Patent Grant
10622755
The invention generally relates to a connector assembly, particularly to a sealed connector assembly.
The present invention will now be described, by way of example with reference to the accompanying drawings, in which:
The present invention will now be described, by way of example with reference to the accompanying drawings, in which:
Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.
According to one embodiment of the invention, a connector assembly includes a mat seal that is shaped to fit within an opening in a connector housing. The mat seal defines a seal passage extending through the mat seal. The connector assembly also includes a conductor seal that defines a conductor passage extending therethrough. The conductor passage is configured to receive an end of a conductor. The conductor seal is received within the seal passage. The mat seal and the conductor seal cooperate to inhibit intrusion of contaminants into the connector housing.
The conductor may be an insulated wire cable having an electrical terminal attached thereto. The electrical terminal may have a first crimping feature attached to an inner wire of the insulated wire cable and a second crimping feature attached to the conductor seal. An outer wall of the conductor seal may define an outer groove and the second crimping feature may be disposed within the outer groove.
The conductor seal may be configured to extend beyond the connector housing when the conductor seal is fully inserted within the mat seal.
The conductor seal may be configured to inhibit bending of the end of the conductor as the conductor seal is received within the seal passage.
An inner wall of the conductor passage may define a plurality of inner grooves.
The seal passage may be a first seal passage, the conductor may be a first conductor, the conductor seal is may be first conductor seal, and the conductor passage may be a first conductor passage. The mat seal may define a second seal passage extending therethrough. The connector assembly further comprises a second conductor seal defining a second conductor passage extending therethrough and configured to receive an end of a second conductor, wherein the second conductor seal is received within the second seal passage, and wherein a first inner diameter of the first conductor passage is different than a second inner diameter of the second conductor passage. A first outer diameter of the first conductor seal may be equal to a second outer diameter of the second conductor seal. The first inner diameter of the first conductor passage may be not equal to the second inner diameter of the second conductor passage. A first diameter of the first seal passage may be equal to a second diameter of the second seal passage. The first conductor seal and the second conductor seal may be formed of a silicone-based material.
According to another embodiment of the invention, a method of forming a connector assembly includes the steps of:
The method may further include the steps of:
The conductor seal may extend beyond the connector housing when the conductor seal is fully inserted within the mat seal.
The conductor seal may be configured to inhibit bending of the end of the electrical cable during the step of inserting the conductor seal within the seal passage.
An inner wall of the conductor passage may define a plurality of grooves. An outer wall of the conductor seal may also define a plurality of grooves.
The electrical cable may be a first electrical cable, the electrical terminal may be a first electrical terminal, the conductor seal may be a first conductor seal, and the seal passage may be a first seal passage. The mat seal may define a second seal passage extending therethrough. The method may further include the steps of:
A first outer diameter of the first conductor seal may be equal to a second outer diameter of the second conductor seal. A first diameter of the first conductor passage may be not equal to a second diameter of the second conductor passage. A first diameter of the first seal passage may be equal to a second diameter of the second seal passage.
The first conductor seal and the second conductor seal may be formed of a silicone-based material.
Some connector assembly have had conductors that were inserted directly into conductor passages defined by the mat seal, but this has not sufficiently addressed the needs of the industry because each conductor passage had to be sized to fit a particular cable size in connector assembly applications having a mix of conductor diameters. This often required a different mat seal to be tooled for each particular application in which the connector assembly was used. Additionally, the diameter of the conductor passage must be reduced in order for the mat seal to properly seal to the conductor as smaller diameter conductors are used. If a terminal is attached to an end of the conductor having a small diameter, e.g. having a dimeter of 0.85 mm or less, it may be too large to easily pass through the conductor passage, leading to difficult insertion of the terminal and conductor through the conductor passage due to a high insertion force caused by contact between the edges of the terminal and the conductor passage and/or damage to the mat seal also caused by contact between the edges of the terminal and the conductor passage that reduces the effectiveness of the mat seal to seal out contaminants.
The connector assembly 100, as shown in the nonlimiting example of
The mat seal 110 includes defines forward and aft peripheral edge sealing ribs 114 that are arranged parallel to one another and are axially-spaced from one another. The peripheral edge sealing ribs inhibit contaminants from passing between an outer periphery of the mat seal 110 and a corresponding inner sealing surface 116 of the connector housing 108. Each of the peripheral sealing ribs 114 extends integrally edgewise outward from around the mat seal 110 so that the peripheral sealing ribs 114 will be elastically compressed when the mat seal 110 is received within the rear opening 112 and will seal against the inner sealing surface 116 of the connector housing 108 into which the mat seal 110 has been received.
The mat seal 110 may also include a plurality of seal passages 118. The seal passages 118 each configured to receive insertion of a conductor seal 120, hereinafter referred to as a cable seal 120. The cable 120 seal is characterized as having a generally cylindrical shape. Each seal passage 118 includes forward and aft annular sealing ribs 122 that extend radially and integrally inwardly from around a major diameter of each seal passage 118. Each annular sealing rib 122 includes a circular aperture 124 that is smaller in diameter than the cable seal 120. Because the diameter of the annular sealing rib 122 is smaller than that the cable seal's diameter, each of the circular apertures 124 of the annular sealing ribs 122 wi11 be elastically enlarged when receiving the cable seal 120 and will constrict around and seal against the outer surface of the cable seal 120. The annular sealing ribs 122 inhibit contaminants from passing between an outer periphery of the cable seal 120 and the mat seal 110.
