EP2795735B1

EP2795735B1 - Electrical connector, its assembly and its method of manufacture

Info

Publication number: EP2795735B1
Application number: EP12808334.2A
Authority: EP
Inventors: Frédéric MENEZ; Frédéric BELLIARD; Claude Casses
Original assignee: Delphi International Operations Luxembourg SARL
Current assignee: Delphi International Operations Luxembourg SARL
Priority date: 2011-12-22
Filing date: 2012-12-13
Publication date: 2015-12-09
Anticipated expiration: 2032-12-13
Also published as: JP6029248B2; WO2013092376A1; JP2015506534A; EP2795735A1

Description

The instant invention relates to electrical connectors, their assemblies and methods of manufacture.
In particular, the instant invention is related to electrical connectors.
It has been known to provide an electrical connector as a housing made of electrically insulating material, and which defines one or more pathways which receive electrical contacts to be electrically connected to a mating connector.
One also strives to uncouple the electrical signals carried through the connector from the surroundings. A shield is used to reduce the emission of electro-magnetic waves from the connector, and/or to prevent surrounding waves to influence the carried signal. Such a shield is for example provided by an electrically conductive plate which surrounds the contacts, and is grounded by any suitable means. WO 2010/112,457 and US2006/063415A1 provide examples of such a shielding shell.
Although the connector described in the above document behaves satisfactorily, the instant invention has notably for object to improve both the shielding efficiency and the secure connection at the interface between the connector and its mating connector.
To this aim, according to the invention, it is provided an electrical connector which comprises an inner housing defining at least one pathway for electrical contacts. The inner housing has an abutment surface.
The connector comprises a shield, provided as a folded plate sheet, assembled to the inner housing and surrounding the inner housing. The shield has two lateral portions and a planar back side extending between the two lateral sides. The connector comprises an outer housing, surrounding the shield. It has an abutment surface. The abutment surface of the inner housing and abutment surface of the outer housing cooperate to prevent a movement of the inner housing with respect to the outer housing along an assembly direction.
The outer housing further comprises a support surface.
The shield comprises extensions extending continuous with a respective lateral side, and folded over the back side. The extensions press on the support surface to elastically bias the shield and the inner housing together along the assembly direction until the abutment surfaces come in contact.
With these features, the elasticity of the folded wings enables to maintain good mechanical contact of the two housings.
In some embodiments, one might also use one or more of the features as defined in the dependent claims.
Other characteristics and advantages of the invention will readily appear from the following description of one of its embodiments, provided as a non-limitative examples, and of the accompanying drawings.
On the drawings :

Figure 1 is an exploded perspective view of an electrical connector assembly according to an embodiment of the present invention,
Figure 2 is a partial view, according to another perspective, of the connector assembly of Figure 1 in an unassembled condition,
Figure 3 is a partial view, according to another perspective, of one of the connectors of the assembly of Figure 1 and Figure 2,
Figure 4 is a sectional view along line IV-IV of Figure 3 of the connector,
Figure 5 is an enlarged view of Figure 4,
Figure 6 is a bottom view of part of the connector of Figure 3, and
Figure 7 is a perspective enlarged partial view of a mating connector to be mated with the connector of Figure 3.

