Electrical connector with high impact strength locking assemblies

• US 7,390,210 B2
• Filed: 11/08/2006
• Issued: 06/24/2008
• Est. Priority Date: 11/08/2006
• Status: Expired due to Fees

• Current Assignee: DSM&T Company Inc.
• Original Assignee: DSM&T Company Inc.
• Inventors: Corona, Sergio
• Primary Examiner(s): Gilman; Alexander
• Application Number:
  US11/594,318
• Publication Number:
  US 20080108243A1
• Time in Patent Office: 594 Days
• Field of Search: 439/278, 439/281, 439/283, 439/286, 439/275, 439/276, 29856-858
• US Class Current: 439/281
• CPC Class Codes: B29C 2045/14139 positioning inserts having a part extending into a positioning cavity outside the mould cavity
• CPC Class Codes: B29C 45/14065 Positioning or centering articles in the mould
• CPC Class Codes: B29C 45/14639 for obtaining an insulating effect, e.g. for electrical components
• CPC Class Codes: H01R 13/405 Securing in non-demountable manner, e.g. moulding, riveting
• CPC Class Codes: H01R 13/5219 Sealing means between coupling parts, e.g. interfacial seal
• CPC Class Codes: H01R 13/6273 comprising two latching arms
• CPC Class Codes: H01R 43/24 Assembling by moulding on contact members

Abstract

A weather-resistant electrical connector having an environmental seal and including a locking assembly made from a high impact strength thermoplastic. A method is disclosed for overmolding the connectors in one step. A locking yoke latches the connectors together. Locking tabs secure the connectors to mounting plates. The locking tabs have steps to retain the connectors upon compression of a seal. An insulated mounting post supports the contact and is of sufficient length to seal and contain any arcs from live connections.

Claims

1. In a water tight electrical connector assembly having a male connector and a female connector with a mating seal formed cooperatively upon connection of the male connector to the female connector, wherein one of the connectors includes locking tabs and the other connector comprises:

a locking yoke made from an impact resistant thermoplastic having a bit portion with opposed ends and locking arms integrally formed on either end of the bit portion;

an electrical contact forming a terminating end of a wire; and

a dielectric thermoplastic overmold body including a portion of the mating seal at the proximal end thereof and encasing said bit portion and said electrical contacts whereby the locking arms extend outside the body with a degree of flexibility so that the arms are capable of engaging and disengaging the locking tabs on the mating connector.

2. The assembly of claim 1, wherein said bit portion comprises a C shaped retention band that is configured and designed to pass around, and partially encircle, the electrical contacts.

3. The assembly of claim 2, wherein the retention band and the electrical contacts are held in a spaced relationship during formation of the overmold body.

4. The assembly of claim 3, wherein said yoke includes pivot plates between the bar and the locking arms, wherein the pivot plates pass through the exterior surface of the overmold body.

5. The assembly of claim 4, wherein the impact resistant material forming the locking yoke has an tensile strength at yield of between about 7,500 psi to about 10,500 psi according to ASTM D638.

6. The assembly of claim 5, wherein the locking arms are connected to the pivot plates at a midpoint thereof to provide a lever for pivoting the locking arms off of the tabs.

7. The assembly of claim 1, wherein the impact resistant material forming the locking yoke has a tensile strength at yield of between 3 and 20 times greater than the dielectric material forming the overmold body.

8. The assembly of claim 7, wherein the impact resistant material is selected from the group consisting of nylon 66 and polycarbonate, and the dielectric material is selected from the group consisting of PVC, TPR and TPE.

9. The assembly of claim 8, wherein said connectors each include one of a complementary shaped extension or cavity, both having lateral surfaces, and wherein said mating seals are formed on lateral surfaces.

10. The assembly of claim 9, wherein said band bit portion is axially aligned with said lateral surfaces.

11. The assembly of claim 9, wherein said band bit portion is axially aligned with said seal.

12. The assembly of claim 11, wherein said locking arms and said locking tabs engage at a location that is radially aligned with said lateral surfaces.

13. The assembly of claim 1, comprising a post integrally formed with said overmold body and having a free end for supporting said electrical contact.

14. The assembly of claim 13, wherein said post has a length that is greater than the length of said electrical contact.

15. The assembly of claim 14, wherein said post has a section of uniform cross sectional shape and area that is longer than said electrical contact.

16. The assembly of claim 15, wherein said post includes a base section having a frusto-conical shape.

17. The assembly of claim 14, wherein the one connector has a sleeve and female contact correspondingly shaped and dimensioned to receive said post and said electrical contact.

18. The assembly of claim 17, wherein said post occupies the sleeve opening to enclose the contacts before they enter arcing range.

19. The assembly of claim 1, further comprising

the one connector including a shoulder, at least one step and flexible arms that carry and bias the step outwardly into a face-plate contacting configuration.

20. The assembly of claim 19, wherein said one connector is overmolded with a dielectric material to include a bead extending around the shoulder for sealing engagement with the plate.

21. The assembly of claim 20, wherein said flexible arms carry a stepped profile to increase the pressure of the bead against the plate so that the bead forms an O-ring type seal meeting standard IP65.

22. The assembly of claim 21, wherein the bead comprises a tapered lip about 0.01 inches in height and extending off the shoulder in the direction of the tabs.

23. The assembly of claim 19, wherein said one connector is provided with channels underneath the flexible arms, wherein the flexible arms are adapted to be depressed into the channels to clear the face plate aperture for removal of the one connector.

24. The assembly of claim 23, comprising an attachment assembly having a capture block integrally formed with the flexible arms, and wherein said capture block releasably secures the attachment assembly to the one connector.

25. The assembly of claim 24, wherein said one connector is made from a dielectric thermoplastic material and includes the other portion of the waterproof seal.

26. The assembly of claim 25, wherein said one connector and the other connector are made from the same dielectric material.

27. The assembly of claim 25, wherein said attachment assembly is made from an impact resistant thermoplastic material having a tensile strength at yield of between about 7,500 psi to about 10,500 psi according to ASTM D638.

28. The assembly of claim 27, wherein said locking yoke and said attachment assembly are made from the same impact resistant material.

29. The assembly of claim 27, wherein said capture block includes windows and wherein said one connector includes engagement tabs at a distal end thereof, to latch into the windows of said capture block.

30. The assembly of claim 1, further comprising

the one connector including a shoulder and ramp tabs adapted to resiliently compress for passing through a face plate aperture and then expand to capture the face plate between the shoulder and the tabs.