GB2323214A

GB2323214A - Connector

Info

Publication number: GB2323214A
Application number: GB9704982A
Authority: GB
Inventors: David P Lintern
Original assignee: STANDARD PROD Ltd
Current assignee: STANDARD PROD Ltd
Priority date: 1997-03-11
Filing date: 1997-03-11
Publication date: 1998-09-16
Also published as: GB9704982D0

Abstract

A connector 3 suitable for use with a safety switch having at least one aperture 7 extending longitudinally through the switch and at least one longitudinal core wire comprises a main body 8 which has one face 9 and an opposing face 10, one or more protuberances 13 extending from the one face 9; and one or more holes 15 extending longitudinally through the main body from the one face 9 to the opposing face 10; the arrangement being such that, when fitted to the end of a safety switch, the protuberance(s) 13 fit into the aperture(s) 7 and the wire(s) 2 pass through the hole(s) 15, with the connector closing off the end region(s) of the aperture(s) 7. The protuberance(s) 13 prevent any molten plastics blocking the aperture(s) 7 during an over-moulding process. The switch is used for sensing an obstruction in a window opening of a vehicle.

Description

CONNECTOR This invention relates to a connector. In some vehicles, in particular cars, a safety switch is fitted to the window frame seal to sense an obstruction present in the window opening upon closure of the window.

Such switches commonly comprise an elastomeric strip with one or more apertures running longitudinally of the strip. Typically there are two core wires which run parallel to the aperture and connect with a resistor at one end of the switch and extend beyond the switch at the other end to connect with wires which feed into the vehicle's electrical loom connector. The region surrounding the aperture has at least two electrically conductive areas separated by areas made up of electrically insulating material such that if an external force is applied to the safety switch, the two electrically conductive areas on either side of the aperture are brought into contact causing a short circuit.

A connection is required to join the core wire with a resistor of a known value, at one end, and with the vehicle's electrical harness wires at the other end.

Figure 1 shows an elongate safety switch A with two core wires B running through it. At one end of the safety switch A there is a connection C which joins the core wires B to a resistor D. At the other end of the safety switch A there is a connection E which joins the core wires B to the harness wires F. The harness wires are then fitted with a loom connector G which plugs into the vehicle's electrical system.

Figure 1A shows a cross-section view of a safety switch A with two core wires B running through it.

Many of the current connection designs rely on surface contact with the electrically conductive material surrounding the aperture, which can lead to unpredictable contact due to differences in the resistivity of the materials used. As they are usually simply pushed into the end of the safety switch, highly variable resistance readings can result, for example depending on the precise distance between the core wire and the connecting wire.

When such switch ends are made from "over-moulded" molten plastics material, the plastics material can flow down the aperture at the end of the safety switch and then set. This results in a considerable "dead" area, within which the security switch will not function as the aperture is blocked. Not only is this undesirable in terms of safety but it also is likely not to meet the United States Safety Standard FMVSS118, which states that the switch must detect an obstruction as small as 2mm radius at any point along the exposed area.

Finally, many switch ends are not capable of housing the resistor and it is often difficult to place and fix the resistor in those that are.

The present invention relates to a connector, suitable for use with a safety switch having at least one aperture extending longitudinally through the switch and at least one longitudinal core wire, the connector comprising: a main body which has one face and an opposing face; one or more protuberances extending from the one face; and one or more holes extending longitudinally through the main body from the one face to the opposing face; the arrangement being such that, when fitted to the end of a safety switch, the protuberance(s) fit into the aperture(s) and the wire(s) pass through the hole(s), with the connector closing the aperture(s).

Typically the one face of the main body projects laterally beyond the protuberance(s), to form a flange.

Conveniently the connector is made from a nylon or a polypropylene.

The opposing face is preferably about 16-25mm2, and can have a moulded recess suitable for accommodating a chip or other resistor.

Preferably the protuberances are 3mm long or less.

Preferably the distance between the one face and the opposing face is 2mm or less.

