EP4654398A1

EP4654398A1 - Sealed connector assembly for automotive applications

Info

Publication number: EP4654398A1
Application number: EP24178099.8A
Authority: EP
Inventors: Norbert Dobernig; Nithish Sukumar
Original assignee: Aptiv Technologies AG
Current assignee: Aptiv Technologies AG
Priority date: 2024-05-24
Filing date: 2024-05-24
Publication date: 2025-11-26

Abstract

A connector (2) comprising a first housing (3) having a mating face (5), a mating skirt (6) with an external surface and an internal surface, mate assist features (9) located on the external surface, a terminal block (10) configured to accommodate electrical terminals, a flange (11) having a sealing face located on the same side of the flange (11) as the mating skirt (6), a seal (12). The seal (12) comprises a first seal portion (13) running on the sealing face of the flange (11) and forming a continuous thread around the mating skirt (6) and a second seal portion (14) running continuously on the mating skirt (6), the mate assist features (9) being located in a zone bounded by the first seal portion (13) and the second seal portion (14).

A connector assembly comprising such a connector. A method for mounting the connector assembly through a wall (4) of a car body.

Description

Technical Field

This disclosure relates to a sealing assembly for automotive applications. More particularly, this sealing assembly comprises a connector assembly that can be used in the automotive industry for ensuring the watertightness between a frame element (e.g., made of a metal sheet of a car body) and a wiring harness.
For example, this disclosure relates to a cable connector assembly designed to connect cables through an aperture in a frame of a car door (i.e., for so-called "Door-to-Body" counter-connector applications).

Prior Art

Door-to-Body connectors are exposed to the vehicle's external environment. Seals are therefore necessary in particular for protecting the terminals accommodated in the connectors.
In some Door-to-Body connectors of the prior art, a seal is provided on the outer periphery of the female connector which is exposed. In addition, the male connector can also be provided with an annular seal configured to engage on the inner periphery of the female counter-connector. Providing a seal on the male and on the female counter-connectors is a relatively expensive solution.
In other Door-to-Body counter-connectors of the prior art, seal lips are provided on the periphery of the female connector. As it is important to maintain the aesthetics of the connector that is exposed to the view, the seal must be of the same or similar color to that of the connector. But it is then difficult by visual inspection to detect if the seal has a manufacturing defect and/or if it has been damaged by mishandling.
Therefore, there is a need for improved sealing means for connector assemblies.

Summary of the invention

Accordingly, it is disclosed below an improved connector comprising a first housing. The first housing having

a mating face perpendicular to a mating direction,
a mating skirt having four walls perpendicular to the mating face, each one of these walls having an external surface and an internal surface,
mate assist features located on at least one external surface,
a terminal block configured to accommodate a plurality of electrical terminals,
a flange extending perpendicularly to the mating direction from the external surface of each wall, the flange having a sealing face located on the same side of the flange as the mating skirt,
a seal,

Further, the seal comprises a first seal portion running on the sealing face of the flange and forming a continuous thread around the mating skirt and a second seal portion running continuously on the mating skirt, the mate assist features being located in a zone bounded by the first seal portion and the second seal portion.
In other words, the present disclosure relates to a connector wherein the first seal portion can be hidden between the flange and the body onto which the connector is mounted, and wherein the second seal portion can be inserted between the mating skirt and a second connector configured to be mated with the first connector. In such a configuration, the sealing areas are hidden and protected from direct water splashes.
Advantageously, this connector possibly comprises one or more of the following features, each one of these features being considered independently of each other or in combination of one or several others.

the mate assist features extends longitudinally parallel to the mating direction and the second seal portion comprises segments extending from a region located in the vicinity of the flange, towards the mating face and at least partially around the mate assist features;
it comprises at least two bumps located inside the mating skirt, each respectively made from a first seal extension of at least one of the first and second seal portions;
each of said first seal extension passes through at least one hole in the flange and one channel in the mating skirt communicating with said at least one hole; possibly this channel is a slot or another kind of opening through the mating skirt; thereby, the molding channels used to form the sealing means (i.e., first seal portion, second seal portion and the seal extensions) and into which the liquid seal is injected in the mold, communicate with each other; this can have the advantages of having easier and quicker molding operations, of providing a cost effective and a design friendly manufacturing;

the first housing is made of plastic and the first and second seal portions are made of an elastomeric material overmolded on the first housing;
it comprises a latch integrally molded with the first housing and a cavity configured for demolding the latch, this cavity being filled with a second extension of at least one of the first and second seal portions of the seal.

