3D printed high resolution electrical connectors with novel material removal features

A single piece electrical connector having a housing with a mating face, a wire receiving face, and housing side walls. Terminal receiving cavities extend from the mating face to the wire receiving face. The terminal receiving cavities have cavity side walls. Resilient securing arms are provided in the terminal receiving cavities. The resilient securing arms have fixed portions which extend from and are integrally attached to base members which extend from and are integrally attached to the cavity side walls of the terminal receiving cavities. The resilient securing arms are made from the same material and in the same manufacturing process that forms the housing. The fixed ends are spaced from the cavity side walls by gaps. The gaps between the resilient securing arms and the cavity side walls facilitate the cleaning or removal of excess material formed during the manufacturing process of the electrical connector.

FIELD OF THE INVENTION

The present invention is directed a one piece 3D printed electrical connector with securing arms which facilitates the removal of material, such as resin or powder, from the connector. In particular, the invention is directed to a one piece printed electrical connector which has passageways which allow the resin to be rinsed from the printed connector.

BACKGROUND OF THE INVENTION

Electrical connector components are typically manufactured from traditional methods and are designed to accommodate the respective traditional tooling methods. Connectors manufactured from multiple components also require assembly and may have lengthy and complex bills of materials and component lead times. A connector designed with the 3D printing or additive manufacturing process in mind can be constructed with consolidated components and/or eliminate many components and manufacturing steps, however all connectors need to be designed for manufacturability. Such 3D printable connectors must be configured to allow the photo curable resin to be completely rinsed from the resulting product in order to obtain optimal performance. However, known connectors have product features which do not allow for adequate residual material removal and cleaning and, ultimately, result in the product not performing as intended.

It would, therefore be beneficial to provide an electrical connector which is configured to prevent material entrapment and allow adequate material, such as resin or powder, drainage and final rinsing/cleaning resulting in superior product performance. In particular, it would be beneficial to position components and provide weep holes to facilitate improved material removal and cleaning during an additive manufacturing process.

SUMMARY OF THE INVENTION

An embodiment is directed to a single piece electrical connector having a housing with a mating face, a wire receiving face, and housing side walls. Terminal receiving cavities extend from the mating face to the wire receiving face. The terminal receiving cavities have cavity side walls. Resilient securing arms are provided in the terminal receiving cavities. The resilient securing arms have fixed portions which extend from and are integrally attached to base members or projection members which extend from and are integrally attached to the cavity side walls of the terminal receiving cavities. The resilient securing arms are made from the same material and in the same manufacturing process that forms the housing. The fixed ends are spaced from the cavity side walls by gaps. The gaps between the resilient securing arms and the cavity side walls facilitate the cleaning or removal of excess material formed during the manufacturing process of the electrical connector.

An embodiment is directed to an electrical connector made from an additive manufacturing process. The electrical connector includes a housing having a mating face, a wire receiving face, and housing side walls. Terminal receiving cavities extend from the mating face to the wire receiving face. The terminal receiving cavities have cavity side walls. Resilient securing arms are provided in the terminal receiving cavities. The resilient securing arms have fixed portions which extend from and are integrally attached to base members or projection members which extend from and are integrally attached to the cavity side walls of the terminal receiving cavities. The resilient securing arms are made from the same material and in the same process that forms the housing. The fixed ends are spaced from the cavity side walls by gaps. Cleaning openings are provided on the mating face of the connector housing. The cleaning openings extend through the mating face and into the terminal receiving cavities. Mating terminal receiving openings extend through the mating face of the connector housing. The mating terminal receiving openings extend into the terminal receiving cavities. The cleaning openings are positioned proximate to the mating terminal receiving openings. The gaps between the resilient securing arms and the cavity side walls and the cleaning openings facilitate the removal of excess material formed during the manufacturing process of the electrical connector.

