WO2015110936A1

WO2015110936A1 - Modular connector

Info

Publication number: WO2015110936A1
Application number: PCT/IB2015/050298
Authority: WO
Inventors: Xiaobing Li; Kaixuan JIANG; Haomai YIN; Cheng Li
Original assignee: Tyco Electronics (Shanghai) Co. Ltd.; Tyco Electronics Uk Ltd
Priority date: 2014-01-23
Filing date: 2015-01-15
Publication date: 2015-07-30
Also published as: CN203707421U

Abstract

The invention discloses a modular connector (10), having a connector housing (20) and a terminal module assembly (40), whereby the terminal module assembly includes one or more integrally formed terminals (30); the terminal module assembly and the connector housing are separately-formed components; and it is sealed with glue between the terminal module assembly and the connector housing. According to the invention, by adopting the modular terminal module assembly, good sealing performance can be achieved by sealing with just single-side glue filling, thus reducing the cost of the connector.

Description

MODULAR CONNECTOR

Field of the Invention

[0001] The invention relates to a connector, particularly to a modular connector.

Background of the Invention [0002] In general, an electric connector mainly comprises a housing and connection terminals arranged in the housing. To meet electrical, mechanical and other requirements on the electric connector, the connection terminals are usually arranged in the housing in a sealed manner. Especially for a connector applied in an engine to transmit an internal signal of the engine to the outside of the engine, there is a higher requirement on sealing performance of the connector.

[0003] In the case of such an existing electric connector, a stitching process is usually adopted to insert the connection terminals into the corresponding terminal channels of the connector housing, respectively. However, as there are various inevitable different large or small clearances between the terminals and the terminal channels, it is necessary to seal by filling glue between the terminals and the terminal channels, for example, double-side glue filling for sealing is carried out on both ends of the terminal channels, after insertion of the terminals, to achieve sealing performance meeting requirements.

[0004] Such double-side glue filling for sealing needs a large amount of sealing glue, which is high in cost, leading to relatively high cost of the connector. Furthermore, due to relatively large difference of heat expansion coefficients of glue and metal, the effect of the sealing between the connection terminals and the sealing glue is not ideal.

Summary of the Invention

[0005] An object of the invention is to overcome the above shortcomings in the prior art.

[0006] According to the invention, a modular connector is provided, which comprises a connector housing and a terminal module assembly, wherein the terminal module assembly includes one or more integrally formed terminals; the terminal module assembly and the connector housing are separately-formed components; and it is sealed with glue between the terminal module assembly and the connector housing.

[0007] In a preferred embodiment according to the invention, the terminal module assembly includes a plurality of terminal modules that are individually separately formed.

[0008] In a preferred embodiment according to the invention, the terminal modules of the terminal module assembly are formed through an insert-molding process to the terminals.

[0009] In a preferred embodiment according to the invention, the terminal module assembly includes a plurality of terminal modules individually separately formed and preassembled to form the terminal module assembly, the terminal module assembly as a whole being inserted into the connector housing.

[0010] In a preferred embodiment according to the invention, each terminal module is provided with assembly positioning structures, wherein the assembly positioning structures may include convex posts and/or concave holes.

[0011] In a preferred embodiment according to the invention, two assembly faces of each terminal module are respectively provided with assembly positioning structures with different configurations.

[0012] In a preferred embodiment according to the invention, each terminal module is provided with concave structures.

[0013] In a preferred embodiment according to the invention, it is sealed with glue between the plurality of terminal modules.

[0014] In a preferred embodiment according to the invention, the connector housing is provided with a terminal module assembly receiving portion. The terminal module assembly receiving portion and the terminal module assembly are in interference fit with each other.

