Patent Application
20200052421
The invention generally relates to connector assemblies, particularly a method for securing a terminal within a connector housing of a connector assembly and a connector assembly formed by this method.
Resilient locking tangs 2, as illustrated in
The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions.
In accordance with an embodiment of the invention, a method of securing an electrical terminal within a connector body is provided. This method includes step a) providing the connector body defining a longitudinal terminal cavity therethrough and step b) providing the electrical terminal. The electrical terminal includes a first connection portion configured to attach the electrical terminal to a first conductor, e.g. a first corresponding terminal, a second connection portion configured to interconnect with a second conductor, e.g. a second corresponding terminal, and a transition portion intermediate the first connection portion and the second connection portion. The method further includes step c) disposing the electrical terminal within the terminal cavity and step d) deforming a portion of an outer surface of the connector body to fabricate a protrusion that projects from an inner surface of the connector body into the terminal cavity intermediate the first connection portion and the second connection portion, thereby securing the electrical terminal within the terminal cavity. The steps c) and d) are preferably performed in the order listed.
The protrusion may be characterized as having a generally domic shape. The protrusion may be formed by pressing the outer surface of the connector body toward the inner surface of the terminal cavity using a generally cylindrical probe. An end of the probe contacting the outer surface has a generally flat central section concentrically surrounded by a compound curved section having a convex-concave-convex profile. The inner surface of the terminal cavity may define a ridge which extends from the inner surface into the terminal cavity. This ridge is preferably formed prior to step c). The ridge is configured to engage the second connection portion of the electrical terminal.
A radial distance between the portion of the outer surface of the connector body and the inner surface of the terminal cavity may be less than a radial distance between a remaining portion of the outer surface and the inner surface.
The connector body is preferably formed of a polymeric material, e.g. 20% glass filled polybutylene terephthalate.
In accordance with another embodiment, a connector assembly is provided. This connector assembly is formed by the method described above.
The present invention will now be described, by way of example with reference to the accompanying drawings, in which:
The problem of securing an electrical terminal within a terminal cavity of a connector body of a connector assembly are solved by deforming a portion of the connector body to fabricate a protrusion that projects from an inner surface of the connector body into the terminal cavity after the electrical terminal has been inserted into the terminal cavity.
In the following description, orientation terms such as “longitudinal” will refer to the mating axis X while “lateral” refers to an axis perpendicular to the mating axis, which is not necessarily the transverse axis. Furthermore, terms relating to “top” “bottom”, “upper”, and “lower” are to be understood relative to an axis perpendicular to the mating axis X, which is not necessarily the vertical axis. As used herein the terms “front” and “forward” refer to a lateral orientation from the first connector towards the second connector and the terms “back”, “rear”, “rearward”, and “behind” refer to a lateral orientation oriented from the second connector towards the first connector.
STEP 102, PROVIDE A CONNECTOR BODY DEFINING A LONGITUDINAL TERMINAL CAVITY, includes providing a connector body 16 defining a longitudinal terminal cavity 14 therethrough as best illustrated in
STEP 104, PROVIDE AN ELECTRICAL TERMINAL, includes providing an electrical terminal 12 as illustrated in
Alternative embodiments may include an electrical terminal that is formed by other manufacturing processes, such as casting or machining. Other embodiments may include a first or second connection portion that is a male pin or blade terminal. Yet other embodiments may have a first or second connection portion that is configured to be connected to a wire cable via crimping, soldering, welding, or other known wire/terminal attachment features.
STEP 106, DISPOSE THE ELECTRICAL TERMINAL WITHIN THE TERMINAL CAVITY, includes inserting the electrical terminal 12 within the terminal cavity 14 as best illustrated in
STEP 108, DEFORM A PORTION OF AN OUTER SURFACE OF THE CONNECTOR BODY TO FABRICATE A PROTRUSION THAT PROJECTS FROM AN INNER SURFACE OF THE CONNECTOR BODY INTO THE TERMINAL CAVITY, includes deforming a portion of an outer surface 24 of the connector body 16 to fabricate a protrusion 26 that projects from an inner surface 28 of the connector body 16 into the terminal cavity 14 intermediate the first connection portion 18 and the second connection portion 20, thereby securing the electrical terminal 12 within the terminal cavity 14. STEPS 106 and 108 are performed in the order listed here.
The protrusion 26 is formed by pressing the outer surface 24 of the connector body 16 toward the inner surface 28 of the terminal cavity 14 using a rigid, generally cylindrical probe 30. A tip of the probe 30 contacting the outer surface 24 has a generally flat central section 32 concentrically surrounded by a compound curved section 34 having a convex-concave-convex profile. The protrusion 26 is cold-formed at ambient temperature i.e. within a temperature range of 20° C. to 25° C. The force applied to the probe 30 to form the protrusion 26 is dependent upon the material used to form the probe 30 and the geometry of the probe tip. The formation of the protrusion 26 forms a corresponding indentation 27 in the outer surface 24 of the connector body 16.
The inner surface 28 defines a ridge or stop 36 that extends from the inner surface 28 of the connector body 16 into the terminal cavity 14. This stop 36 engages the second connection portion 20 of the electrical terminal 12, thereby preventing further insertion of the electrical terminal 12 into the terminal cavity 14. The stop 36 is preferably formed when the connector body 16 is molded, in any case before the deformation of the connector body 16 to form the protrusion 26 in STEP 108.
As best shown in
While the illustrated example of the connector assembly 10 shows one terminal cavity 14 and an associated electrical terminal 12, other embodiments may be envisioned in which a connector body defines multiple cavities and contains multiple electrical terminals. In addition, although the examples presented herein are directed to electrical connector assemblies, other embodiments of the connector assembly may be envisioned that are adapted for use with optical cables or hybrid connections including both electrical and optical cables. Yet other embodiments of the connector assembly may be envisioned that are configured for connecting pneumatic or hydraulic lines.
Accordingly a method 100 securing an electrical terminal 12 within a terminal cavity 14 of a connector body 16 of a connector assembly 10 and the connector assembly 10 formed by such a method 100 is provided. This method 100 provides the advantages of reducing the insertion force required to insert the electrical terminal 12 within the terminal cavity 14 by eliminating locking features on the electrical terminal, such as the locking tangs 2 shown in
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 adapt 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.
In the following claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, the use of the terms first, second, etc. does not denote any order of importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Additionally, directional terms such as upper, lower, etc. do not denote any particular orientation, but rather the terms upper, lower, etc. are used to distinguish one element from another and locational establish a relationship between the various elements.
Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 USC § 112(f), unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
