Sealed metal shell connector and method of molding a plastic insert within a metal shell

• US 5,108,317 A
• Filed: 03/21/1991
• Issued: 04/28/1992
• Est. Priority Date: 03/21/1991
• Status: Expired due to Term

• Current Assignee: AMP Limited
• Original Assignee: AMP Limited
• Inventors: Stoner, Daryl L., McClusky, William E., Beinhaur, Ernest L.
• Primary Examiner(s): DESMOND, EUGENE
• Application Number:
  US07/674,858
• Time in Patent Office: 404 Days
• Field of Search: 439/736, 29/841, 29/843, 264/274, 174/522, 174/163 R
• US Class Current: 439/736
• CPC Class Codes: H01R 13/405 Securing in non-demountable manner, e.g. moulding, riveting
• CPC Class Codes: H01R 4/028 comprising means for preventing flowing or wicking of solder or flux in parts not desired
• CPC Class Codes: H01R 43/24 Assembling by moulding on contact members
• CPC Class Codes: Y10T 29/49146 with encapsulating, e.g., potting, etc.

Abstract

An article such as an electrical connector (10) formed by molding a plastic septum (50) transversely across an axially extending cavity (22) through a metal shell (20) and about the array of contacts (60) extending axially within the axial shell cavity (22). The metal shell (20) includes a peripheral flange (34) around the inner surface (30) axially at the location (32) of the plastic septum (50), and upon curing and cooling the plastic septum includes portions of solid material axially to each side of the peripheral flange (34). The flange (34) has a dovetail cross-section having undercuts within which solid material of the plastic septum (50) is disposed forming a seal peripherally around the axial cavity (22). The contact sections (62) extending from the connector may then be subjected to a forming step to define right angles for example, with portions (66) of the contacts (60) embedded with the plastic septum (50) being of irregular cross-section to establish resistance to the stresses of such forming and maintain the sealed nature of the connector (10).

Claims

1. An electrical connector of the type having an array of contacts extending through a transverse body portion of plastic, comprising:

a metal shell having an axially extending shell wall defining an axial cavity therethrough and surrounding said transverse body portion of plastic and said array of contacts extending therethrough, said metal shell including a peripheral flange extending inwardly from inwardly facing surface portions of said shell wall located radially around said plastic body portion, said peripheral flange having an axial length less than an axial length of said transverse body portion, said peripheral flange having a dovetailed cross-section thereby having undercuts on both sides thereof;

said transverse body portion being molded about body sections of said contacts of said array and within said metal shell to extend transversely across said axial cavity between said inwardly facing surface portions, and being molded to form solid material upon curing axially to each side of said peripheral flange and within said undercuts peripherally around said transverse body portion,

whereby said transverse body portion is retained within said shell and stopped against axial movement with respect thereto by said solid material axially to each side of said peripheral flange and forms a seal with said shell walls at said peripheral flange and a seal with said contacts at said body portions thereof.

2. The electrical connector as set forth in claim 1 wherein said body portions of said contacts include asymmetric cross sections embedded within said transverse body portion of plastic, thereby preventing even incremental rotation of said contacts within said transverse body portion upon subjection to stress, and maintaining said seal.

3. A method of fabricating an article having a plastic insert within a metal shell, comprising:

forming a metal shell having a circumferentially continuous shell wall enclosing an axially extending cavity therethrough to have an insert region defined between a periphery of inwardly facing surface portions of said axially extending shell wall at a selected axial location, including forming a peripheral flange extending inwardly from said surface portions a selected distance having an axial length less than an axial length of said insert region, said flange tapering to define undercuts axially along each side thereof; and

molding within said metal shell at said insert region a transverse septum of plastic to embed said peripheral flange, whereby said septum upon curing and cooling establishes solid material axially to each side of said peripheral flange and within said undercuts, minimizing shrinking transversely from said inwardly facing surface portions of said shell wall and preventing axial movement of said septum when subjected to stress or strain.