In practical use it is convenient if a plug connector can be fixed to the end of a safety switch by interference fit with the safety switch, or by using and adhesive. The connector can also be "over-moulded" on the safety switch.

For a better understanding of the present invention and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which: Figure 2 is a perspective view of the end of a safety switch, a connector in accordance with the present invention, and three possible connections that may be made by the core wires once they have passed through the connector; and Figure 3 shows a longitudinal section through a safety seal with one embodiment of a connector, in accordance with the present invention, secured in position in the switch, the connector then having been over-moulded.

Referring firstly to Figure 2, there is shown a safety switch 1, running through which are two core wires 2, and extending through which are two apertures 7.

The safety switch 1 is shown to be made up of areas of electrically conductive material 5 and electrically insulating material 6. A connector is shown which consists of a main body 8 which has one face 9 and an opposing face 10. Two protuberances 13 extend from the one face 9 of the main body 8, which can fit into the apertures 7 of the safety switch 1.

The connector 3 also has two longitudinal holes 15, through which the core wires 2 of the safety switch 1 may pass. The opposing face 10 of the connector 3 may be moulded to form a recess 17.

When the connector 3 is fitted to the end of the safety switch 1, the core wires 2 extend through the holes 15 and may connect with a chip resistor 4, a wire wound resistor 19 or the harness wires 21 which are fitted with an electrical loom connector 20. The means of contact may be soldering, crimping, ultrasonic welding or any other suitable method.

The chip resistor 4 can be fitted into the recess 17 of the opposing face 10 of the connector 3.

In Figure 3, there is shown a safety switch 1, which has a connector 3 fitted to one end. The core wires 2 pass through the connector 3 and connect with a resistor 4. The connector 3 is shown connected to the safety switch 1 and engulfed in an overmoulding 22.

The protuberances 13 of the connector 3 also act as plugs to the apertures 7 of the safety switch 1 and prevent any molten plastic blocking the apertures 7 during the over-moulding process.

There is thus provided a connector which can be fitted to the end of a safety switch and allows the core wire to pass directly through, and on to the desired component. The connector also plugs the ends of both apertures to prevent any molten plastic from flowing down the apertures and ruining the switch.

When inserted into the safety switch, the connector causes a minimum dead area of the safety switch.

Due to the flat back design of the connector, it is possible to lay or fix the resistor in place easily by various methods. Once the connector is inserted into the safety switch, the connector can be overmoulded to produce the desired end region.

Claims

1. A connector suitable for use with a safety switch having at least one aperture extending longitudinally through the switch and at least one longitudinal core wire, the connector comprising: a main body which has one face and an opposing face; one or more protuberances extending from the one face; and one or more holes extending longitudinally through the main body from the one face to the opposing face; the arrangement being such that, when fitted to the end of a safety switch, the protuberance(s) fit into the aperture(s) and the wire(s) pass through the hole(s), with the connector closing off end regions of the aperture(s).

2. A connector according to claim 1, which is made from a nylon or polypropylene.

3. A connector according to claim 1 or 2, wherein the one face of the main body projects laterally beyond the protuberance(s), to form a flange.

4. A connector according to any preceding claim, in which the opposing face is about 16-25mm2.

5. A connector according to any preceding claim, in which the opposing face has a moulded recess suitable for accommodating a resistor.

6. A connector according to any preceding claim, in which the or each protuberance is 3mm long or less.

7. A connector according to any preceding claim, in which the distance between the one face and the opposing face is 2mm or less.

8. A connector according to any preceding claim, which can be fixed to the end of a safety switch by interference fit with the safety switch.

9. A connector according to any preceding claim, which can be fixed to the end of a safety switch using an adhesive material.

10. A connector substantially as herein before described with reference to, and as illustrated in, Figures 2 and 3 of the accompanying drawings.

11. A connector according to any of the preceding claims, to which is fitted a resistor.

12. A safety switch to which is fitted a connector according to any of the preceding claims.

13. A safety switch according to claim 12, wherein the main body of the connector is over-moulded.

14. A motor vehicle having a window seal to which is fitted a safety switch according to claim 12 or 13.