On the different Figures, the same reference signs designate like or similar elements.
Figure 1 schematically shows in perspective an example of an electrical connector assembly 1 according to the invention. The electrical connector assembly 1 comprises a first connector 2 and a second connector 3, which are to be mated/unmated along a mating direction Z, or according to the present example, the vertical direction Z. The mating direction Z is the direction along which the unmating of the first connector 2 and the second connector 3 takes place.
The first connector 2 comprises a housing 4 which defines a plurality of pathways 5 for respective electrical contacts 6. The housing 4 is made of an electrically insulating material, so as to insulate the electrical contacts 6 from one another. Electrical contacts 6 extend for example in respective pathways 5 along the mating direction Z. The housing 4 may further comprise attachment parts 7, such as through holes, adapted to fasten the first connector 2 to an electrical appliance (not shown).
According to the here described embodiment, the second connector 3 is a right-angled connector. However, the invention could be implemented alternatively for straight connectors.
When the second connector 3 is a right-angled electrical connector, electrical parts are right angled. They are, for example, provided as right-angled contact elements, each corresponding to respective electrical contacts 6 of the first connector 2, and attached to a respective wire 9. The wires 9 enter the second connector 3 along a longitudinal direction X, or assembly direction X, and the contact elements have a first portion extending along the longitudinal direction X, and electrically connected to the wire 9, and a second portion extending in the direction opposite to the mating direction Z.
As well as the first connector 2, the second connector 3 comprises a housing 10 defining a plurality of pathways 11 each corresponding to the respective contact element.
The second connector 3 further comprises a cover 12 which is slidable with respect to the housing 10 between an initial position and a final position.
In the present example, the cover 12 is provided to slide along the longitudinal direction X and is provided on the side of the second connector 3 which is opposite to the side which receives the electrical wires 9. The cover 12 slides with respect to the housing 10 from its initial position to its final position along the direction opposite to the longitudinal direction X. Sliding is provided by complementary shapes of the housing 10 and the cover 12, such as for example, lateral wings 13 of the housing 10 which are guided in a longitudinal groove 14 of the cover 12, as shown on Figure 1. The cover 12 is provided with a through opening 51.
The second connector 3 further bears a lock 15 which is part of a locking system of the connector assembly 1. The lock 15 is an integral rigid part which is guided for movement on the housing 10 between a lock and a release conditions. In the present example, the lock 15 is provided to slide with respect to the housing 10 along a transversal direction Y from its lock condition to its release condition. It is, for example, also provided on the side of the housing 10 which is opposite to the wires 9.
As shown on Figures, the longitudinal direction X, the transversal direction Y and the mating direction Z are respectively perpendicular with each other.
Referring back to Figure 1, the electrical connector assembly 1 further comprises a mate assisting system. The mate assisting system is adapted to cause a relative mating movement of the housing 4 of the first connector 2 and the housing 10 of the second connector 3 relative to one another, as the cover 12 of the second connector 3 moves with respect to the housing 10 of the second connector 3 from its initial to its final positions.
As a purely illustrative example, the mate assistance system can be provided as pins 34 of the housing 4 of the first connector 2 and complementary grooves 35 of the cover 12 of the second connector 3. For example, the housing 4 of the first connector 2 has two lateral walls 36 and 37 which extend in the X-Z plane, and spaced apart along the transversal direction Y, with the pins 34 provided on an outer surface of such lateral walls 36 and 37. Two pins 34 are provided per lateral walls 36 and 37.
Similarly, the cover 12 has two lateral walls 38, 39 corresponding respectively to the lateral walls 36 and 37 and which each comprise two grooves 35, each pair of grooves 35 correspond to a pair of pins 34. Each groove 35 comprises a first portion 35a, which extends along the mating direction Z, and a second slanted portion 35b, which is slanted in the X-Z plane.
Providing four parallel pin/groove systems enable to guide the movement along a given axis.
The second connector 3 further comprises a locking system adapted, in its active condition, to lock the cover 12 and the housing 10 in the initial position of the cover 12.
In particular, it prevents a movement of the cover 12 along the longitudinal direction X with respect to the housing 10.
As shown on Figure 2, the lock 15 can, for example, be provided by a flexible lance 40 provided on a first side of the housing 10 of the second connector 3 and which cooperates with a stop of the cover 12.
In the initial position of the cover 12 with respect to the housing 10, an end 40a of the flexible lance 40 cooperates with the stop so as to prevent the movement of the cover 12 along the longitudinal direction X. The movement of the cover 12 along the direction opposite to the longitudinal direction X is normally hindered by friction of the flexible lance 40 on a stop provided facing the external face of the flexible lance 40.
As visible on Figure 3, the housing 10 of the second connector 3, which is only partially shown on Figure 3, comprises an inner housing 16 which defines pathways 11 which receive the electrical contact elements.
A shield 17 is provided surrounding the inner housing 16. The shield 17 surrounds the inner housing 16, except at two ends where the receptacles are to be accessible to the outer world :

a rear opening 49, which is for insertion of cables in the housing 10 of the second connector 3, and
a front opening 50, which is for connection to a complementary contact.

The shield 17 will usually be contacted with a shield of the cable at the rear opening 49 and with a shield of a complementary connector at the front opening 50.
The shield 17 is made of an electrically conductive (metallic) sheet plate which is formed and folded over the inner housing 16. The shield 17 can, for example, have a box shape which corresponds to an external box shape of the inner housing 16. The shield 17 comprises two lateral sides 18a and 18b extending parallel to one another. A top side 19 of the shield 17 extends between the two lateral sides 18a and 18b and extends continuously between them. The shield 17 further comprises a back side 20 which is planar and extends between the two side portions 18a and 18b. The shield 17 comprises a bottom side 21 extending parallel to the top side 19.
For reasons of ease of assembly, the shield 17 may be made in two parts which are assembled in electrical contact with one another :

a first part 22a comprises the top side 19, parts of the two lateral sides 18a and 18b and the back side 20,and
a second part 23 comprises the bottom side 21 and the other parts of the two lateral sides 18a and 18b.

