Connector shroud configuration

An illustrative example embodiment of a connector includes a terminal configured to establish an electrically conductive connection with another component and a shroud surrounding the terminal. The shroud includes a first sidewall and a second sidewall that is transverse to the first sidewall. The first sidewall and the second sidewall have a sidewall dimension in a direction parallel to a longitudinal axis of the terminal. The shroud includes a first transition between the first sidewall and the second sidewall in the form of a hollow cylindrical sector having a first angular measurement of more than 90 degrees. The transition has a transition dimension that is less than the sidewall dimension.

BACKGROUND

Connector assemblies are useful on automotive vehicles for making electrical connections. A variety of connector configurations are known in the industry. Fuel economy and material cost are considerations that have tended to lead to lighter weight connectors. In some cases, the connector features are less robust. As a result, additional care is required when making connections using such connectors.

SUMMARY

An illustrative example embodiment of a connector includes a terminal configured to establish an electrically conductive connection with another component and a shroud surrounding the terminal. The shroud includes a first sidewall and a second sidewall that is transverse to the first sidewall. The first sidewall and the second sidewall have a sidewall dimension in a direction parallel to a longitudinal axis of the terminal. The shroud includes a first transition between the first sidewall and the second sidewall in the form of a hollow cylindrical sector having a first angular measurement of more than 90 degrees. The transition has a transition dimension that is less than the sidewall dimension.

In an example embodiment having one or more features of the connector of the previous paragraph, the shroud includes a third sidewall and a second transition between the second sidewall and the third sidewall in the form of a hollow cylindrical sector having a second angular measurement of more than 90 degrees. The second sidewall is transverse to the third sidewall. The third sidewall has the sidewall dimension, and the second transition has the transition dimension.

In an example embodiment having one or more features of the connector of any of the previous paragraphs, the first and second transitions are situated at corners of the shroud and the first and second transitions protrude beyond the first, second, and third sidewalls.

In an example embodiment having one or more features of the connector of any of the previous paragraphs, the first and second transitions include a radius of curvature and the first angular measurement is equal to the second angular measurement.

In an example embodiment having one or more features of the connector of any of the previous paragraphs, the first sidewall includes a first edge, the second sidewall includes a second edge, the first and second edges are at least partially in a first plane, the transition includes a third edge, and the third edge is at least partially in a second plane that intersects the first plane at an oblique angle.

In an example embodiment having one or more features of the connector of any of the previous paragraphs, the angle is between 60° and 20°, preferably between 50° and 30°, and more preferably 40°.

An illustrative example embodiment of a connector assembly includes a first connector including a first terminal and a first shroud surrounding the first terminal and a second connector including a second terminal configured to establish an electrically conductive connection with the first terminal. The second connector includes a second shroud surrounding the second terminal. The second shroud is configured to be received adjacent and overlapping with the first shroud when the first and second connectors are connected. The second shroud includes a first sidewall and a second sidewall that is transverse to the first sidewall. The second shroud includes a first transition between the first sidewall and the second sidewall in the form of a hollow cylindrical sector having a first angular measurement of more than 90 degrees. The first transition has a transition dimension that prevents contact between the transition and the at least one first terminal.

In an example embodiment having one or more features of the connector assembly of the previous paragraph, the first sidewall and the second sidewall have a sidewall dimension in a direction parallel to a connection direction of the terminals, the transition dimension is in the connection direction, and the transition dimension is less than the sidewall dimension.

In an example embodiment having one or more features of the connector assembly of any of the previous paragraphs, the shroud includes a third sidewall and a second transition between the second sidewall and the third sidewall in the form of a hollow cylindrical sector having a second angular measurement of more than 90 degrees, the second sidewall is transverse to the third sidewall, the third sidewall has the sidewall dimension, and the second transition has the transition dimension.

In an example embodiment having one or more features of the connector assembly of any of the previous paragraphs, the first and second transitions are situated at corners of the shroud and the first and second transitions protrude beyond the first, second, and third sidewalls.

In an example embodiment having one or more features of the connector assembly of any of the previous paragraphs, the first and second transitions include a radius of curvature and wherein the first angular measurement is equal to the second angular measurement.

In an example embodiment having one or more features of the connector assembly of any of the previous paragraphs, the first sidewall includes a first edge, the second sidewall includes a second edge, the first and second edges are at least partially in a first plane, the transition includes a third edge, and the third edge is at least partially in a second plane that intersects the first plane at an oblique angle.

