WO2007131534A1

WO2007131534A1 - Sealed electrical connector and process for manufacturing the same

Info

Publication number: WO2007131534A1
Application number: PCT/EP2006/005330
Authority: WO
Inventors: Stéphane HERNANDEZ; Christian Campfort; Frédéric CHAZOTTES; Michel Lecuivre
Original assignee: Fci
Priority date: 2006-05-12
Filing date: 2006-05-12
Publication date: 2007-11-22

Abstract

This connector comprises - an insulative housing (103) having a plurality of terminal accommodating chambers (5), - a grommet-type seal (7) formed with a plurality of cable passages (27) and arranged within the housing (103) at the rear end of the chambers (5) , and - a peripheral seal (9) provided to sealingly engage an inner wall of a corresponding connector housing. The grommet-type seal (7) and the peripheral seal (9) are integrally made as a single moulded sealing part. The invention also relates to a process for manufacturing such a connector.

Description

SEALED ELECTRICAL CONNECTOR AND PROCESS FOR MANUFACTURING

THE SAME

BACKGROUND OF THE INVENTION

The invention relates to an electrical connector comprising

- an insulative housing having a front mating face and a plurality of terminal accommodating chambers with an open rear end for the insertion of the respective terminals,

- a grommet-type seal formed with a plurality of cable passages in correspondence with the chambers and arranged within the housing at the rear end of the chambers, - a peripheral seal arranged on a peripheral outer wall of the housing and provided to sealingly engage an inner wall of a corresponding connector housing.

In prior art connectors of this type, on the one hand the peripheral seal and the grommet-type seal are separately moulded, for example of a silicone material, and on the other hand the housing is moulded, for example of a plastic material. The seals are then assembled on the housing.

Such a manufacturing process involves at least three moulding steps and three injection moulds, as well as at least two assembling steps.

This represents one of the main causes for the manufacturing costs of such sealed electrical connectors.

SUMMARY OF THE INVENTION

It is an object of the invention to provide a sealed electrical connector of the above type, the manufacturing costs of which are substantially reduced. Accordingly, the invention provides an electrical connector of the above-mentioned type, wherein the grommet- type seal and the peripheral seal are integrally made as a single moulded sealing part. The invention also relates to a process for manufacturing an electrical connector as described above, comprising the following steps:

- manufacturing the insulative housing, and - moulding the single sealing part and assembling the insulative housing and the single sealing part.

The invention will be better understood on reading the following description of particular embodiments of the invention, given as a non-limiting examples.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a perspective view, from the rear side, of an electrical connector according to a first embodiment of the invention;

Fig. 2 is a sectional view, in an axial plane along the 2-2 direction, of the connector of Fig. 1;

Fig. 3 is a perspective view of the housing of the connector of Fig. 1, illustrating a first step of the manufacturing process of said connector;

Fig. 4 is a perspective view of the sealing part of the connector of Fig. 1, illustrating a second step of the manufacturing process;

Fig. 5 is a perspective view, from the rear side, of an electrical connector according to a second embodiment of the invention, with the flaps in their open position;

Fig. 6 is a sectional view, in an axial plane along the 6-6 direction, of the connector of Fig. 5 with terminals inserted in the housing; Fig. 7 is a perspective view, from the rear side, of an electrical connector according to a third embodiment of the invention, with the flaps in their open position;

Fig. 8 is a sectional view, in an axial plane along the 8-8 direction, of the connector of Fig. 7; Fig. 9 is a perspective view, from the rear side, of an electrical connector according to a fourth embodiment of the invention, with the grid being in a ready to be mounted position; and Fig. 10 is a perspective sectional view, in an axial plane, of the connector shown on Fig. 9, with terminals inserted in the housing and with the grid fully mounted in its active position.

DETAILED DESCRIPTION OF ONE PREFERRED EMBODIMENT

A connector 1 according to a first embodiment of the invention is shown on Figures 1 through 4.

In the example shown, the connector 1 is a female terminal-holder module of a type used in an automotive application. Such a module is suitable to be mounted in a casing and mate with a counterpart connector including complementary male terminals. However, the invention may apply to a large number of different connector types. For the sake of clarity, the Figures are orientated according to an X-axis, which represents the mating direction of the connector 1 with the counterpart connector

(not shown) . The X-axis is supposed to be orientated from the connector 1 towards the counterpart connector in mating conditions.

Every direction- or orientation-related term in the following description, in particular the terms "rear" and "front", should be interpreted as referring to this axis.

In this respect, the connector 1 has a front face 2 corresponding to the mating side.