[0015] In a preferred embodiment according to the invention, at least one of the connector housing and the terminal module assembly is provided with stop components for stopping further movement of the connector housing and the terminal module assembly in the insertion direction when the terminal module assembly is inserted in the connector housing in position. [0016] In a preferred embodiment according to the invention, the stop components are configured as a plurality of rod-like members arranged parallel to each other on a transverse section of the connector housing, with a clearance for passing through of the terminals being formed between two adjacent rod-like members

[0017] In a preferred embodiment according to the invention, the terminal module assembly is provided on its side faces with bosses projecting outwards, and the connector housing is provided with recesses matched with the bosses; and when the terminal module assembly is inserted into the connector housing in position, the bosses are received in the recesses. Preferably, forward faces of the bosses in the pointing direction of the terminals are configured as bevels tilted backwards relative to the side faces of the terminal module assembly. Further preferably, the bosses are symmetrically arranged on opposite side faces of the terminal module assembly.

[0018] In a preferred embodiment according to the invention, the terminal module assembly is formed by assembling two first terminal modules, two second terminal modules and two third terminal modules; each first terminal module is formed through an insert-molding process to four terminals arranged in a row; each second terminal module is formed through the insert-molding process to six terminals arranged in a row; and each third terminal module is formed through the insert-molding process to eight terminals arranged in a row. Here, the first terminal modules, the second terminal modules and the third terminal modules may be respectively provided with assembly positioning structures.

[0019] Preferably, the terminal module assembly is provided on its side faces with bosses projecting outwards, and the connector housing is provided with recesses matched with the bosses; and when the terminal module assembly is inserted into the connector housing in position, the bosses are received in the recesses. Here, the bosses can be formed on end sides of the third terminal modules.

[0020] Preferably, it is sealed with glue between adjacent terminal modules of the two first terminal modules, the two second terminal modules and the two third terminal modules.

[0021] The invention also relates to a terminal module assembly, which comprises a plurality of terminal modules. The terminal modules are each individually and separately formed through an insert-molding process to one or more terminals. The terminal modules are each formed with assembly positioning structures, whereby the terminal modules can be assembled to one another forming the terminal module assembly. At least some of the terminal modules are formed with bosses projecting outwards for assembling the terminal module assembly with a connector housing.

[0022] According to the invention, by improving the configuration of the connector, specifically by adopting the modular terminal module assembly, good sealing performance can be achieved by sealing with just single-side glue filling, thus reducing the cost of the connector. Brief Description of the Drawings

[0023] The following description is set forth in connection with the attached drawing figures, which are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the drawing figures:

Figs. 1 and 2 show perspective views of a modular connector according to a preferred embodiment of the invention in different orientations respectively;

Fig. 3 is an axial sectional perspective view of a modular connector according to a preferred embodiment of the invention;

Fig. 4 schematically shows an axial view of a modular connector according to a preferred embodiment of the invention;

Fig. 5 is a sectional view along line A-A in Fig. 4;

Figs. 6a and 6b show axial sectional perspective views of a connector housing and a terminal module assembly, corresponding to Fig. 3, respectively;

Figs. 7a and 7b show axial views of a connector housing and a terminal module assembly, corresponding to Fig. 4, respectively;

Figs. 8a and 8b show axial sectional views of a connector housing and a terminal module assembly, corresponding to Fig. 5, respectively;

Figs. 9a and 9b schematically show a first terminal module in the terminal module assembly according to a preferred embodiment of the invention; Figs. 10a and 10b schematically show a second terminal module in the terminal module assembly according to a preferred embodiment of the invention;

Figs. 11a and l ib schematically show a third terminal module in the terminal module assembly according to a preferred embodiment of the invention;

Fig. 12 schematically shows a perspective view of the terminal module assembly according to a preferred embodiment of the invention; and

Figs. 13-15 schematically show an alternative configuration of a connecter housing in a modular connector according to the invention.

Detailed Description of the Drawings

[0024] A modular connector of the invention is described below in detail in conjunction with the accompanying drawings. A person skilled in the art should understand the embodiments described below are intended for exemplary illustration rather than for any limitation on the invention. In all the drawings, the same reference numerals denote the same or like components.

[0025] First, it needs to be noted that for convenience of description, the modular connector of the invention is described below in detail by taking a 36-pin connector as an example.