In order to maintain the shield 17 on the inner housing 16, the shield 17 and the inner housing 16 are provided with complementary mechanical features. For example, the inner housing 16 is provided with two symmetrical projection stops 24 which project through a respective cut out of a similar shape of the shield 17. The cut out is sensibly L-shaped, so as to prevent a movement of the shield 17 with respect to the inner housing 16 in two directions.
The housing 10 of the second connector 3 further comprises an outer housing 25, as shown on Figure 4, which surrounds the shield 17 and the inner housing 16. The geometry of the outer housing 25 is, for example, visible on Figure 1, since the outer housing 25 forms the outer surface of the housing 10. The outer housing 25 comprises the lateral wing 13, the flexible lance 40, receives the lock 15, ...
In order to lock the outer housing 25 to the inner housing 16, the outer housing 25 is provided with abutment surfaces 26 which cooperate with the projection stops 24 of the inner housing 16.
As can be seen on Figure 4, the outer housing 25 defines a window 27 defined by walls, including the abutment surface 26 which faces an abutment surface 28 of the projection stop 24.
The cooperation of the abutment surface 26 of the outer housing 25 and the abutment surface 28 of the projection stop 24 prevents any relative movement of the inner housing 16 and the outer housing 25 along the longitudinal direction X.
The longitudinal direction X is the direction along which the inner housing 16 and the outer housing 25 are assembled to one another, with the shield 17 interposed in between.
Therefore, upon assembly of the second connector 3, the inner housing 16 is provided. Then, the shield 17 is assembled to the inner housing 16 by being folded thereon. The outer housing 25 is slid with respect to the assembly along the longitudinal direction X. Frames 29, which surround the windows 27, are elastically deformed by insertion of the projection stops 24, until the projection stops 24 are retained in the window 27 by cooperation of the abutment surface 26 of the outer housing 25 and the abutment surface 28 of the projection stop 24, as discussed above.
Referring back to Figure 3, the back side 20 of the shield 17 has two lateral edges 30a, 30b which are not joined to the lateral sides 18a, 18b of the shield 17, respectively.
Instead of that, the lateral sides 18a and 18b of the shield 17 each have an extension 31a, respectively an extension 31b, which is, for example, provided as a wing extending longitudinally along the whole height of the lateral sides 18a and 18b. The extensions 31a and 31b are first provided aligned with the respective lateral sides 18a and 18b and are folded by about 90 degrees over the back side 20 of the shield 17.
As can be seen on Figure 5, the extension 31b acts as a cantilever between the back side 20 (and associated inner housing 16) and outer housing 25. Hence, the outer housing 25 has a support surface 32 which faces the back side 20 of the shield 17. The support surface 32 may even comprise a protrusion 33 protruding toward the inner housing 16.
The extension 31b is elongated along the mating direction Z and has the shape of a plate with an inner face 42a and an opposed outer face 42b. Moreover, the extension 31b is provided with a bump 41 which protrudes from the inner face 42a.
When the inner housing 16 and the outer housing 25 are locked to one another. The bump 41, projecting from the inner face 42a of the extension 31b, bears on the back side 20 of the shield 17, and the outer face 42b of the extension 31b, opposed to the inner face 42a will bear on the support surface 32 of the outer housing 25.
These two contacts are possible only through elastic deformation of the extension 31b. The elastic deformation biases the abutment surface 26 of the outer housing 25 and the abutment surface 28 of the projection stop 24 of the inner housing 16 in contact with one another for a secure mechanical locking of the inner housing 16 and the outer housing 25 together. A plurality of bumps 41 can be provided along the mating direction Z.
As can be seen on Figure 4, a slot 43 is defined between the outer housing 25 and the assembly of the inner housing 16 and the shield 17.
As shown on Figure 6, one of the walls of the slot 43 is defined by the bottom portion of the back side 20 of the shield 17 and the extensions 31a and 31b.
The support portion 32 of the outer housing 25 does not extend along the whole length of the extensions 31a and 31b. It is present mainly at the same height as the projection stops 24 and the abutment surfaces 26, at the level of section IV-IV on Figure 3.
Another wall 52 of the slot 43, facing the back side 20 of the shield 17, is a wall 52 of the outer housing 25. The slot 43 has an opening 48 designed to allow insertion of a complementary portion 44 of the first connector 2 as shown on Figure 6.
The complementary portion 44 comprises a plastic part, with a bearing surface in contact with the wall 52 of the outer housing 25 of the second connector 3, which is designed to be introduced into the slot 43 to guide and retain the first connector 2 and the second connector 3 with respect to one another upon connection.
The complementary portion 44 further comprises an electrical part 45 such as, for example, a shield made from a formed metallic sheet plate which is to be contacted with the shield 17 of the second connector 3. For example, the electrical part 45 comprises a base 46 and elastic tongues 47 which are in contact with the back side 20 of the shield 17 of the second connector 3 when the first connector 2 and the second connector 3 are assembled.
Therefore, an excellent electrical contact is provided from the base 46 through the elastic tongues 47, the back side 20, the bump 41 and the lateral sides 18a and 18b of the shield 17 of the second connector 3, thereby providing an effective shield against electromagnetic interferences.