As illustrated in the nonlimiting example of
As illustrated in the non-limiting example of
As shown in
As illustrated in the nonlimiting example of
As shown in the nonlimiting example of
As illustrated in
The outer diameter of the cable seal 120 may be selected based on the size of the electrical terminal 104 to ensure that the inner diameter of the seal passage 118 is greater than the largest cross sectional dimension of the electrical terminal 104 so that the seal passage 118 can accept the electrical terminal 104 without the need for the electrical terminal 104 to deform the seal passage 118.
According to the non-limiting example best illustrated in
STEP 202 inserting an electrical cable 102 having an elongate conductive core 130 surrounded by an insulative sheath 128 into a conductor seal 120 as shown in the transition from
STEP 204 includes with a first crimping feature 132, crimping an electrical terminal 104 to the conductive core 130 as shown in
STEP 206 is includes with a second crimping feature 134, crimping the electrical terminal 104 to an end of the conductor seal 120 as shown in
STEP 208 includes providing a connector housing defining an opening 112, in this nonlimiting example a rear opening, in which a mat seal 110 is disposed, the mat seal 110 defining a seal passage 118 extending therethrough as shown in
STEP 210 includes inserting the conductor seal 120 within the seal passage 118, wherein the mat seal 110 and the conductor seal 120 cooperate to inhibit intrusion of contaminants into the connector housing 108 as shown in
STEP 212 includes inserting a second electrical cable 102 having an elongate conductive core 130 surrounded by an insulative sheath 128 into a second conductor seal 120 as shown in the transition from
STEP 214 includes with a first crimping feature 132, crimping a second electrical terminal 104 to the conductive core 130 of the second electrical cable 102 as shown in
STEP 216 includes with a second crimping feature 134, crimping the second electrical terminal 104 to an end of the second conductor seal 120 as shown in
STEP 218 includes inserting the second conductor seal 120 within the second seal passage 118, wherein the mat seal 110 and the second conductor seal 120 cooperate to inhibit intrusion of contaminants into the connector housing 108 as shown in
The example presented herein is directed to a connector assembly 100 in which the conductors 102 are insulated electrical cables 102. However, alternative embodiments of the connector assembly may be envisioned in which the conductors 102 are fiber optic cables, pneumatic tubes, hydraulic tubes, or a hybrid assembly having a combination of any of these conductors 102. These conductors 102 may be terminated by fittings which may be characterized as terminals.
Accordingly, a connector assembly 100 and a method 200 of manufacturing a connector assembly is presented. The connector assembly 100 may provide significant benefits in comparison to other connector assembly structures. For example, the connector assembly 100 has a mat seal 110 in which the seal passages 118 are large enough to accommodate a terminals 104 attached to the conductors 102 without mechanical interference between the terminals 104 and the seal passages 118 when the terminals 104 are inserted through the seal passages 118 while still properly sealing the mat seal 110 to the conductor seals 120. This provides the benefit of reduced insertion force when inserting the conductor 102 through the mat seal 110. This feature improves ergonomics for the assembly technician 140 and reduces the likelihood of the conductor 102 bending as the conductor 102 is inserted. This feature also provides the benefit of reducing or eliminating the potential of damaging the mat seal 110 by contact between the terminal 104 and the seal passage 118.
The seal passages 118 of the mat seal 110 may be constructed so that all have the same diameter while the conductor 102 passages of the conductor seals 120 may have different diameters to accommodate conductors 102 with different diameters. This feature provides the benefit of using a single mat seal design for a wide variety of configurations with conductors 102 of differing diameters, which reduces the cost of producing the mat seal 110 because the need for different tooling to produce mat seals 110 with seal passages 118 of differing diameter is eliminated. This feature provides further cost saving by reducing the different part numbers that need to be tracked for the mat seal 110.
The conductor seals 120 also provide the benefit of increasing the column strength of the conductors 102 to further reduce or eliminate bending of the conductor 102 as the assembly technician 140 inserts the conductor 102 through the mat seal 110. This is especially beneficial for conductors 102 having a small diameter.
While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to configure a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely prototypical embodiments.
Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the following claims, along with the full scope of equivalents to which such claims are entitled.
As used herein, ‘one or more’ includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.
It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.
The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.
Additionally, while terms of ordinance or orientation may be used herein these elements should not be limited by these terms. All terms of ordinance or orientation, unless stated otherwise, are used for purposes distinguishing one element from another, and do not denote any particular order, order of operations, direction or orientation unless stated otherwise.
| Number | Name | Date | Kind |
|---|---|---|---|
| 7033216 | Ito | Apr 2006 | B2 |
| 7637764 | Yoneda | Dec 2009 | B2 |
| 7883365 | Saitou | Feb 2011 | B2 |
| 7905740 | Chazottes | Mar 2011 | B2 |
| 20080014793 | Okumura | Jan 2008 | A1 |