According to another aspect, it is disclosed below a connector assembly comprising a first connector as mentioned above, and a second connector comprising a second housing. This second housing has a cover and a mate assist device configured to engage the mate assist features of the first connector. Further, the second seal portion is configured to provide a sealing barrier between the mating skirt and the cover.
Advantageously, this connector assembly possibly comprises one or more of the following features, each one of these features being considered independently of each other or in combination of one or several others.

the mate assist device is rotatably mounted on the cover about a pivot means engaged through an aperture formed in the cover and the second seal portion at least partially surrounds the aperture;
the bumps are configured to limit a tilting of the second connector in the mating skirt when the second connector is mated with the first connector.

According to another aspect, it is disclosed below a method for mounting the connector assembly as mentioned above, through a wall of a vehicle body, this method comprising the steps of:

mounting the first connector on one side of the wall with the latch in engagement with the wall, and with the first seal portion clamped between the flange and the wall,
mounting the second connector on the first connector, on a side of the wall opposite the side on which the first connector is mounted, with the second seal portion forming a sealing barrier between the cover and the mating skirt.

Optionally, the mate assist device is a rotating lever and the step of mounting the second connector on the first connector comprises rotating the lever from an open position to a closed position.

Brief description of the drawings

Other features, purposes and advantages of the disclosure will become apparent on reading the following detailed description given with reference to the appended drawings and by way of a non-limiting example and in which:

Figure 1 is a schematic representation in lateral elevation of an example embodiment of connector assembly in fully assembled conditions;
Figure 2 is a schematic exploded perspective view of the male connector of the connector assembly shown in Figure 1;
Figure 3 is a schematic perspective view of a detail of the male connector shown in Figure 2;
Figure 4 is a schematic perspective view of another detail, of the male connector shown in Figure 2 and seen from another angle;
Figure 5 is a schematic cross-section of a perspective view of the male connector shown in Figure 2; the seal being hidden;
Figure 6 is similar to Figure 5, but with a visible seal overmolded on the housing of the male connector shown in Figure 2;
Figure 7 is a schematic cross-section of a portion of the connector assembly shown in Figure 1;
Figure 8 is a schematic perspective view of a detail, of the connector assembly shown in Figure 1;
Figure 9 is a schematic cross-section of a perspective view of the female connector shown in Figure 2, mounted on a wall of a vehicle body;
Figure 10 is a schematic cross-section of a detail of the connector assembly shown in Figure 1; and
Figure 11 is a schematic cross-section of another detail of the connector assembly shown in Figure 1.

Detailed description

In this text (in particular in the specification and claims), the orientations and the adverbs such as above, below, etc. refer to the respective orientations of the connector parts shown in the Figures. The skill person will understand that a change in these orientations will lead to a change in the meaning of these adverbs, without limiting the scope of this disclosure.
An exemplary embodiment of a connector assembly 100 is disclosed below. For example, this disclosure relates to a cable connector assembly 100. For example, this cable connector assembly 100 is designed to connect cables (not shown) through an aperture in a frame of a car door (i.e., for so-called "door-to-body" connector applications).
This cable connector assembly 100 comprises a first connector 2 and a second connector 1. For example, the first connector is a male connector 2 and the second connector is a female connector 1. The female connector 1 and the male connector 2 are mated and electrically connected together in a mating direction MD (Figure 1).
The female connector 1 comprises a female housing 50. For example, the female housing 50 is made of molded plastic. At least a part of the female housing 50 forms a cover. The female housing 50 accommodates female terminals (not shown). The female connector 1 comprises a mate assist device. For example, the mate assist device is formed as a lever 51 rotatably mounted onto the female housing 50 (and more particularly on the cover). The lever 51 rotates about a rotation axis RA between an open position and a closed position. The female connector and the male connector 2 are engaged into each other with the lever 51 in open position. Then, the lever 51 is rotated toward its closed position to assist the mating of the female connector 1 and the male connector 2. The female connector 1 and the male connector 2 are fully mated when the lever 51 is in its closed position (as shown in figure 1).
The cover of the female housing 50 comprises two longitudinal side faces 52 and two transversal side faces 53. The lever 51 is mounted on the longitudinal side faces 52.
The male connector 2 comprises a male housing 3 intended to be fastened to a car body 4 such as a door frame (Figure 2). The male housing 3 comprises

a mating face 5 essentially perpendicular to the mating direction MD (while the female connector 1 and male connector 2 are mated),
a mating skirt 6 configured to accommodate at least partially a portion of the female connector 1, the mating skirt 6 comprising four walls, each essentially perpendicular to the mating face 5: two main side walls 7 and two secondary side walls 8; each one of these walls 7, 8 having respectively an external surface and an internal surface,
first actuating means 9 forming mate assist features, respectively arranged on each one of the two main side walls 7, and more particularly on the external surfaces of the main side walls 7, parallel to the mating direction MD;
a terminal bloc 10 configured to accommodate electrical male terminals (not shown),
a rectangular flange 11 extending from the external surface of each wall 7, 8, essentially in a plane perpendicular to the mating direction MD, this plane being essentially located slightly above the junction between the mating skirt 6 and the terminal bloc 10, the flange 11 having a sealing face located on the same side of the flange 11 as the mating skirt 6;
a seal 12.