In an example embodiment having one or more features of the connector assembly of any of the previous paragraphs, the angle is between 60° and 20°, preferably between 50° and 30°, and more preferably 40°.

The various features and advantages of at least one disclosed example embodiment will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.

DETAILED DESCRIPTION

FIG. 1diagrammatically shows an example embodiment of a connector20. A plurality of terminals22are configured to make an electrically conductive connection with another connector or device. The terminals22are surrounded by a shroud24.

The shroud24includes a first sidewall26that is transverse to a second sidewall28. A third sidewall30is transverse to the second sidewall28and parallel to the first sidewall26. The shroud24includes transitions between the sidewalls. A first transition32is situated between the first sidewall26and the second sidewall28. A second transition34is situated between the second sidewall28and the third sidewall30. The shroud24is generally rectangular in the illustrated example embodiment and the transitions32and34have a radius of curvature having an angular measurement of more than 90 degrees so that the corners of the shroud24are rounded in the form of a hollow cylindrical sector.

Referring toFIGS. 1 and 2, the sidewalls26,28and30have a sidewall dimension SD in a direction parallel to a longitudinal axis35of the terminals22. The axis35extends in an insertion or connection direction along which relative movement between the connector20and an associated component facilitates making the desired connection. The transitions32and34have a transition dimension TD that is smaller than the sidewall dimension SD. The transition dimension TD is also defined in a direction parallel to the axis35. From the perspective ofFIG. 2, the sidewall dimension SD can be considered a height of each sidewall and the transition dimension TD can be considered a height of the transition. With smaller transition sections, the corners of the shroud24do not extend as far in the connection direction as the sidewalls26,28and30. The smaller transitions provide at least two features that are useful.

The inventors have discovered that the shape of the transitions32and34causes a material flow into a correspondingly shaped mold during an injection molding process that produces a shroud24that is less susceptible to warping of the sidewalls26,28,30compared to an alternative arrangement in which the transitions between the sidewalls are just as long or as large as the sidewalls in the connection direction. This is a particular benefit when the mold gate is located opposite the transitions32,34in the mold. In an example embodiment, the shroud24is made of a glass filled nylon material. Reducing the likelihood of sidewall warping provides a better quality connector and reduces the likelihood of difficult connection with the connector20.

In the illustrated example embodiment, the sidewall26includes an edge36at an open end of the shroud24. The sidewall28includes an edge38and the sidewall30includes an edge40. The transition32includes an edge42and a transition34includes an edge44. The edges36,38and40on the respective sidewalls are all situated in a reference plane50as schematically shown inFIG. 2. Given the smaller transition dimension TD compared to the sidewall dimension SD, the edges42and44are outside of the reference plane50(and below it inFIG. 2).

The edges42and44include a surface that is situated within a reference plane52as shown inFIG. 3that is at an oblique angle A relative to the reference plane50. In the illustrated example embodiment, the angle A is between 20° and 60°. In some embodiments, the angle A is between 30° and 50°. According to one particular embodiment, the angle A is 40°.

The smaller transition dimension TD and the angled orientation of the surfaces42and44reduce or eliminate a likelihood that the shroud24will undesirably contact a terminal on a connector or device to which the connector20is being coupled.FIG. 4illustrates an example scenario in which a connector60is designed to be coupled with the connector20. The connector60includes terminals62correspondingly shaped to mate with the terminals22of the connector20. A shroud64surrounds the terminals62.FIG. 4shows the connectors20and60misaligned. When they are properly oriented for making a connection, the shrouds64and24are parallel to each other.

Even though a portion of the shroud24is able to penetrate into the space within the shroud64in the orientation shown inFIG. 4, the size of the transitions32and34prevent undesirable contact between the shroud24and the terminals62. The transitions32and34are the portions of the shroud24that are most likely to penetrate the deepest into the shroud64when the connectors20and60are misaligned in a condition like that shown inFIG. 4. Having a smaller transition dimension TD avoids undesired contact between the shroud24and the terminals62. This protects the integrity of the terminals62.

The illustrated example connector20includes transitions32and34that are configured to avoid undesired contact with terminals on another connector or device. The relationship between the transitions32and34and the adjacent sidewalls26,28and30, also enhances the integrity and reliability of the shroud24by reducing or eliminating the likelihood of those sidewalls warping.