Electrical harness connector

• US 9,731,663 B2
• Filed: 04/24/2014
• Issued: 08/15/2017
• Est. Priority Date: 05/03/2013
• Status: Active Grant

• Current Assignee: Rolls-Royce PLC (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce PLC (Rolls-Royce Holdings Plc)
• Inventors: Wilson, Jonathan, Broughton, Paul
• Primary Examiner(s): Demeree, Christopher
• Application Number:
  US14/260,614
• Publication Number:
  US 20140325993A1
• Time in Patent Office: 1,209 Days
• Field of Search: 60796, 60801, 174254, 29876, 439606, 439 761, 439493
• CPC Class Codes: B60R 16/0207 Wire harnesses
• CPC Class Codes: F02C 7/00 Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants controlling F02C9/00
• CPC Class Codes: F05D 2300/603 Composites; e.g. fibre-reinforced
• CPC Class Codes: H01R 12/77 for flexible printed circuits, flat or ribbon cables or like structures
• CPC Class Codes: H01R 13/52 Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
• CPC Class Codes: H01R 43/20 for assembling or disassembling contact members with insulating base, case or sleeve
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 2201/05 Flexible printed circuits [FPCs]
• CPC Class Codes: H05K 2201/10189 Non-printed connector
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft
• CPC Class Codes: Y10T 29/49208 by assembling plural parts

Abstract

An electrical harness assembly is provided that comprises a flexible printed circuit electrically connected to one end of an electrical connector. The other end of the electrical connector is presented for connection to another electrical component. Electrical tracks or conductors in the flexible printed circuit terminate in receiving holes. The electrical connector comprises terminals, each of which has a first end that is received in one of the receiving holes to form a connection formation, and a second end which is present for connection to the other electrical device. The connection formation is encapsulated so as to be sealed, thereby providing a reliable and robust connection between the connector and the flexible printed circuit.

Claims

1. An electrical harness assembly comprising:

an electrical harness including;

(i) a flexible printed circuit having a plurality of conductive tracks, and (ii) a terminating region at which each conductive track terminates at a receiving hole, each receiving hole being electrically connected to a respective electrical track;

an electrical connector including elongate terminals each having a first end received in one of the receiving holes, thereby forming a connection formation where the elongate terminals are electrically connected with the conductive tracks, and the elongate terminals each having a second end configured to connect to a complimentary connector; and

an encapsulating body continuously surrounding the connection formation in a single, continuous body, the encapsulating body being in direct contact with the connection formation, the encapsulating body forming a non-releasable body around the connection formation and permanently sealing the connection formation within the encapsulating body.

2. The electrical harness assembly according to claim 1, wherein the encapsulating body is a homogeneous body formed around the connection formation.

3. The electrical harness assembly according to claim 1, wherein the encapsulating body forms a hermetic seal around the connection formation.

4. The electrical harness assembly according to claim 1, wherein the encapsulating body is formed from a moldable insulating material.

5. The electrical harness assembly according to claim 1, wherein an outer surface of the electrical harness assembly is formed by the encapsulating body.

6. The electrical harness assembly according to claim 1, wherein:

the electrical connector includes a housing; and

the elongate terminals are supported in the housing such that the second ends of the elongate terminals are configured to connect to a complimentary connector at an open end of the housing.

7. The electrical harness assembly according to claim 1, wherein each terminating region is substantially planar, each receiving hole is arranged such that the elongate terminals extend out of a plane of the terminating region.

8. An electrical raft comprising a rigid material having embedded in the rigid material at least a part of the electrical harness assembly according to claim 1.

9. The electrical raft according to claim 8, wherein the rigid material is a rigid composite material.

10. The electrical raft according to claim 8, wherein a first part of the electrical connector is embedded in the rigid material, and a second part of the electrical connector extends away from the rigid material.

11. The electrical raft according to claim 8, wherein the second ends of the elongate terminals extend away from the electrical raft so as to be configured to connect to an external complimentary connector.

12. A gas turbine engine having an electrical system comprising the electrical raft according to claim 8.

13. A gas turbine engine having an electrical system comprising the electrical harness assembly according to claim 1.

14. A method of providing an electrical harness with an electrical connector for connection to a complimentary connector, the electrical harness including a flexible printed circuit having a plurality of conductive tracks, the method comprising:

forming a terminating region of the electrical harness at which each conductive track terminates at a receiving hole, each receiving hole being electrically connected to a respective electrical track;

providing an electrical connector including elongate terminals each having a first end and a second end;

fitting the first end of each elongate terminal in a respective one of the receiving holes, thereby forming a connection formation where the elongate terminals are electrically connected with the conductive tracks;

presenting the second end of each elongate terminal for connection to a complimentary connector; and

encapsulating the connection formation by surrounding the connection formation with an insulating material forming a single, continuous encapsulating body that is in direct contact with the connection formation forming a non-releasable body around the connection formation and permanently sealing the connection formation within the encapsulating body.

15. The method of providing the electrical harness with the electrical connector according to claim 14, wherein the step of encapsulating the connection formation includes injection molding the insulating material around the connection formation.