Abstract:
An electrical connection system adapted to be environmentally sealed by mounting a conductor block having at least one electrical conductor within a port extending through an electrical component. A first cover portion is telescopically engaged with the conductor block and has at least one wire channel formed therein. A seal is disposed against and extends about the periphery of the front portion of the non-conductive block. A second cover portion is configured to sealingly mate with the first cover portion and configured to engage the non-conductive block whereby electrical leads are retained.

Description:
BACKGROUND OF INVENTION 
     The present invention relates generally to an electrical connection system, and more particularly to an environmentally sealed electrical connection system capable of carrying high current in a package efficient manner. 
     Electrical connection systems are becoming increasingly important in applications that require both environmental isolation and high current capacity, as in electrodrive vehicles or with vehicles having an integrated alternator system. Of course, sealing from the environment and carrying high current are especially difficult to design for in areas such as an engine compartment or underhood applications where protection from the environment is particularly challenging. 
     Generally, a wire harness with many wires and terminals for electrical connections is provided in a vehicle electrical system. At times the connection system must pass through a fixed area such as a dash panel, engine, or transmission. One current method of sealing such system is to use a connector, which includes a seal on both the male and female ends of the connection. Alternatively, small internal seals are placed around the individual wires prior to being pressed into the connector. However, these types of connections pose many problems. Often the connection, though sealed, is not capable of carrying high current due to the wire size required for individual connector. Additionally, these systems are sealed at each termination point, thus increasing the possibility of failure or leakage. Examples of such prior art connectors can be found in U.S. Pat. No. 5,823,811. 
     Therefore, a need exists for an electrical connection system which is capable of mating two electrical components where one of the components is susceptible to fluid contamination, such as oil and/or water. The term “electrical component” means without limitation, motors, switchgear, power transmissions, starters or other electrical, electronic, or electro-mechanical devices known to those skilled in the art and suggested by this disclosure. It is further desired that this connection system be capable of carrying high current uninterrupted from contamination. 
     A connector according to the present invention satisfies the need for a simple to install, hermetically sealed connector system capable of carrying high current which improves on product robustness by reducing wire terminal losses and increases reliability. 
     SUMMARY OF INVENTION 
     According to the present invention, an electrical connector system is adapted to be environmentally sealed by mounting a conductor block sealingly engaged with a port extending through an electrical component. A first cover portion is telescopically engaged with the conductor block and has at least one wire channel formed therein. 
     A second cover portion is applied to a first cover portion, with the second cover having at least one wire channel formed therein such that conductor leads passing through said cover portions will be sealingly engageable with said first and said second cover portions. 
    
    
     A connector according to the present invention is particularly well suited for interconnecting components in an automotive environment; however, it should be appreciated that this electrical connection system will be useful for many non-automotive applications. These and other advantages of the present invention, as well as objects and features of the invention which will be readily apparent from the drawings, discussion and description, which follow. 
     BRIEF DESCRIPTION OF DRAWINGS 
     FIG. 1 is a perspective view of a rear portion of a conductor block according to the present invention; 
     FIG. 2 is a perspective view of a front portion of a conductor block according to the present invention; 
     FIG. 3 is a perspective view of a first cover portion according to the present invention; 
     FIG. 4 is a perspective view of a second cover portion according to the present invention; 
     FIG. 5 is an exploded perspective view of a connector assembly according to the present invention; 
     FIG. 6 is a cross-sectional view of an electrical conductor found in a conductor block according to the present invention; 
     FIG. 7 is a cross-sectional view of an electrical connection assembly according to the present invention; and 
     FIG. 8 is a sectional view partially broken away, taken along line  8 —— 8  of FIG.  7 . 
    
