CONNECTOR ASSEMBLIES AND METHODS OF MANUFACTURE

• US 20150004822A1
• Filed: 06/26/2013
• Published: 01/01/2015
• Est. Priority Date: 06/26/2013
• Status: Active Grant

• Current Assignee: Corning Optical Communications LLC (Corning Incorporated)
• Original Assignee: Corning Cable Systems LLC (Corning Incorporated)
• Inventors: Liu, Ziwei
• Granted Patent: US 9,548,557 B2
• Time in Patent Office: Days
• US Class Current: 439/275
• CPC Class Codes: C09D 183/04 Polysiloxanes
• CPC Class Codes: H01R 13/03 characterised by the material, e.g. plating, or coating materials
• CPC Class Codes: H01R 13/5221 having cable sealing means
• CPC Class Codes: H01R 4/2429 mounted in an insulating base
• CPC Class Codes: H01R 43/005 for making dustproof, splashproof, drip-proof, waterproof, or flameproof connection, coupling, or casing
• CPC Class Codes: H01R 43/01 for connecting unstripped conductors to contact members having insulation cutting edges
• CPC Class Codes: H01R 43/18 for manufacturing bases or cases for contact members
• CPC Class Codes: H01R 9/24 Terminal blocks
• CPC Class Codes: Y10T 29/4922 with molding of insulation

Abstract

A connector assembly that includes an insulation displacement member including a hydrophobic organosilane mono-layer protective coating is disclosed. In one embodiment, the connector assembly may be manufactured by a method that includes assembling the connector assembly, contacting the connector assembly with an organosilane coating solution, and curing the organosilane coating solution. The connector assembly may be assembled by mechanically supporting the insulation displacement member with a connector framework. The connector assembly may be contacted with the organosilane coating solution by contacting at least the wire engaging portion of the insulation displacement member and at least a portion of the connector assembly with the organosilane coating solution.

Claims

1. A method for manufacturing a connector assembly, the method comprising:

assembling the connector assembly by mechanically supporting an insulation displacement member with a connector framework such that the connector framework comprises an insulated-wire passage that is sized and oriented to receive an insulated electrically conductive wire, the insulation displacement member comprising a conductive wire engaging portion permitting forcible engagement of the wire engaging portion with the insulated electrically conductive wire when mechanically supported by the connector framework, the insulation displacement member formed primarily of a material that is hydrophilic relative to a material of the connector framework and defining an electrically conductive path extending from the wire engaging portion to an electrical coupling node of the connector assembly;

contacting at least the wire engaging portion of the insulation displacement member and at least a portion of the connector assembly with an organosilane coating solution; and

curing the organosilane coating solution at a temperature of at least about 50°

C. to form the connector assembly comprising an insulation displacement member comprising a hydrophobic organosilane mono-layer protective coating.

2. The method of claim 1, wherein the protective coating comprises an alkylsilane, an alkoxysilane, or both.

3. The method of claim 1, wherein prior to contacting the insulation displacement member 12 with the organosilane coating solution the insulation displacement member 12 is cleaned by contacting with an acid.

4. The method of claim 1, wherein the insulation displacement member is contacted with the organosilane coating solution by submerging the connector assembly comprising the insulation displacement member and the connector framework in the organosilane coating solution.

5. The method of claim 1, wherein the respective compositions of the organosilane coating solution and the connector framework are such that the connector assembly does not comprise the hydrophobic organosilane mono-layer protective coating upon curing.

6. The method of claim 1, wherein the insulation displacement member is formed primarily of a metal material and the connector framework is formed primarily of polycarbonate.

7. A method for manufacturing a connector assembly, the method comprising:

contacting at least a wire engaging portion of an insulation displacement member with an organosilane coating solution;

curing the organosilane coating solution at a temperature of at least about 50°

C. to form an insulation displacement member comprising a hydrophobic organosilane mono-layer protective coating; and

assembling the connector assembly by mechanically supporting the insulation displacement member comprising the hydrophobic organosilane mono-layer protective coating with a connector framework such that the connector framework comprises an insulated-wire passage that is sized and oriented to receive an insulated electrically conductive wire, the insulation displacement member comprises a conductive wire engaging portion permitting forcible engagement of the wire engaging portion with the insulated electrically conductive wire when mechanically supported by the connector framework, and the insulation displacement member defines an electrically conductive path extending from the wire engaging portion to an electrical coupling node of the connector assembly.

8. The method of claim 7, wherein the protective coating comprises an alkylsilane, alkoxysilane, or both.

9. The method of claim 7, wherein prior to contacting the insulation displacement member 12 with the organosilane coating solution the insulation displacement member 12 is cleaned by contacting with an acid.

10. The method of claim 7, wherein the insulation displacement member is contacted with the organosilane coating solution by submerging the insulation displacement member in the organosilane coating solution.

11. A connector assembly comprising a connector framework and at least one insulation displacement member, wherein:

the connector framework comprises an insulated-wire passage that is sized and oriented to receive an insulated electrically conductive wire;

the insulation displacement member comprises a conductive wire engaging portion and is mechanically supported by the connector framework to permit forcible engagement of the wire engaging portion with the insulated electrically conductive wire, the insulation displacement member defining an electrically conductive path extending from the wire engaging portion to an electrical coupling node of the connector assembly;

at least the wire engaging portion of the insulation displacement member is coated with a cured hydrophobic organosilane mono-layer protective coating such that it seals the insulation displacement member from environmental moisture or otherwise protects the insulation displacement member from damage.

12. The connector assembly of claim 11, wherein the protective coating comprises an alkylsilane.

13. The connector assembly of claim 12, wherein an alkyl functionality of the alkylsilane comprises a carbon chain having a length of greater than or equal to 8 carbons and less than or equal to 36 carbons.

14. The connector assembly of claim 11, wherein the protective coating comprises an alkoxysilane

15. The connector assembly of claim 11, wherein the insulation displacement member is mechanically supported in a static or motive state.

16. The connector assembly of claim 11, wherein the connector framework is not electrically conductive.

17. The connector assembly of claim 11, wherein the connector framework comprises polycarbonate.

18. The connector assembly of claim 11, wherein the connector framework is configured as a housing and the insulation displacement member is partially or entirely disposed within the housing.

19. The connector assembly of claim 11, wherein only an exposed portion of insulation displacement member is completely coated and an unexposed portion of the insulation displacement member is not coated.

20. The connector assembly of claim 11, wherein the insulation displacement member is coated on all surfaces.