This invention relates to electrical terminal connections, in particular, a splice terminal for connecting two different sized wires together for use in a liquid environment such as water or fuel.
The present electrical terminal connections use a mechanical connection between the two wires and the terminal. This style of terminal is made by crimping stranded or solid wires to make an electrical connection wherein the electrical connection must be located in an area having fluid such as water or gasoline surrounding it. For example, a fuel injector to an electronic control module.
As shown in Prior Art
Since the connection between the outside of insulation 13 and the inside of 15 of the crimp ferrule depends solely on the tightness of fit, it is possible that the connection will fail due to the blind fit between the wire and connector, especially when subjected to repeated stress movement. The entire connection is molded with a covering (which will be discussed below) to maintain water tightness.
While this system works, the inventors have found that this process can be substantially improved upon by eliminating the costly crimp ferrule thus, eliminating the difficulty of making certain that the respective wires are properly inserted there for a proper crimping. To improve the water/gasoline tightness of the connector, multiple diameters serve as fuel barriers as well as maintaining the same amount of material for the pre-mold and the same dimensions for the overmold portion.
The invention is an electrical connector for use in an area subject to fluids such as gasoline or water. Typically, the connector would be used in a fuel injector to an electronic control module found in automotive and recreational motors. Once the wires have been stripped, they are then fused to a centering section to provide a common joint. The centering section is provided with a encapsulating mold centering section featuring two opposing alignment bosses and two sections of four circumferential centering tips. Finally, a second molding process is applied. The tips and the bosses re-melt or re-flow during the second encapsulation process to provide for a centered assembly that prevents fuel or water leaking from one wire to the next through the connection.
It is an aspect of the invention to provide a connector for two wires that can be used in a fluid environment without leaking.
It is another aspect of the invention to provide a connector that connects two different sized wires even when placed in a fluid environment such as gasoline, water or any application that requires electrical current flow in a fluid environment.
Another aspect of the invention is to provide a connector that has the same sized external plastic molded protective cover so that a defective part can be replaced with the new inventive part.
Still another aspect of the invention is to use no more molded material than had been used required for a Prior Art system.
Finally, it is an aspect of the invention to provide a connection that can be manufactured at a lower cost yet have a reliability that is equal or better than the present part it is being used to replace.
These and other aspects of the invention will become apparent in light of the detailed description of the invention which follows.
To fabricate connector 10, wires 12, 14 first have a short portion of the insulation stripped from the end as shown in
Referring to
While certain representative embodiments of the invention have been described herein for the purposes of illustration, it will be apparent to those skilled in the art that modification therein may be made without departure from the spirit and scope of the invention.
This application claims benefit under Title 35 USC, §119(e) of U.S. Provisional Application Ser. No. 60/722,687 filed Sep. 30, 2005.
Number | Name | Date | Kind |
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7230214 | Kirby | Jun 2007 | B2 |
20030015341 | Ito | Jan 2003 | A1 |
20040074667 | Endacott | Apr 2004 | A1 |
Number | Date | Country | |
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20070082553 A1 | Apr 2007 | US |
Number | Date | Country | |
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60722687 | Sep 2005 | US |