The mating skirt 6, the terminal block 10 and the flange 11 are formed as a single molded plastic part.
The seal 12 extends essentially over the main side walls 7 and over the flange 11. More particularly, the seal 12 has

a first seal portion 13 extending essentially along a rectangular shape on the flange 11 (for example first seal portion 13 extends at the peripheral edge of the flange 11),
a second seal portion 14 with
- two bottom portions 15 extending essentially on the mating skirt 6 (for example, the two bottom portions 15 extends at the bottom of the mating skirt 6, or in other words, at the junction between the mating skirt 6 and the flange 11), and
- two main side portions or segments 16 each extending respectively essentially on one main side wall 7.

More particularly, the second seal portion 14 comprises segments 16 extending from a region located in the vicinity of the flange 11, towards the mating face 5 and at least partially around the mate assist features 9.
Each bottom portion 15 comprises two main side branches 17, extending parallel to each other and to the main side walls 7, and a secondary side branch 18 connected to a first end 19 of the two main side branches 17 (Figure 3). Each secondary side branch 18 connects two main side branches 17, each located on an opposite main side wall 7.
Each main side portion 16 has a U-shape and each end of this U-shape is connected to a second end 20 of a main side branch 17, each end of this U-shape being connected to the other bottom portion 15 located on the same main side wall 7 (Figure 2).
The first seal portion 13 is configured to provide a seal between the flange 11 and the car body 4 (e.g., the sheet metal of a door frame). The first seal portion 13 is made of interconnected segments so as to form a continuous sealing element between the male housing 3 (and more particularly the flange 11) and the car body 4. Therefore, a watertightness is ensured between the male housing 3 and the car body 4. The first seal portion 13 provides a first sealing barrier between the outside (on the side of the mating skirt 6) and the inside (on the side of the terminal block 10) of the car body 4.
The second seal portion 14 is configured to provide a seal between the female connector 1 and the male connector 2. The second seal portion 14 is made of interconnected segments so as to form a continuous sealing element between the male housing 3 (and more particularly the mating skirt 6) and the female housing 50 of the female connector 1. Therefore, if a watertightness is ensured between the inside and outside of the female housing 50, no water and/or no any other ingress can pass inside the male housing 3. The second seal portion 14 provides a second sealing barrier between the outside (on the outer side 22 of the mating skirt 6, above the second seal portion 14) and the inside (on the inner side 23 of the mating skirt 6) of the car body 4 (see Figure 2).
As a consequence, these first and second sealing barriers formed by the seal 12 prevent water and/or other ingresses from penetrating inside the car body 4 (i.e., between the female connector 2 and the car body 4), as well as penetrating inside the male connector 2 and/or the female connector 1 (i.e., between the mating skirt 6 and the cover of the female housing 50) - See Figure 11).
The seal 12 is overmolded onto the male housing 3. During the overmolding process the liquid seal is directed inside the mating skirt 6, through two opposite holes 24 (see figures 3 to 6). These holes 24 are formed though the flange 11. These holes 24 are located between a secondary side branch 18 and the first seal portion 13. Each one of these holes 24 opens out in a channel 25 running in the mating skirt 6, up to the terminal block 10, where another hole 26 opens out inside and at the bottom of the mating skirt 6 (Figures 4 and 5). This liquid seal then forms a bump 27 inside the mating skirt 6 (Figure 6). These two bumps 27 are made from a first seal extension (in the channel 25) of at least one of the first 13 and second 14 seal portions. Thus, there are two bumps 27, one at each opposite side of the mating skirt 6 which is essentially parallel to the rotation axis RA of the lever 51. These bumps 27, limit and/or prevent the female housing 50 from tilting when the lever 51 is in closed position (Figure 7).
Further, the male housing 3 comprises locking means 28 configured to snap with a sheet metal of the car body 4 (Figure 8). The locking means 28 comprise a latch 29. A cavity 30 in the male housing 3 is necessary for demolding the latch 29. This cavity 30 is filled with a second extension of at least one of the first 13 and second 14 seal portions of the seal 12. A seal channel 31 is formed so as to fill the cavity 30 with the liquid seal (Figures 8 and 9). The portions of the seal 12 filling the cavity 30 and the channel 31 ensure an ingress protection.
As can be seen in Figure 10, the lever 51 is rotatably mounted on the female housing 50 about a pivot means 54 engaged through an aperture 55 formed in the cover and the second seal portion 14 at least partially surrounds the aperture 55.
For mounting the connector assembly 100, through the wall of the car body 4, at least the following steps are carried out:

mounting the first connector 2 on one side of the wall of the car body 4, with the latch 29 in engagement with the wall of the car body 4 (Figures 8 and 9), thereby clamping the first seal portion 13 between the flange 11 and the wall of the car body 4,
mating the second connector 1 with the first connector 2, on a side of the wall of the car body 4 which is opposite the side on which the first connector 2 is mounted (indeed at least a part of the mating skirt 6 passes through the wall of the car body 4),
rotating the lever from an open position to a closed position, in which the second seal portion 14 forms a sealing barrier between the cover and the mating skirt 6.

Claims

A connector (2) comprising a first housing (3), the first housing (3) having
- a mating face (5) perpendicular to a mating direction (MD),

- a mating skirt (6) having four walls (7, 8) perpendicular to the mating face (5), each one of these walls (7, 8) having an external surface and an internal surface,

- mate assist features (9) located on at least one external surface,

- a terminal block (10) configured to accommodate a plurality of electrical terminals,

- a flange (11) extending perpendicularly to the mating direction (MD) from the external surface of each wall (7, 8), the flange (11) having a sealing face located on the same side of the flange (11) as the mating skirt (6),

- a seal (12),
the mating skirt (6), the terminal block (10) and the flange (11) forming a single molded part,

characterized in that the seal (12) comprises a first seal portion (13) running on the sealing face of the flange (11) and forming a continuous thread around the mating skirt (6) and a second seal portion (14) running continuously on the mating skirt (6), the mate assist features (9) being located in a zone bounded by the first seal portion (13) and the second seal portion (14).
The connector (2) according to claim 1, wherein the mate assist features (9) extends longitudinally parallel to the mating direction (MD) and the second seal portion (14) comprises segments (16) extending from a region located in the vicinity of the flange (11), towards the mating face (5) and at least partially around the mate assist features (9).
The connector (2) according to claim 1 or 2, comprising at least two bumps (27) located inside the mating skirt (6), each respectively made from a first seal extension of at least one of the first (13) and second (14) seal portions.
The connector (2) according to claim 3, wherein each of said first seal extension passes through at least one hole (24) in the flange (11) and one channel (25) in the mating skirt (6) communicating with said at least one hole (24).
The connector (2) according to any preceding claim, wherein the first housing (3) is made of plastic and the first (13) and second (14) seal portions are made of an elastomeric material overmolded on the first housing (3).
The connector (2) according to any preceding claim, comprising a latch (29) integrally molded with the first housing (3) and a cavity (30) configured for demolding the latch (29), this cavity (30) being filled with a second extension of at least one of the first (13) and second (14) seal portions of the seal (12).
A connector assembly (100) comprising a first connector (2) according to the connector of any of claims 1 to 6, and a second connector (1) comprising a second housing (50), the second housing (50) having a cover and a mate assist device (51) configured to engage the mate assist features (9) of the first connector (2), and the second seal portion (14) being configured to provide a sealing barrier between the mating skirt (6) and the cover.
The connector assembly (100) according to claim 7, wherein the mate assist device (51) is rotatably mounted on the cover about a pivot means (54) engaged through an aperture (55) formed in the cover and the second seal portion (14) at least partially surrounds the aperture (55).
The connector assembly (100) according to claim 7 or 8, considered in combination with claim 3, wherein the bumps (27) are configured to limit a tilting of the second connector (1) when the second connector (1) is mated with the first connector (2).
A method for mounting the connector assembly (100) according to claim 7 to 9, considered in combination with claim 6, through a wall (4) of a vehicle body, comprising the steps of:
- mounting the first connector (2) on one side of the wall (4) of the vehicle, with the latch (29) in engagement with the wall (4) of the vehicle, and with the first seal portion (13) clamped between the flange (11) and the wall (4) of the vehicle,

- mounting the second connector on the first connector (2), on a side of the wall (4) of the vehicle, opposite the side on which the first connector (2) is mounted, with the second seal portion (14) forming a sealing barrier between the cover and the mating skirt (6).
The method of claim 10, wherein mate assist device (51) is a rotating lever and the step of mounting the second connector (1) on the first connector (2) comprises rotating the lever from an open position to a closed position.