An embodiment is directed to a method of manufacturing an electrical connector with integral resilient securing arms. The method includes: printing a body of the electrical connector in an additive printing process, the body having terminal receiving cavities therein; printing the resilient securing arms simultaneously with the printing of the body, the resilient securing arms being positioned in the terminal receiving cavities; spacing the resilient securing arms from walls of the terminal receiving cavities to form gaps between the walls; and cleaning excess material created during the additive printing process from the terminal receiving cavities. The spacing of the resilient securing arms from the walls of the terminal receiving cavities allows the excess material to be removed from the terminal receiving cavities and the body of the electrical connector.

DETAILED DESCRIPTION OF THE INVENTION

Moreover, the features and benefits of the invention are illustrated by reference to the preferred embodiments. Accordingly, the invention expressly should not be limited to such embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features, the scope of the invention being defined by the claims appended hereto.

With reference toFIGS. 1 through 5, an illustrative arrangement of terminal receiving cavities20in an illustrative single piece electrical connector housing10is shown. While the terminal receiving cavities20are shown in the illustrative connector housing10, the invention, as described herein, can be used with terminal receiving cavities20in any type of connector housing or assembly. The connector housing10has a mating face12, a wire receiving face14, and housing side walls16. In the embodiment shown, the side walls16extend beyond the mating face12and the wire receiving face14, however, other configurations of the side walls16can be used without departing from the scope of the invention. In the illustrative embodiment shown, the connector housing10has a generally square or rectangular configuration, however, other types, sizes and shapes or housings may be used. The electrical connector housing10is manufactured using an additive manufacturing process, such as, but not limited to 3D printing, to form a one piece connector housing.

As best shown inFIG. 3, the connector housing10has terminal receiving cavities20which extend from the mating face12to the wire receiving face14. The terminal receiving cavities are dimensioned to receive terminals (not shown) therein. The particular configuration of the terminals may vary depending upon the application and amount of current required to flow across the terminal.

Each terminal receiving cavity20, as best shown inFIGS. 3 and 4, has a wire receiving portion22, a securing portion24and a mating terminal receiving portion26. The wire receiving portion22is positioned proximate to the wire receiving face14of the housing10. The mating terminal receiving portion26is position proximate to the mating face12of the housing. The securing portion24extends between the wire receiving portion22and the mating terminal receiving portion26.

The wire receiving portion22has a diameter A which is large enough to receive the terminal therethrough. The mating terminal receiving portion26has a diameter B which is smaller than the diameter A of the wire receiving portion22. The diameter B is dimensioned to be large enough to allow a mating contact or pin to be inserted therethrough. However, the diameter B is sufficiently small to prevent the terminal inserted through the wire receiving portion22to be removed through the mating terminal portion26.

The securing portion24has resilient securing arms30provided therein. In the illustrative embodiment shown inFIGS. 1 through 5, three resilient securing arms30are provided in each terminal receiving cavity20. However, other numbers of resilient securing may be provided. The securing arms30have a fixed portion32which extends from and is integrally attached to base member or projection member38which extends from and is integrally attached to a cavity side wall34of the terminal receiving cavity20. As the securing arms30and the housing10are made in a single piece, the securing arms30are made from the same material and are made in the same process that forms the other parts of the housing10. The fixed portion32is positioned proximate to or offset from the wire receiving face14of the housing10. In the illustrative embodiment shown inFIGS. 1 through 5, the length of the securing arms30is equal to or proximate the length of the securing portion24.

The resilient securing arms30extend from the fixed ends32toward the mating face12of the housing10. The resilient securing arms30terminate at free ends36which are spaced from the side wall34of the terminal receiving cavity20. The resilient securing arms30are configured to cooperate with the terminal inserted therein to maintain the terminal in the terminal receiving cavity20. The free ends36of the resilient securing arms30tilt into the terminal receiving cavity further than the fixed ends32, such that the diameter D of passage formed by the fixed ends32is greater than the diameter C of passage formed by the free ends36.

