Method of forming a connector for an electrical cable for electrically connecting to a camera of a vehicle

• US 10,250,004 B2
• Filed: 11/02/2016
• Issued: 04/02/2019
• Est. Priority Date: 11/05/2015
• Status: Active Grant

• Current Assignee: Magna Electronics Incorporated (Magna International Incorporated)
• Original Assignee: Magna Electronics Incorporated (Magna International Incorporated)
• Inventors: Conger, Jonathan D., Byrne, Steven V., Mleczko, Jamie A.
• Primary Examiner(s): Kim, Paul D
• Application Number:
  US15/341,048
• Publication Number:
  US 20170133811A1
• Time in Patent Office: 881 Days
• CPC Class Codes: H01R 13/405 Securing in non-demountable manner, e.g. moulding, riveting
• CPC Class Codes: H01R 2107/00 Four or more poles
• CPC Class Codes: H01R 24/28 Coupling parts carrying pins, blades or analogous contacts and secured only to wire or cable
• CPC Class Codes: H01R 4/023 between cables or wires and terminals
• CPC Class Codes: H01R 4/186 using a body comprising a plurality of cable-accommodating recesses or bores
• CPC Class Codes: H01R 43/005 for making dustproof, splashproof, drip-proof, waterproof, or flameproof connection, coupling, or casing
• CPC Class Codes: H01R 43/02 for soldered or welded connections
• CPC Class Codes: H01R 43/048 Crimping apparatus or processes H01R43/042 takes precedence
• CPC Class Codes: H01R 43/24 Assembling by moulding on contact members
• CPC Class Codes: H04N 23/57 Mechanical or electrical details of cameras or camera modules specially adapted for being embedded in other devices

Abstract

A method of forming an electrical cable connector for electrically connecting to a camera of a vehicle includes providing a cable, a plurality of terminals and a retaining element. The terminals are pressed into respective receiving portions and passageways of the retaining element, such that pin ends of the terminals protrude from the retaining element. Ends of the electrically conductive wires of the cable are electrically connected at wire receiving ends of the terminals. When the terminals are pressed into the retaining element and the wire ends are electrically connected at the wire receiving ends of the terminals, a wire-terminal-retainer construction is formed at the end of the cable. The wire-terminal-retainer construction is placed in a molding device and a unitary connector end is molded at and over the wire-terminal-retainer construction. The molded unitary connector end includes a connector portion and a sleeve portion.

Claims

1. A method of forming a connector for an electrical cable for electrically connecting to a camera of a vehicle, said method comprising:

providing a cable having a plurality of electrically conductive wires, wherein each of said wires is electrically insulated from the others of said wires, and wherein said wires are within an outer sleeve of said cable;

stripping said outer sleeve of said cable and stripping electrically insulating material from ends of said wires to provide exposed ends of said electrically conductive wires;

providing a plurality of terminals each having a wire receiving end and a pin end opposite said wire receiving end;

providing a non-electrically conductive retaining element having a plurality of receiving portions and passageways separated by respective walls of said retaining element;

pressing said terminals into respective ones of said receiving portions and passageways of said retaining element, wherein walls of said retaining element electrically isolate said terminals from one another, and wherein said pin ends of said terminals pass through said passageways and protrude from said retaining element when said terminals are pressed into respective ones of said receiving portions and passageways of said retaining element;

electrically connecting the exposed ends of said electrically conductive wires at said wire receiving ends of said terminals,

wherein, when said terminals are pressed into respective ones of said receiving portions and passageways of said retaining element and the exposed ends of said electrically conductive wires are electrically connected at said wire receiving ends of said terminals, a wire-terminal-retainer construction is formed at the end of the cable; and

placing said wire-terminal-retainer construction in a molding device and molding a non-electrically conductive plastic resin to form a unitary connector end at and over said wire-terminal-retainer construction,

wherein said molded unitary connector end comprises (i) a connector portion that is at and partially around exposed portions of said pin ends of said terminals that protrude from said retaining element, (ii) an attaching structure for attaching the cable at the camera, and (iii) a sleeve portion that at least partially overlaps said outer sleeve of said cable and seals or bonds at said outer sleeve to seal the molded unitary connector end at said cable.

2. The method of claim 1, wherein said exposed ends of said electrically conductive wires are electrically connected at said wire receiving ends of said terminals before said terminals are pressed into said receiving portions and passageways of said retaining element.

3. The method of claim 1, wherein said exposed ends of said electrically conductive wires are electrically connected at said wire receiving ends of said terminals after said terminals are pressed into said receiving portions and passageways of retaining element.

4. The method of claim 1, wherein said exposed ends of said electrically conductive wires are electrically connected at said wire receiving ends of said terminals via soldering said wire receiving ends of said terminals at respective ones of said exposed ends of said electrically conductive wires.

5. The method of claim 1, wherein said exposed ends of said electrically conductive wires are electrically connected at said wire receiving ends of said terminals via crimping said wire receiving ends of said terminals at respective ones of said exposed ends of said electrically conductive wires.

6. The method of claim 1, wherein the step of molding a unitary connector end at and over said wire-terminal-retainer construction comprises injection molding.

7. The method of claim 1, wherein said attaching structure is configured for attaching the cable at an attachment plate of the camera for the vehicle.

8. The method of claim 1, wherein said connector portion comprises a molded plug or socket element disposed at and partially around exposed pin ends of said terminals.