[0026] Figs. 1 and 2 respectively show perspective views of a modular connector 10 according to a preferred embodiment of the invention. Fig. 3 schematically shows an axial sectional perspective view of the modular connector 10. Fig. 4 schematically shows an axial view of the modular connector 10. Fig. 5 is a sectional view along line A- A in Fig. 4.

[0027] Referring to Figs. 1-5, the modular connector 10 according to a preferred embodiment of the invention comprises a connector housing 20 and a terminal module assembly 40 which includes a plurality of integrally formed terminals 30 (although a plurality of terminals 30 are shown in the figure, obviously it is also possible to only provide one terminal 30). The terminal module assembly 40 and the connector housing 20 are separately-formed components and sealed by glue. The terminal module assembly 40 can be inserted in the connector housing 20. [0028] The terminal module assembly 40 may include one or more terminal modules 400. Here, each terminal module 400 in the terminal module assembly 40 is individually separately formed, and can be formed through an insert-molding process to terminals 30. In the terminal module 400 made through the insert-molding process, good sealing is achieved between the terminals 30 and the terminal module 400, so that only one end of the connector 10 needs sealing after the terminal module assembly 40 is inserted into the connector housing 20. In a preferred embodiment of the invention, after the terminal module assembly 40 and the connector housing 20 are assembled, the modular connector 10 is filled with glue for sealing. For example, sealing glue is used for sealing clearances between the terminal modules 400 of the terminal module assembly 40. Furthermore, sealing glue may also be used for sealing clearances between the terminal module assembly 40 and the connector housing 20. According to a preferred embodiment of the invention, sealing requirement can be met by glue filling on the side of the terminal module assembly 40 where terminals 30 project outwards (the upper side as shown in Figs. 1 and 3).

[0029] It can be seen especially from Figs. 3 and 5, the terminal module assembly 40 includes a plurality of terminal modules 400, and specifically, it includes six terminal modules 400 in the shown embodiment. The six terminal modules 400 can be preassembled to form the terminal module assembly 40, and then the terminal module assembly 40 as a whole is inserted into the connector housing 20. The configuration of the six terminal modules 400 will be described below in more detail.

[0030] To more clearly illustrate the configuration of the modular connector 10 of the invention, Figs. 6a and 6b show axial sectional perspective views of the connector housing 20 and the terminal module assembly 40, corresponding to Fig. 3, respectively; Figs. 7a and 7b show axial views of the connector housing 20 and the terminal module assembly 40, corresponding to Fig. 4, respectively; and Figs. 8a and 8b show axial sectional views of the connector housing 20 and the terminal module assembly 40, corresponding to Fig. 5, respectively. In other words, Figs. 6a, 7a and 8a show the configuration of the connector housing 20, and Figs. 6b, 7b and 8b show the configuration of the terminal module assembly 40. [0031] It can be seen from Figs. 6a-8b that the connector housing 20 is provided with a terminal module assembly receiving portion 50 for receiving insertion of the terminal module assembly 40. Here, the terminal module assembly receiving portion 50 and the terminal module assembly 40 are preferably in interference fit with each other. According to an embodiment of the invention, the connector housing 20 is also provided with a plurality of rod-like members 21 arranged parallel to each other on a transverse section thereof, with a clearance 22 being formed between two adjacent rod-like members 21. The plurality of rod-like members 21 here can be called stop components. The plurality of rod-like members 21 have the function of stopping and positioning when the terminal module assembly 40 is inserted into the terminal module assembly receiving portion 50 of the connector housing 20, to ensure proper assembly of the terminal module assembly 40 and the connector housing 20. The clearances 22 between the rod-like members 21 are used for passing through of the terminals 30 of the terminal module assembly 40 during insertion.

[0032] A person of ordinary skill in the art can understand that the shown plurality of rod-like members 21 functioning as stop components are only exemplarily illustrated, and stop components with various other configurations may be provided. Moreover, although the stop components are provided on the connector housing 20 in the embodiment, obviously, it is also possible to provide the stop components on the terminal module assembly 40, or to respectively provide the stop components on the connector housing 20 and on the terminal module assembly 40.