As shown on Fig. 1 and 2, the connector 1 has an insulative housing 3 made of a plastic material and formed with a plurality of terminal accommodating chambers 5, a grommet-type seal (or "grommet") 7 and a peripheral seal 9. In the example shown, the connector 1 is a 6-way module, the chambers 5 of which are disposed in a single row.

The housing 3 has an open rear end 11 for the insertion of the terminals into the respective accommodating chambers 5.

The housing is mainly composed of a body section 13 wherein the chambers 5 are formed and a grid 15, extending at the rear end of the body section 13 and attached thereto. The body section 13 and the grid 15 define between them a recess 17 for accommodating the grommet 7.

The body section 13 is formed with resilient arms

(not shown) for each accommodating chamber 5. Said arms are provided to snap-fit with respective terminals accommodated in the chambers 5, thereby securing the terminals within the chambers .

The connector may also have a secondary locking member (not shown) which is, in the operative position, engaged from the front side on the body section 13. For example, the secondary locking member may be formed as a cap, having a front plate and fingers rearwards projecting from said plate. In the operative position of the locking member, the fingers engage respective resilient arms, thereby preventing the arms from deflecting and disengage from the respective terminals.

The body section 13 also has a peripheral outer wall 19 and a flange 21 radially projecting therefrom.

In the first embodiment shown on Fig. 1-4, the housing 3 is one-piece moulded, and more particularly the body section 13 and the grid 15 are integrally made as a single moulded housing part. In addition, the grid 15 is rigidly connected to the body section 13 by connecting walls 23 of the housing. The grid 15 is formed with a row of axial passages

25 aligned with respective chambers 5 of the body section

13. The passages 25 are suitable to guide the cabled terminals when inserted into the corresponding chambers 5. The grommet 7 is essentially made of one generally parallelepiped-shaped elastomeric piece (for example of silicone) , with through passages 27 formed therein. The passages 27 extend from a rear side to a front side of the grommet 7 and correspond to respective passages 25 of the grid 15 and to the chambers 5.

The grommet 7 also has a peripheral outer groove 28, which makes the passages 27 radially expandable and the grommet axially compressible.

The grommet 7 is accommodated within the recess 17, and thus interposed between the grid 15 and the body section

13, such that it engages the rear face of the body section

13 as well as the front face of the grid 15. The grommet 7 is also designed and accommodated within the recess 17, such that the passages 27 of the grommet are axially aligned with the respective passages 25 of the grid and the chambers 5.

The passages 27 are designed to allow the insertion of the terminals, from the rear end 11 of the housing 3, into the respective chambers 5, and to ensure the sealing of the chambers around the cables . For the sake of clarity of the drawings, the terminals and cables are not shown on Fig. 1 and 2.

In order to ensure the sealing effect at the rear side around the cables, the grommet 7 has a pair of annular lips 29 in each passage 27, said lips being axially offset and each defining a narrow section in the respective passage.

The grid 15 functions as a guide for the cables, for maintaining the end section of the cables which are connected to the respective terminals in an axial orientation X. The grid 15 thus prevents the passages 27 of the groratnet 7 from being deformed in flexion, such a deformation causing a loss of sealing performance.

The peripheral seal 9 is made as a sleeve of an elastomeric material, axially fitted on the outer peripheral wall 19 of the body section 13. It has, in the example shown, a pair of radial lips 31 to sealingly engage an inner wall of a corresponding connector (not shown) , and thereby provide a peripheral sealing between mated complementary housings.

The peripheral seal 9 is arranged on the body section 13 such that the flange 21 provides an axial stop for the peripheral seal in the rearward direction.

According to the invention, the grommet 7 and the peripheral seal 9 are made as a one-piece sealing part 33, which is shown on Fig. 4, whereas the housing 3 is shown alone on Fig. 3.

The peripheral seal 9 and the grommet 7 are connected by axial arms 35 fitting corresponding channels 37 formed in lateral walls of the body section 13. The channels 37 define a duct between the recess 17 and the peripheral area of the body section 13 to be engaged by the peripheral seal 9.

The integrally made sealing part 33 is moulded from an elastomeric material such as silicone, and preferably overmoulded on the housing 3.

The material has to be selected with care, only some known silicone types being, for example, adapted to be overmoulded with keeping their basic resiliency and adhesion performances.

It should also be noted that the housing 3 has lateral openings 39 defining opposite lateral accesses into the recess 17. These openings 39 are provided to be engaged by slides for forming the groove 28 as the grommet 7 is overmoulded on the housing 3.

The provision of the channels 37 permits the connecting arms 35 to be formed as the sealing part 33 is overmoulded on the housing 3, since the elastomeric material can flow in these channels 37 when injected in the mould.