Claims

Electrical connector (3) comprising:
- an inner housing (16) comprising at least one pathway (11) for a contact element and an abutment surface (28),

- a shield (17), provided as a folded sheet plate, assembled to the inner housing (16) and surrounding the inner housing (16), the shield (17) having two lateral sides (18a, 18b) and a back side (20) extending between the two lateral sides (18a, 18b),

- an outer housing (25) surrounding the shield (17), and comprising an abutment surface (26) and a support surface (32),
wherein the abutment surface (28) of the inner housing (16) and the abutment surface (26) of the outer housing (25) are adapted to cooperate to prevent relative movement of the inner housing (16) and the outer housing (25) along an assembly direction (X), and
wherein the shield (17) comprises extensions (31a, 31b) extending continuous with respective lateral sides (18a, 18b), folded over the back side (20), adapted to press on the support surface (32) to elastically bias the shield (17) and the inner housing (16) together along the assembly direction (X) until the abutment surface (28) of the inner housing (16) and the abutment surface (26) of the outer housing (25) come in contact.
Electrical connector (3) according to claim 1, defining a mating direction (Z) along which the electrical connector (3) is to be connected to a mating connector (2), wherein the mating direction (Z) is perpendicular to the assembly direction (X).
Electrical connector (3) according to claim 1 or 2, defining a mating direction (Z) along which the electrical connector (3) is to be connected to a mating connector, wherein a slot (43) is defined between the assembly of the inner housing (16) and the shield (17) and the outer housing (25), the extensions (31a, 31b) projecting in the slot (43), and wherein the slot (43) has an opening (48) shaped to allow insertion of a complementary device (44) along the mating direction (Z).
Electrical connector (3) according to any of claims 1 to 3, defining a mating direction (Z) along which the electrical connector (3) is to be connected to a mating connector,
wherein the shield (17) has an front opening (50) shaped to allow electrical connection of the contact element arranged in the pathway (11) with electrical contacts (6) of the mating connector along the mating direction (Z).
Electrical connector (3) according to any of claims 1 to 4, defining a mating direction (Z) along which the electrical connector (3) is to be connected to a mating connector,
wherein the extensions (31a, 31b) are elongated along the mating direction (Z).
Electrical connector (3) according to any of claims 1 to 5,
wherein the extensions (31a, 31b) each comprise a plate having an inner face (42a) and an opposed outer face (42b), and
wherein the inner face(42a), facing the back side (20), has at least one bump (41).
Electrical connector (3) according to any of claims 1 to 6,
wherein one of the abutment surface (28) of the inner housing (16) and the abutment surface (26) of the outer housing (25) extend through the shield (17).
Electrical connector (3) according to any of claims 1 to 7, further comprising a contact element in the pathway (11).
Electrical connector assembly (1) comprising:
- a first connector (2) mated with a second connector (3) according to any of claims 1 to 8 in a connected condition,
the first connector (2) comprising a complementary portion (44) having a electrical part (45) electrically contacting the back side (20) of the shield (17).
Electrical connector assembly (1) according to claim 9,
wherein the outer housing (25) of the second connector (3) has a wall (52) defining the slot (43), and
wherein said complementary portion (44) has a bearing surface in contact with the wall (52) of the outer housing (25) of the second connector (3).
A method of manufacturing an electrical connector (3), comprising :
- providing an inner housing (16) comprising at least a pathway (11) for a contact element and an abutment surface (28),

- assembling a shield (17) to the inner housing (16), as a folded sheet plate which surrounds the inner housing (16), the conductive shield having two lateral sides (18a, 18b) and a back side (20) extending between the two lateral sides (18a, 18b),

- assembling an outer housing (25) surrounding the shield (17) and comprising an abutment surface (26) and a support surface (32),
wherein the shield (17) is provided with extensions (31a, 31b) extending continuous with a respective lateral sides (20), folded over the back side (20), pressing on the support surface (32) to elastically bias the shield (17) and the inner housing (16) together along an assembly direction (X) until abutment surface (28) of the inner housing (16) and the abutment surface (26) of the outer housing (25) cooperate to prevent further relative movement in the assembly direction (X).