9. The method of claim 1, wherein the step of pressing said terminals into respective ones of said receiving portions and passageways of said retaining element comprises pressing said terminals so that said pin ends pass through said passageway and protrude from said retaining element and said wire receiving ends are received in said receiving portions of said retaining element.

10. The method of claim 9, wherein said wire receiving end of each of said terminals has a greater diameter than a diameter of said pin end of said terminal.

11. The method of claim 10, wherein each of said receiving portions of said retaining element has a greater diameter than a diameter of the respective passageway of said retaining element.

12. The method of claim 9, wherein, when said terminals are pressed into respective ones of said receiving portions and passageways of said retaining element, said wire receiving ends of said terminals are press-fit in respective ones of said receiving portions of said retaining element.

13. A method of forming a connector for an electrical cable for electrically connecting to a camera of a vehicle, said method comprising:

providing a cable having a plurality of electrically conductive wires, wherein each of said wires is electrically insulated from the others of said wires, and wherein said wires are within an outer sleeve of said cable;

providing a plurality of terminals each having a wire receiving end and a pin end opposite said wire receiving end;

providing a non-electrically conductive retaining element having a plurality of receiving portions and passageways separated by respective walls of said retaining element;

pressing said terminals into respective ones of said receiving portions and passageways of said retaining element, wherein walls of said retaining element electrically isolate said terminals from one another, and wherein said pin ends of said terminals pass through said passageways and protrude from said retaining element when said terminals are pressed into respective ones of said receiving portions and passageways of said retaining element;

after pressing said terminals into respective ones of said receiving portions and passageways of said retaining element, electrically connecting ends of said electrically conductive wires at said wire receiving ends of said terminals,

wherein, when said terminals are pressed into respective ones of said receiving portions and passageways of said retaining element and the ends of said electrically conductive wires are electrically connected at said wire receiving ends of said terminals, a wire-terminal-retainer construction is formed at the end of the cable; and

placing said wire-terminal-retainer construction in a molding device and molding a non-electrically conductive plastic resin to form a unitary connector end at and over said wire-terminal-retainer construction,

wherein said molded unitary connector end comprises (i) a connector portion that is at and partially around exposed portions of said pin ends of said terminals that protrude from said retaining element, and (ii) a sleeve portion that at least partially overlaps said outer sleeve of said cable and seals or bonds at said outer sleeve to seal the molded unitary connector end at said cable.

14. The method of claim 13, wherein said ends of said electrically conductive wires are electrically connected at said wire receiving ends of said terminals via soldering said wire receiving ends of said terminals at respective ones of said ends of said electrically conductive wires.

15. The method of claim 13, wherein said ends of said electrically conductive wires are electrically connected at said wire receiving ends of said terminals via crimping said wire receiving ends of said terminals at respective ones of said ends of said electrically conductive wires.

16. The method of claim 13, wherein the step of pressing said terminals into respective ones of said receiving portions and passageways of said retaining element comprises pressing said terminals so that said pin ends pass through said passageway and protrude from said retaining element and said wire receiving ends are received in said receiving portions of said retaining element.

17. A method of forming a connector for an electrical cable for electrically connecting to a camera of a vehicle, said method comprising:

providing a cable having a plurality of electrically conductive wires, wherein each of said wires is electrically insulated from the others of said wires, and wherein said wires are within an outer sleeve of said cable;

providing a plurality of terminals each having a wire receiving end and a pin end opposite said wire receiving end;

providing a non-electrically conductive retaining element having a plurality of receiving portions and passageways separated by respective walls of said retaining element;

electrically connecting ends of said electrically conductive wires at said wire receiving ends of said terminals;

after electrically connecting ends of said electrically conductive wires at said wire receiving ends of said terminals, pressing said terminals into respective ones of said receiving portions and passageways of said retaining element, wherein walls of said retaining element electrically isolate said terminals from one another, and wherein said pin ends of said terminals pass through said passageways and protrude from said retaining element when said terminals are pressed into respective ones of said receiving portions and passageways of said retaining element,

wherein, when said terminals are pressed into respective ones of said receiving portions and passageways of said retaining element and the ends of said electrically conductive wires are electrically connected at said wire receiving ends of said terminals, a wire-terminal-retainer construction is formed at the end of the cable; and

placing said wire-terminal-retainer construction in a molding device and molding a non-electrically conductive plastic resin to form a unitary connector end at and over said wire-terminal-retainer construction,

wherein said molded unitary connector end comprises (i) a connector portion that is at and partially around exposed portions of said pin ends of said terminals that protrude from said retaining element, and (ii) a sleeve portion that at least partially overlaps said outer sleeve of said cable and seals or bonds at said outer sleeve to seal the molded unitary connector end at said cable.

18. The method of claim 17, wherein said ends of said electrically conductive wires are electrically connected at said wire receiving ends of said terminals via soldering said wire receiving ends of said terminals at respective ones of said ends of said electrically conductive wires.

19. The method of claim 17, wherein said ends of said electrically conductive wires are electrically connected at said wire receiving ends of said terminals via crimping said wire receiving ends of said terminals at respective ones of said ends of said electrically conductive wires.

20. The method of claim 17, wherein the step of pressing said terminals into respective ones of said receiving portions and passageways of said retaining element comprises pressing said terminals so that said pin ends pass through said passageway and protrude from said retaining element and said wire receiving ends are received in said receiving portions of said retaining element.