The manufacturing process of the electrical connector 1 comprises the following successive steps: manufacturing the insulative housing 3 such as shown on Fig. 3, and

- moulding the single sealing part 33 as shown on Fig. 4 and assembling the insulative housing 3 and the single sealing part 33.

The latter step is preferably performed by overmoulding the sealing part 33 on the housing 3.

The second embodiment shown on Fig. 5 and 6 essentially differs from the first embodiment in that the connector 101 has a housing 103 including a grid 115 which is not rigidly attached to the body section 13, but made in two parts (flaps) 115A, 115B connected to the body section 13 by deformable hinges 116.

The flaps 115A, 115B are substantially symmetrical with respect to the axial plane defined by the row of chambers 5 and are hinged on the body section 13 so as to be substantially symmetrically pivotable.

The flaps 115A, 115B are pivotable between an open position (shown on Fig. 5 and 6) and a closed position (not shown) on the body section 13. In the open position of the flaps, terminals 130 (only shown on Fig. 6) can be inserted in respective accommodating chambers 5 in the body section 13 through the grommet 7. In the closed position of the flaps, the latter co-operate for guiding the cables 132 (only shown on Fig. 6) connected to the terminals 130.

The flaps 115A, 115B are formed with parallel elongated ribs 118, two successive ribs 118 of one flap defining between them a half passage 125A, 125B. The corresponding half-passages 125A, 125B of respectively one and the other flaps define together a passage 125 for the respective cable 132 when the flaps 115A, 115B are closed in their active position.

In the active position of the flaps 115A, 115B, the ribs 118 engage the rear side of the grommet 7 and thus provide a slight compression of the grommet 7. This improves the sealing performance of the grommet 7. The flaps 115A, 115B also comprise complementary snap-fit locking members 134, 136 which come in a mutual engagement as the flaps are brought in their closed position, so as to secure the flaps in their active position. It will be noted that the connector 101 includes a secondary locking member 138 shown on Fig. 5 and 6 in its active position, wherein it is fully engaged from the front side on the body section 13 so as to secure the terminals 130 in their locked position in the respective chambers 5. In the embodiment of Fig. 5 and 6, the grommet 7 is arranged within the body section 13 and attached therein.

As the case in the formerly described embodiment, the sealing part including the grommet 7, the peripheral seal 9 and connecting portions 135 is also made as one piece integrally overmoulded on the housing 103.

The third embodiment shown on Fig. 7 and 8 is similar to the second described with reference to Fig. 5 and 6, in that the connector 201 has a grid 115 under the same form of two pivotable flaps 115A, 115B. It essentially differs therefrom in that the grommet 207 is made in two substantially symmetrical parts 207A, 207B. The symmetry is appreciated in this case with respect to the axial plane defined by the row of chambers 5. Each of said grommet parts 207A, 207B is arranged in a respective flap 115A, 115B and attached thereto, whereby the grommet parts 207A, 207B are pivotable on the body section 13 together with the flaps 115A, 115B. Passages 227 in the grommet 207 for the cables are defined by corresponding half-passages 227A, 227B in both grommet parts 207A, 207B. Similarly to the passages 125 in the grid 115, which are formed by corresponding half- passages 125A, 125B in the flaps 115A, 115B constituting the grid as said flaps are closed on the body portion 13, the passages 227 are formed by the half-passages 227A, 227B as the flaps are closed in the active position.

The grommet parts 207A, 207B are designed and arranged within the flaps 115A, 115B such that the grommet parts are slightly axially compressed between a rear side of the body section 13 and inner walls 230 of the flaps.

As the case in the formerly described embodiments, the sealing part, including the grommet 207, the peripheral seal 9 and connecting portions 135, is made as one piece integrally overmoulded on the housing 103.

The connector 301 shown on Fig. 9 and 10 for illustrating a fourth embodiment essentially differs from the second one, described with reference to Fig. 5 and 6, in that the insulative housing 303 has a body section 13 and a grid 315 made as separate parts.

The grommet 7 is arranged within a rear end recess 317 of the body section 13 and the grid 315 is slideably mounted within said recess at the rear side of the grommet 7, in a transversal direction. The grid has axial through passages 325 corresponding to respective passages 27 of the grommet 7.

On Fig. 9, the connector 301 is shown with no terminal inserted in the housing 303, the grid 315 being shown in a dismounted position, ready to be mounted in the body section 13. On Fig. 10, which is a sectional perspective view in an axial plane passing through a chamber 5, the connector

301 is shown with terminals 130 and cables 132, the grid 315 being mounted in the body section 13 and secured in its active position.

The grid 315 and the body section 13 have complementary locking means 332, 334 suitable to snap-fit in the fully mounted and active position of the grid within the body section, and thus secure the grid 315 in its active position.