[0033] It can be seen from Figs. 7b and 8a the terminal module assembly 40 is symmetrically provided on its upper side and lower side with bosses 41 projecting outwards, and the connector housing 20 is provided with recesses 23 matched with the bosses 41. When the terminal module assembly 40 is inserted into the connector housing 20, the bosses 41 are received in the recesses 23, to achieve auxiliary positioning function. It can be understood that the bosses 41 and recesses 23 shown are only exemplary, and can be formed at different positions or in different arrangement forms according to specific application. [0034] In addition, as shown in Figs. 7b and 8b, the terminal module assembly 40 is formed by assembling two first terminal modules 401, two second terminal modules 402 and two third terminal modules 403.

[0035] Next, the configuration of a terminal module assembly 40 implemented as having 36 pins according to a preferred embodiment of the invention is described in more detail with reference to Figs. 9a- 12.

[0036] Figs. 9a and 9b respectively schematically show the configuration of the first terminal module 401. As shown in Figs. 9a and 9b, each first terminal module 401 is formed through an insert-molding process to four terminals 30 arranged in a row. The first terminal module 401 can be provided with concave structures, which may also be called material-reducing structures, thus saving material on the one hand, and keeping the wall thickness more uniform on the other hand, so that the product shrinks evenly after the injection molding, which is more favorable for stability of product dimensions. For example, an assembly face 401a is provided with a material-reducing structure 405, and an assembly face 401b is provided with a material-reducing structure 405. The first terminal modules 401 may also be provided with assembly positioning structures to facilitate the interconnection between the terminal modules 400. For example, the assembly face 401b is provided with a convex post 406 and a concave hole 407, which can cooperate and be connected with the matched assembly positioning structures on an adjacent terminal module 400, respectively.

[0037] Figs. 10a and 10b schematically show the configuration of the second terminal module 402, respectively. As shown in Figs. 10a and 10b, the second terminal module 402 is formed through an insert-molding process to six terminals 30 arranged in a row. The assembly faces 402a and 402b are each respectively provided with a material-reducing structure 405 as well as a convex post 406 and a concave hole 407.

[0038] Figs. 11a and l ib schematically show the configuration of the third terminal module 403, respectively. As shown in Figs. 11a and l ib, the third terminal module 403 is formed through an insert-molding process to eight terminals 30 arranged in a row. The assembly faces 403a and 403b are each respectively provided with a material-reducing structure 405 as well as a convex post 406 and a concave hole 407. [0039] The concave structures 405 provided on the first terminal module 401, the second terminal module 402 and the third terminal module 403, as described above, can save material on the one hand, and can keep the wall thickness more uniform on the other hand, so that the product shrinks evenly after the injection, which is more favorable for stability of product dimensions. The convex posts 406 and the concave holes 407 can be used as assembly positioning structures, and the terminal modules can be assembled together as needed by means of the convex posts 406 and the concave holes 407 to form the terminal module assembly 40. Here, the convex posts 406 and the concave holes 407 are only exemplarily illustrated, and other convexes and concaves with other different configurations may also be used as the assembly positioning structures. Furthermore, configurations of assembly positioning structures on the two assembly faces of a same terminal module can be different, for example, spacing between a convex post 406 and a concave hole 407 on one assembly face of a terminal module can be different from that between a convex post 406 and a concave hole 407 on the other assembly face. Such a design can ensure sole correctness of assembling the terminal modules, and this is the so-called "fool-proof design.

[0040] Two third terminal modules 403 are assembled together, then two second terminal modules 402 are assembled to the two sides of the obtained structure respectively, and finally two first terminal modules are further assembled to the two sides of the obtained structure respectively, thus obtaining the terminal module assembly 40 as shown in Fig. 12. It may be sealed with glue between the adjacent terminal modules.

