Environmental connector
DCFirst Claim
1. A method of making an electrical connector, comprising the steps of:
- forming a plastic housing having an axis and being formed with an axial chamber extending between opposing open ends, said housing having an external annular shoulder and an aperture adjacent to said shoulder;
positioning said housing in a cavity of an insertion mold having at least one post extending axially through said chamber of said housing, said cavity having an annular void adjacent to said shoulder;
injecting thermoplastic rubber into said chamber of said housing to form a rubber insert of predetermined shape within said housing and around said at least said one post, and to cause said thermoplastic rubber to flow out of said aperture and around said housing in said annular void to form an annular ring against said shoulder wherein said insert and said ring are interconnected as one piece;
removing said housing and insert from said cavity and away from said at least one post to form at least one axial bore through said insert within said chamber in the space vacated by said at least one post; and
inserting at least one conductive contact into said bore.
7 Assignments
Litigations
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Accused Products
Abstract
An environmental connector formed by insert molding a thermoplastic rubber insert into a plastic cylindrical housing having an external shoulder adjacent to an exit aperture for the thermoplastic rubber to flow to an annular void in the cavity of the mold. In such manner, an annular ring such as a gasket or o-ring is formed by the insert molding process, and is connected as one piece with the thermoplastic rubber insert formed in the internal chamber of the housing. The housing is made of polypropylene and the thermoplastic rubber is Santoprene so the two materials stick together to hold the annular ring snugly against the shoulder. The insert of the female connector has a concentric opening to receive the housing of the male connector, and the concentric opening terminates in thin protrusion that is compressible to from an inner seal to prevent the ingress of moisture into the connectors.
22 Citations
9 Claims
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1. A method of making an electrical connector, comprising the steps of:
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forming a plastic housing having an axis and being formed with an axial chamber extending between opposing open ends, said housing having an external annular shoulder and an aperture adjacent to said shoulder; positioning said housing in a cavity of an insertion mold having at least one post extending axially through said chamber of said housing, said cavity having an annular void adjacent to said shoulder; injecting thermoplastic rubber into said chamber of said housing to form a rubber insert of predetermined shape within said housing and around said at least said one post, and to cause said thermoplastic rubber to flow out of said aperture and around said housing in said annular void to form an annular ring against said shoulder wherein said insert and said ring are interconnected as one piece; removing said housing and insert from said cavity and away from said at least one post to form at least one axial bore through said insert within said chamber in the space vacated by said at least one post; and inserting at least one conductive contact into said bore. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of making an electrical connector, comprising the steps of:
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forming a substantially tubular polypropylene housing having an elongated hollow chamber extending between opposing open ends, said housing having an external annular flange and an aperture adjacent to said flange; positioning said housing in a cavity of an insertion mold having a predetermined plurality of posts extending axially through said chamber of said housing, said cavity having an annular void adjacent to said flange on the outside of said housing; injecting thermoplastic rubber into said chamber of said housing to form a rubber insert of predetermined shape within said housing around said posts, and to cause said thermoplastic rubber to flow from said chamber through said aperture and around said housing in said annular void to form an annular gasket against said flange wherein said insert and said gasket are interconnected as one piece; removing said housing and insert from said cavity and away from said plurality of posts to form a plurality of axial bores through said insert in the space vacated by said plurality of posts; and inserting a plurality of conductive contacts into said plurality of bores, respectively.
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Specification