In this fourth embodiment, the sealing part including the grommet 7, the peripheral seal 9 and connecting portions 135 is made as one piece integrally overmoulded on the body section 13. The grid 315, which is made as a separate part from the body section 13, is assembled with the body section and secured in an intermediate or in its active position in a subsequent step of the manufacturing process.

The terminals 130 are then inserted in the respective chambers 5.

In an eventual further step, should the grid 315 have been placed in an intermediate position, the grid 315 is then locked in its active position.

It will be appreciated that the invention provides sealed connectors the manufacturing of which is simplified, due to the reduction of the amount of parts and of assembling steps. This is obtained with no drawback on the sealing performances.

In addition, provided an appropriate materials combination is used, overmoulding the elastomeric material of the grommet on the housing provides a strong adherence between the contact surfaces of the grommet and the housing. This makes unnecessary to apply a pressure on the grommet to ensure the sealing effect.

Claims

1. Electrical connector comprising

- an insulative housing (3; 103; 303) having a front mating face (2) and a plurality of terminal accommodating chambers (5) with an open rear end (11) for the insertion of the respective terminals (130) , a grommet-type seal (7; 207) formed with a plurality of cable passages (27; 227) in correspondence with the chambers (5) and arranged within the housing (3; 103; 303) at the rear end of the chambers (5), and

- a peripheral seal (9) arranged on a peripheral outer wall (19) of the housing (3; 103; 303) and provided to sealingly engage an inner wall of a corresponding connector housing, characterized in that the grommet-type seal (7; 207) and the peripheral seal (9) are integrally made as a single moulded sealing part (33).

2. Electrical connector as claimed in claim 1, characterized in that said single sealing part (33) is overmoulded on the housing (3; 103; 303).

3. Electrical connector as claimed in claim 1 or 2 , characterized in that the housing (3; 103; 303) has a body section (13) wherein the chambers (5) are formed, and a grid (15; 115; 315) attached to the body section (13) at the rear end thereof, such that in the assembled configuration, the grommet-type seal (7; 207) is interposed between the body section (13) and the grid (15; 115; 315), said grid having a plurality of passages (25; 125; 325) in correspondence with the passages (27; 227) of the grommet-type seal (7; 207) and being provided to guide cables (132) connected to the terminals (130) and prevent the passages (27; 227) of the grommet-type seal (7; 207) from being excessively deformed by the cables (132) .

4. Electrical connector as claimed in claim 3, characterized in that said body section (13) and said grid ((15; 115) are integrally made as a single moulded housing part.

5. Electrical connector as claimed in claim 3 or 4, characterized in that said grid (15) is rigidly attached to the body section (13).

6. Electrical connector as claimed in claim 3 or 4, characterized in that said grid (115) has at least one flap

(115A, 115B) hinged on the body section (13), whereby said flap (115A, 115B) can be pivoted between an open position, wherein terminals (130) can be inserted in respective accommodating chambers (5) in the body section (13), and a closed position, wherein the flap (115A, 115B) is in an active position for guiding the cables (132) .

7. Electrical connector as claimed in claim 6, characterized in that said grid (115) has two such flaps (115A, 115B) arranged symmetrically on the body section (13) and co-acting in their closed position.

8. Electrical connector as claimed in claim 6 or 7 , characterized in that the grommet-type seal (7) is arranged within the body section (13).

9. Electrical connector as claimed in claim 6 or 7 , characterized in that the grommet-type seal (207) is at least partly arranged within the flap (115A, 115B) and attached thereto.

10. Electrical connector as claimed in claims 7 and 9 combined together, characterized in that the grommet-type seal (207) is made in two grommet parts (207A, 207B) , each of which is arranged within a respective flap (115A, 115B) and attached thereto .

11. Electrical connector as claimed in claim 3, characterized in that said grid (315) is made of a separate part from the body section (13) and is slideably mounted within the body section (13) in a transversal direction with respect to an axis (X) of insertion of the terminals (130) in the housing (303).

12. Process for manufacturing the electrical connector as claimed in anyone of the preceding claims, comprising the following steps: manufacturing the insulative housing (3; 103; 303), and moulding the single sealing part (33) and assembling the insulative housing (3; 103; 303) and the single sealing part (33) .

13. Process as claimed in claim 12, the electrical connector being further such as claimed in claim 2 , wherein the single sealing part (33) is overmoulded on the insulative housing (3; 103; 303).

14. Process as claimed in claim 12 or 13, the electrical connector being further such as claimed in claim 11, wherein the single sealing part (7, 9, 135) is overmoulded on the body section (13) and the grid (315) is then mounted within the body section (13) .