[0041] It can be seen from Fig. 12 that the bosses 41 are formed on end sides of the third terminal modules 403. Of course, the bosses 41 may also be formed on end sides of other terminal modules, and even can be formed on assembly faces uncovered during assembly, only needing to correspondingly change the positions of the matched recesses 23 on the connector housing 20. Furthermore, forward faces 41a of the bosses 41 in the pointing direction (upward direction in Fig. 12) of the terminals 30 are configured as bevels tilted backwards relative to the side faces of the terminal module assembly 40, to facilitate the insertion of the terminal module assembly 40 into the connector housing 20. [0042] It needs to be particularly emphasized that the specific configurations of the first terminal modules 401, the second terminal modules 402 and the third terminal modules 403 are only exemplarily illustrated, and for a 36-pin connector, a different mode for dividing modules can be adopted according to a specific application. Moreover, apparently, the above modular configuration may also be adopted for a connector with other number of connecting channels other than 36 pins.

[0043] Finally, Figs. 13-15 schematically show an alternative configuration of a connecter housing in a modular connector according to the invention. Such a connecter housing 20' mainly differs from the connecter housing 20 described above in that the stop components and the matched recesses as described above are not provided. The terminal module assembly 40 can be directly inserted into a receiving portion 50' for receiving a terminal module assembly, of the connecter housing 20'. In this case, the stop components can be provided on the terminal module assembly.

[0044] Specific shape and configuration of the modular connector described above and shown in the figures are only exemplary, and various changes or modifications can be made by a person of ordinary skill in the art under teachings of the invention without departing from the scope of the invention defined by the claims.

Claims

1. A modular connector, comprising a connector housing and a terminal module assembly characterized in that the terminal module assembly includes one or more integrally formed terminals; the terminal module assembly and the connector housing are separately-formed components; and the terminal module assembly and the connector housing are sealed to each other through glue.

2. The modular connector according to claim 1, characterized in that the terminal module assembly comprises a plurality of terminal modules that are individually and separately formed.

3. The modular connector according to claim 2, characterized in that the terminal modules of the terminal module assembly are formed through an insert-molding process to the terminals.

4. The modular connector according to claim 1, characterized in that the terminal module assembly includes a plurality of terminal modules individually separately formed and preassembled to form the terminal module assembly the terminal module assembly as a whole being inserted into the connector housing.

5. The modular connector according to claim 4, characterized in that each of the terminal modules is provided with assembly positioning structures.

6. The modular connector according to claim 5, characterized in that two assembly faces of each of the terminal modules is respectively provided with assembly positioning structures with different configurations.

7. The modular connector according to any of claims 2-6, characterized in that the plurality of terminal modules are sealed to each other through glue.

8. The modular connector according to claim 1, characterized in that the connector housing is provided with a terminal module assembly receiving portion, and the terminal module assembly receiving portion and the terminal module assembly are in interference fit with each other.

9. The modular connector according to claim 1, characterized in that at least one of the connector housing and the terminal module assembly is provided with stop components for stopping further movement of the terminal module assembly and the connector housing in the insertion direction when the terminal module assembly is inserted into the connector housing in position.

10. The modular connector according to claim 9, characterized in that the stop components are configured as a plurality of rod-like members arranged parallel to each other on a transverse section of the connector housing, with a clearance for passing through of the terminals being formed between two adjacent rod-like members.

11. The modular connector according to claim 1, characterized in that the terminal module assembly is provided on its side faces with bosses projecting outwards, and the connector housing is provided with recesses matched with the bosses; and when the terminal module assembly is inserted into the connector housing in position, the bosses are received in the recesses.

12. The modular connector according to claim 11, characterized in that forward faces of the bosses in the pointing direction of the terminals are configured as bevels tilted backwards relative to the side faces of the terminal module assembly.

13. A terminal module assembly, characterized in that the terminal module assembly comprises a plurality of terminal modules; the terminal modules are each individually and separately formed through an insert-molding process to one or more terminals.

14. The terminal module assembly according to claim 13, characterized in that characterized in that the terminal modules are each formed with assembly positioning structures, whereby the terminal modules can be assembled to one another forming the terminal module assembly.

15. The terminal module assembly according to claim 13, characterized in that at least some of the terminal modules are formed with bosses projecting outwards for assembling the terminal module assembly with a connector housing.