a step of pressing the outer shell and the terminal block against each other to compress the seal member and connect the wire to the contact A method of manufacturing an electrical connector with a gel-like seal, comprising: