Abstract:
An electrical connector assembly  10  includes a seal  20  including sealing apertures  25  that including glands for sealing a wire extending through the aperture. A sealing unit  24  includes a lead in recess  26 , a contact ingress seal gland  28 , a core seal gland  30  and a contact egress seal gland  29 . The core seal gland  30  establishes the primary seal with a wire extending through the seal, and the ingress seal gland  28  is deformable between the core seal gland  30  and the contact during contact insertion to protect the core seal gland  30  from damage. A pattern  40  of stress relieving recesses  42  et seq. surrounds the seal apertures, and include canted webs  43  et seq. The stress relieving recesses aid flexure of the seals and the seal glands. Other stress relieving recesses  56  located between seal apertures including perpendicular webs  57.

Description:
CROSS REFERENCE TO CO-PENDING APPLICATION 
     This application claims the benefit of U.S. Provisional Application(s) No(s). 60,037,971, Filed Feb. 20, 1997 and Provisional Application No. 60/041,617, Filed Mar. 27, 1997. 
     This application claims the benefit of Provisional Application 16902L, filed Feb. 20, 1997 entitled Sealed Electrical Conductor Assembly, and the benefit of Provisional Application 16906L, entitled Sealed Electrical Conductor Assembly filed Mar. 27, 1997. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an electrical conductor assembly comprising a seal for sealing an electrical conductor terminated to an electrical contact. The seal of the present invention allows a contact having corners, e.g. a box-shaped receptacle contact, to be manually or automatically inserted through the seal without degrading the sealing quality of the seal. 
     2. Description of the Prior Art 
     Seals are often used with electrical connectors to provide a barrier to contaminants, including water and other fluids. Seals are typically located at the mating interface between two electrical connectors and around conductors, typically wires, that extend into the connector. Typically, the wires are attached to electrical terminals and the terminals are then inserted into terminal cavities in electrical connector housings. The terminals are inserted through terminal receiving apertures or holes in the seals and into corresponding cavities in the housing. These holes in the seals typically includes sealing glands or cylindrical bumps or protuberances that establish sealing integrity with the round wires or conductors extending though the seals when the terminals have been fully inserted into the housing cavities. 
     The terminals are typically larger than the conductors to which they are attached. Therefore one problem that occurs is that during insertion of the terminal or electrical contact through the seal holes or apertures, the contact can damage the seal glands. For example, the front end of the contact can tear the seal, thereby compromising the sealing capability of the seal. The problem is especially significant for typical terminals or contact having a box shaped receptacle section with a generally rectangular or square cross section. The round hole must be deformed to allow the rectangular terminal to pass through the seal. During insertion, the edges of the terminal or contact can bite into the seal and rip or tear the seal. 
     SUMMARY OF THE INVENTION 
     A primary object of the sealing assembly and the seal depicted herein is to provide a good barrier to contaminants, including fluids, and to reduce the damage to seals as electrical contacts or terminals are inserted through the seal apertures. This seal is especially adapted for use with box contacts or receptacles having a rectangular cross section that are inserted through round apertures or holes. 
     In accordance with this invention, a sealed electrical conductor assembly includes a seal having a seal surface with at least one a contact receiving aperture extending into the seal from the seal surface for receiving said contact and said conductor therethrough. A lead-in recess is formed on the seal surface adjacent to the contact receiving aperture for receiving said contact. The contact receiving aperture comprises a plurality of sealing glands including an ingress gland and a core gland. As the contact is inserted into a contact receiving aperture, the contact is operative to push the ingress gland into engagement with the core gland. The ingress gland is interposed between the core gland and a corner area of the contact. The ingress gland thereby protects the core gland from tearing as the contact is inserted through the seal. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 shows a front view of a seal according to the present invention. 
     FIG. 2 shows a cross section of the seal of FIG. 1 taken along line  2 — 2 . 
     FIG. 3 shows a cross section of the seal of FIG. 1 taken along line  3 — 3 . 
     FIG. 4 shows the seal of FIG.  1 . 
     FIG. 5 shows a cross section of the seal of FIG. 4 taken along line  5 — 5 . 
     FIG. 6 shows a cross section of the seal of FIG. 4 taken along line  6 — 6 . 
     FIG. 7 shows a cross section of the seal of FIG. 4 taken along line  7 — 7 . 
     FIG. 8 shows a cross section of the seal of FIG. 4 taken along line  8 — 8 . 
     FIG. 9 shows a side view of the seal and contact components of the assembly of the present invention in a pre-staged position. 
     FIG. 10 shows initial insertion of the contact into the seal. 
     FIG. 11 shows a first intermediate insertion position of the contact into the seal. 
     FIG. 12 shows a second intermediate insertion position of the contact into the seal. 
     FIG. 13 shows a side view of the assembly of the present invention in a completed state. 
     FIG. 14 shows the assembly of the present invention installed in a housing assembly. 
     FIG. 15 shows a cross section of an alternative embodiment of the seal. 
     FIG. 16 the insertion of the contact into the seal of FIG.  15 . 
     FIG. 17 shows the full insertion position of the contact into this field. 
     FIG. 18 shows a cross sectional view of an alternative embodiment of the seal of the present invention. 
     FIG. 19 shows the insertion of a contact into the seal of FIG.  18 . 
     FIG. 20 shows an alternative manner in which the contact may be inserted into the seal of FIG.  18 . 
     FIG. 21 shows the contact in the fully inserted position. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to FIGS. 1 and 13, a sealed conductor assembly  10  according to the present invention will be described. Sealed assembly  10  includes a wire seal  20 , and an electrical contact  12  terminated in a conventional fashion to a conductor  14 . Sealed conductor assembly  10  is suitable for being housed within a contact receiving area of an electrical connector housing assembly  60  (FIG.  14 ). As indicated in FIGS.  13 - 14 , seal  20  is in sealing engagement with conductor  14  thereby creating a sealed barrier, which barrier advantageously inhibits the influx of foreign matter into the contact receiving area of electrical connector housing  60 . 
     Now referring to FIGS.  1 - 8 , seal  20  will be further described. Seal  20  is formed of a sealing material, of about 50 durometer, preferably 30 durometer, or most preferably 18 durometer. Seal  20  includes first and second exterior surfaces  21  and  22 , respectively. Extending through the seal between exterior surfaces  21 , 22  are a plurality of sealing units  24 . A given sealing unit  24  comprises a contact/conductor receiving aperture  25 . Adjacent to aperture  25  and formed in exterior surfaces  21 , 22  are a lead-in recess  26  and an exit recess  27  (FIG.  3 ). In the present embodiment, recesses  26 , 27  comprise a generally box-shaped form, complementary to the contours of contact  12 , which is preferably a box-shaped receptacle contact. Sealing unit  24  also includes sealing sections comprising a contact ingress gland  28  adjacent to lead-in recess  26 , a contact egress gland  29  adjacent exit recess  27 , and a core gland  30  disposed between glands  28 , 29  (FIG.  3 ). Seal  20  also includes a stress relieving pattern  40  comprising stress relieving recesses  42 , 42   a , 44 , 44   a , 46 ,  46   a , 48 , 48   a , 50 , 50   a , 52 , 54 , 56  (FIG.  4 ). As best shown in FIGS.  2  and  4 - 8 , recesses  42 , 42   a , 44 , 44   a , 46 , 46   a ,  48 , 48   a , 50 , 50   a , 52 , 54  comprise major recesses located adjacent sealing units  24 . The major recesses of pattern  40  are strategically spaced between the outer periphery of seal  20  and sealing units  24 . Each major recess comprises a respective canted web  43 , 45 , 47 , 49 ,  51 , 53 , 55  which extends across the respective major recess (FIGS.  2  and  5 - 9 ). The cant of each web is made such that the portion of the major recess web which is adjacent a given sealing unit  24  is contiguous with a wall of the major recess adjacent respective egress and core glands  29 , 30 , which advantageously permits a high degree of deformation of the major recess in the area of ingress gland  28 , as will be further described below. Each major web has a facing portion which faces toward exterior surface  21 , and a facing portion which faces exterior surface  22 . The facing portion of a given major web nearest a given sealing unit  24  defines an acute angle α with respect to a wall of the respective major recess, e.g. as shown in FIG.  9 . Thus, the cant of a web  43 , 45 , 47 , 49 , 51 , 53 , 55  traverses its respective major recess, toward exterior surface  21 , as the web extends away from an adjacent sealing unit  24 . Additionally, pattern  40  comprises a row of minor recesses  56 , each including a respective transverse web  57  extending thereacross. Minor recesses  56  are strategically located between certain ones of the sealing units  24  for stress relieving action, as will be further described below. 
     Assembly of sealed conductor assembly  10  will now be described. As shown in FIG. 9, contact  12  is in a pre-staged position with respect to a sealing unit  24  so that the complementary shape of lead-in recess  26  is aligned with the face of contact  12 . Contact  12  is then inserted into lead-in recess  26 , which recess serves to align and position contact  12  with respect to aperture  25 , as shown in FIG.  10 . The generally flat surface of gland  28  is pushed by the face of contact  12 , with gland  28  folding and stretching in response, whereby contact ingress gland  28  is stretched into a protective, stretched gland state  28 ′ around contact  12  but between contact  12  and core gland  30 . However, it is to be understood that recesses  26  and  27  are not required to be formed in exterior surfaces  21 , 22 , but the invention hereof will perform satisfactorily where glands  28  and  29  are substantially coterminous with exterior surfaces  21  and  22 , respectively. As contact  12  is further inserted into sealing unit  24 , ingress gland  28  is elastically stretched about contact  12  into a protective, extended gland state  28 ″. Extended gland state  28 ″ is thereby interposed between contact  12  and core gland  30 . Core gland  30  becomes pressed into a deformed state  30 ′ thereby allowing contact  12  to pass. At this point, core gland  30  has been shielded from tearing engagement with contact  12  by the protective stretched and extended gland states  28 ′, 28 ″. The stretched and extended states of gland  28  are effected by the durometer characteristic of the material from which seal  20  is made, which is most preferably a characteristic of about  18  durometer. According to the present invention, whether or not ingress gland  28  is torn during insertion of contact  12 , core gland  30  is protected by the compressed and extended gland states  28 ′, 28 ″ as contact  12  is inserted through seal  20 . Extraction of contact  12  from seal  20  will result in generally a reversal of the foregoing, i.e. gland  29  will be stretched over core gland  30  by the rear portion of contact  12 , thereby protecting core gland  30  from tearing during removal of contact  12 . 
     Moreover, as contact  12  is inserted in sealing unit  25 , stress relieving pattern  40  is operative to relieve stress in the material of seal  20  by allowing the seal material to flow away from a given sealing unit  20  when contact  12  is being inserted therethrough. As contact  12  presses on lead-in gland  28 , the seal material is compelled to flow toward adjacent major and minor recesses of pattern  40 . As best shown in FIG. 11, and using major recess  48  and minor recess  56  as illustrative examples, upon insertion of contact  12  the seal material flows toward adjacent recesses  48 , 56  of pattern  40 , whereby the respective internal dimensions of which are changed as indicated at  48 ′, 56 ′. Additionally, webs  49 , 57  are deformed under stress to bow, as shown at  49 ′, 57 ′ of FIG.  11 . Additionally, angle α is squeezed to generally a lesser angle α′. Thus, because the seal material of seal  20  is permitted to flow into the major and minor recesses, stress is advantageously relieved therein sufficient enough to avoid a stress build-up in the seal material in excess of its tear strength. 
     As shown in FIG. 12, further insertion of contact  12  through sealing unit  24  results in elastic regression of ingress gland  28  as shown at  281 ′″; however, core gland  30  is not torn but, as described above, remains fully intact for performing its sealing function. After contact  12  has been fully inserted through seal  20 , as indicated by FIG.  13 - 14 , sealing glands  28 , 29 , 30  assume respective sealing postures  28   s , 29   s , 30   s , with respect to conductor  14 . Preferably, as shown in FIG. 14, assembly  10  is made according to the foregoing description in a housing assembly  60 . Housing assembly  60  comprises a housing  62 , a latchable cover  64  having a contact receiving aperture  64   a . Spacers  65 , 67 , of a suitable thickness, are formed on housing  62  and cover  64 , respectively, for allowing space to remain between seal  20  and housing  62  and cover  64 , respectively. This reservation of space allows the seal material to flow, in the front and back of seal  20 , as contact  12  is inserted through hole  64   a  and aperture  25 . 
     In the present invention, the sealing integrity of core gland  30  is preserved as a primary sealing gland, even if ingress gland  29  has been torn by insertion of contact  12 . In this way, ingress gland  29 , if torn by the insertion process of contact  12 , is a sacrificial gland which is stretchably sacrificed in order to protect core gland  30 . Moreover, the final state of electrical conductor assembly  10  is compact because it does not require a funnel-type lead-in recess. 
     Referring to FIGS.  15 - 17 , a second embodiment of the seal will now be described. Seal  120  is suitable for use as a sealed assembly around an electrical contact  12  and the conductor  14  terminated thereto. Seal  120  is formed of a similar;r sealing material as was described earlier for seal  20 . Seal  120  includes first and second exterior surfaces  121  and  122  respectively. A given sealing unit  124  has a contact/conductor receiving aperture  125 . Adjacent to aperture  125  and formed in exterior surfaces  121 ,  122  are lead-in recesses  126  and exit recess  127 . The recesses  126 ,  127  comprise a generally box shaped form, complimentary to the contours of contact  12  which is a box shaped receptacle contact. Alternatively, the seal of the present invention can be used for a round contact also. The contact receiving aperture  125  is generally round shaped to a good sealing surface against the round conductor  14 . The contact receiving aperture  125  has a first, frangible gland  128 . The seal  120  also has an egress gland  129  and a core gland  130 . 
     During assembly of the contact  12  to the connector, the contact is received into lead-in recess  126  against the frangible gland  128 . As the contact  12  is inserted further into the connector and through the seal  120 , to the right as shown in FIG. 16, the frangible gland  128  stretches along the surface of the contact  12  as it is inserted through the aperture  125 . When the contact  12  is inserted far enough into the connector, the frangible gland  128  will be stretched beyond its limits and will break forming broken glands  128 ′. The broken glands  128 ′ will spring back towards their original position within the seal  120 . 
     As the contact is being inserted through the seal, as shown in FIG. 16, the frangible gland  128  stretches around the contact  12  thereby protecting the core gland  130  and the egress gland  129  from damaging the engaging glands  129  and  130  and thereby scratching or cutting glands  129 ,  130 . Therefore, the frangible glands  128  serves to protect the sealing ability of glands  129 ,  130 . Because the glands were protected during the insertion, they provide a good seal against the wire or conductor  14  once the contact is fully inserted into the connector housing. 
     Now referring to FIGS.  18 - 21 , an alternative embodiment of the present invention will now be described. FIG. 18 shows an alternative embodiment of the seal which can be used in an electrical connector to provide a seal around the wires or conductors thereof. The seal  220  has exterior surfaces  221  and  222 . The seal  220  also has a contact/conductor aperture  225  extending therethrough. Adjacent to aperture  225  and formed in exterior surfaces  221 ,  222  are a lead in recess  226  and an exit recess  227 . Along the contact receiving aperture  225  are a series of glands, ingress gland  228 , egress gland  229 , and core gland  230 . In this embodiment, core gland  230  is substantially wider than ingress and egress glands  228 ,  229 . This gives the core gland  230  better strength and durability to hold up to tears and also to provide a better sealing surface against the wires or conductors. 
     During insertion of the contact through the contact receiving aperture  225 , the ingress gland  228  will be pushed towards the opposite side of the seal  220 , as shown in FIG. 19, and will provide a protective surface for the core gland  230  during insertion of the contact. The ingress gland  228  will bear the force of any tears or scratches during contact insertion thereby protecting the core gland  230 . Alternatively, as shown in FIG. 20, the ingress gland can be pushed and stretched by the contact  12  if the contact  12  stubs on the gland during insertion thereby pushing it past the core gland  230 . The ingress gland  228  would then form a protective barrier against the core  230  to prevent cuts and scratches on the core gland to  230 . This allows better sealing of the core gland  230  against the wire upon full insertion of the contact into the connector housing. The ingress gland  228  acts as a sacrificial gland during the insertion process of the contact  12  into the aperture  225 . By absorbing the cuts and scratches that occur during insertion of the contact  12 , the ingress gland protects the core gland  230  from these cuts and scratches and, therefore, allows the core gland  230  to provide a better sealing surface against the conductor  14  when the contact is fully inserted within the electrical connector. 
     When the contact  12  is removed from the electrical connector, the rear portion of the contact  12  will engage the egress gland  229 . The egress gland will serve to protect the core gland  230  from cuts and scratches in the same manner as the ingress gland  228  protects during insertion. Therefore, the seal  220  can be reused as the core gland  230  will remain intact and can provide a good seal against a conductor  14  after a subsequent insertion. 
     The seal of the present invention allows a contact having corners, e.g. a box-shaped receptacle contact, to be manually or automatically inserted through the seal without degrading the sealing quality of the seal. 
     The seal of the present invention and many of its attendant advantages will be understood from the foregoing description. It is apparent that many changes may be made in the form, construction, and arrangement of parts thereof without departing from the spirit or scope of the invention, or sacrificing all of their material advantages.