    
     DETAILED DESCRIPTION 
     With reference to FIG. 1 of the drawings, electrical connector  10  generally includes conductor block  12  containing a plurality of electrical conductors  14 . 
     Conductor block  12  may be made of thermosetting compound or any other non-conductive material typically used in various types of electrical connectors. Electrical conductors  14 , which will be described in greater detail below, are disposed in conductor block  12  by either being molded into place or pressed into conductor block  12 . The resulting interference between the electrical conductor  14  and the conductor block  12  provides a sealing feature to prevent both contamination from interfering with the electrical conductors  14 , and fluid leakage. 
     With reference to FIG. 2 of the drawings, the front portion of conductor block  12  includes mounting lugs  22 , having threaded apertures  24  allowing conductor block  12  to be mounted through a port located in an electrical component (not shown in FIG.  2 ). As described briefly above, electrical conductors  14  are designed as solid conductors that entirely fill cavities in conductor block  12 . This design prevents fluids or other contaminates from passing through the front and rear portions of the conductor block  12 . 
     The front portion  13  of conductor block  12  further includes guide posts  26  that separate electrical conductors  14  and contain holes  28 , whereby a cover ( 40 ) (not shown in FIG. 2) can be affixed to conductor block  12 . Additionally, the front portion of conductor block  12  includes a metallic shield  15 , which provides an electrical path for the purpose of controlling electromagnetic interference “EMI”, as is more fully explained in connection with FIG.  5 . 
     With reference to FIG. 3 of the drawings, first cover portion  30  is preferably molded in thermosetting material. Each wire channel  32  are formed in cover portion  30  to create a routing path for electrical leads. Wire channels  32  include a dimpled edge  36  which assists in forming a seal around an electrical lead when a second cover portion  40  (not shown in FIG. 3) is connected to first cover portion  30 . Additionally, first cover portion  30  includes mounting apertures  38  that are used to mount second cover portion  40  as viewed in FIG.  4 . 
     FIG. 4 illustrates second cover portion  40  according to the present invention. In a preferred embodiment, second cover portion  40  is molded for example, in thermosetting material and designed to sealingly cover first cover portion  30  and conductor block  12 . Wire channels  42  are formed in the thermoset of second cover portion  40  to aid with the routing of electrical leads when they are attached to the conductor block  12 . Wire channels  42  include a dimpled edge  46  for sealing purposes. Electrical leads (not shown in FIG. 4) are compressed between first cover portion  30  and the second cover portion  40  forming a seal around the insulation of the leads. Mounting holes  48  are included in second cover portion  40  to allow for attachment to first cover portion  30 . Additionally, apertures  50  are provided to affix second cover portion  40  to conductor block  12 . 
     FIG. 5 illustrates an exploded view of the electrical connector system  60 . The elemental parts of an electrical connector system  60  according to the present invention may be combined to form a hermetically sealed system as follows. First, conductor block  12  is positioned such that electrical leads  62  may be attached with bolts  64  to electrical conductors  14  extending from a rear portion of conductor block  12 . 
     Prior to insertion of conductor block  12  into a port  74  extending through component  70 , a seal or other sealing mechanism  72  is placed over the front portion of conductor block  12 . Seal  72  provides a resilient sealing engagement when the front portion of conductor block  12  is inserted through port  74  of electrical component  70  which may comprise, a dash panel, transmission, switchgear or other electrical device. More particularly, conductor block  12  is placed within port  74  a wall, panel or other surface so that the front portion  13  of conductor block  12  protrudes through port  74 . Fasteners, such as screws  76  are used to affix conductor block  12  to electrical component  70  by inserting fastener  76  through component hole  78  and electrical conductor hole  22 . 
     After conductor block  12  is mounted in its permanent position, first cover portion  30  is telescopically placed over the front portion  13  of conductor block  12 . Seal  80  is placed between first cover portion  30  and electrical component  70  so as to provide for a resilient sealing engagement, whereby contaminates such as fluids are prevented from escaping between the walls of port  74  and conductor block  12 . 
     Electrical leads  84  are attached with fasteners  86  to front side of electrical conductors  14 . The attachment of the electrical leads  84  prevents the first cover portion  30  from becoming dislodged from the front portion of conductor block  12 . 
     Additionally, the attachment of electrical leads  84  achieves the desired electrical contact required between the ends of the electrical conductors  14 . It is envisioned that electrical conductors  14  may be female or male type conductors and it will be understood that either may be used to attach electrical leads thereof. 
     Seal  90  is applied to inner edge  33  of first cover portion  30  and edge of second cover portion  40  thus accomplishing a sealing engagement system upon attachment when fasteners  92  are inserted through holes  48 . Additionally, a seal is created around electrical leads  84  due to the compression of the insulation that surrounds each electrical lead by dimpled edges  36  and  46 . Furthermore, as an enhancement of electrical connector system  60 , it is envisioned that a metallic shield  15  shown in FIG. 2 added to the external surfaces of the cover components  30  and  40 , with an electrical (copper) path from the cover mounting screws ( 92 ) to the electrical component ( 70 ) mounting screw ( 76 ) provides an electrical path to the electrical component, such as an aluminum transmission housing, for EMI purposes. Once assembled, the electrical connection system  60  is hermetically sealed and electrically isolated as shown in FIG.  7 . 
     FIG. 6 is a cross-sectional view of electrical conductor  14  as formed in conductor block  12 . Electrical conductor  14  can either be molded into conductor block  12  or pressed into the block. The electrical conductor  14  is made of highly conductive material, such as copper, capable of carrying electrical current at high amperages. Electrical current is transferred through the electrical conductor stem  82  when electrical leads (not shown in FIG. 6) are attached to both ends of the conductor  14 . 
     FIG. 7 illustrates cross-sectional view of electrical connection system  60  as assembled according to FIG.  5 . 
     FIG. 8 a sectional view  130  taken along line  8 —— 8  of FIG. 7 shows a plurality of electrical conductors  14  formed in conductor block  12 . Each of the electrical conductors is sealed independently against the conductor block  12  to prevent fluid wicking. At least one of the electrical conductors  14  centered on rear portion of conductor block  12 , is set-off in height to provide that attachment of electrical leads  84  thereto is isolated from remainder of electrical conductors or electrical leads  14  thus preventing electrical shorts. 
     It is understood that the particular configuration of the preferred embodiment of the present invention was designed with specific packaging requirements for a preferred application. However, it is also understood that the present invention is not limited to a particular construction herein described and/or shown in the drawings, but also comprises any modifications or equivalents within the scope of the claims. For example, a wide range of conductors  14  may be furnished within conductor block  12 .