The number, size, shape and positioning of the resilient securing arms30may vary. The length of the resilient securing arms30as measured from the fixed ends32to the free ends36may vary, as may the length of the terminal receiving cavity20. The thickness of the resilient securing arms30may vary from one embodiment to another. In addition, the thickness of the resilient securing arms30may vary from the fixed ends32to the free ends36. The amount of tilt of the free ends36may also be varied. While the resilient securing arms30in the embodiment shown have a longitudinal axis which is relatively straight, the resilient securing arms30may have a curved or helical configuration. The resilient securing arms30may be curved inward or outward depending upon the resiliency needed to maintain the terminal in position in the terminal receiving cavity20.

Although the fixed ends32are fixed to base members or projection members38which extend from side wall34of the terminal receiving cavity20, the fixed ends32are spaced from the side wall34by a gap40. The size of the gap can be varied. As the resilient securing arms30are formed in the same process as the housing10, and as tooling cannot be inserted into the terminal receiving cavity20to properly form the resilient securing arms30, the housing10and resilient securing arms30must be formed by an additive manufacturing process, such as, but not limited to 3D printing. Consequently, it is imperative that excess material or unwanted material be able to be cleaned out or removed from the terminal receiving cavity20upon completion of the formation of the housing20and the resilient securing arms30. Providing gaps40between the resilient securing arms30and the side wall34facilitates the cleaning or removal of the excess material.

In order to properly maintain the position of the free ends36prior to the insertion of the terminal in the terminal receiving cavity20, holders or tabs42extend between the free ends36of adjacent resilient securing arms30, as best shown inFIG. 5. The holders or tabs42are integrally formed with the free ends36to maintain the free ends36in position relative to each other as the connector housing10and the resilient securing arms30are cleaned and cured. The holders or tabs42are configured to break as the mating terminal is inserted into the terminal receiving cavity20to allow the resilient securing arms30to act independently to secure the terminal in position.

Referring toFIGS. 1, 3 and 4, mating terminal receiving openings58extend through the mating face12of the connector housing10. Cleaning openings60are provided on the mating face12of the connector housing10. The cleaning openings60are positioned proximate to the mating terminal receiving openings58and extend through the mating face12and into the mating terminal receiving portions26of the terminal receiving cavities20. In the illustrative embodiment shown, the cleaning openings60are smaller in size than the mating terminal receiving openings58, whereby the mating terminals cannot be inserted into the cleaning openings60. However, other embodiments the cleaning openings60may be integrally connected to the mating terminal receiving openings58.

In this illustrative embodiment, three cleaning openings60extend into each terminal receiving cavity20, with the cleaning openings60positioned in approximate alignment with the securing arms30of the respective terminal receiving cavity20. However, other numbers and positioning of the cleaning openings60may be used. The cleaning openings60facilitates the removal of the excess material or unwanted material from the terminal receiving cavity20upon completion of the formation of the housing20and the resilient securing arms30.

With reference toFIGS. 6 through 10, an alternate illustrative electrical connector housing110is shown. The connector housing110has a mating face112, a wire receiving face114, and side walls116. In the embodiment shown, the side walls116extend between the mating face112and between the wire receiving face114, however, other configurations of the side walls116can be used without departing from the scope of the invention. In the illustrative embodiment shown, the connector housing110has a generally square or rectangular configuration, however, other configurations, such as, but not limited to circular, may be used.

As best shown inFIG. 8, the connector housing110has terminal receiving cavities120which extend from the mating face112to the wire receiving face114. The terminal receiving cavities are dimensioned to receive terminals (not shown) therein. The particular configuration of the terminals may vary depending upon the application and amount of current required to flow across the terminal.

As best shown inFIGS. 8 and 9, each terminal receiving cavity120has a wire receiving portion122, a securing portion124and a mating terminal receiving portion126. The wire receiving portion122is positioned proximate to the wire receiving face114of the housing110. The mating terminal receiving portion126is position proximate to the mating face112of the housing. The securing portion124extends between the wire receiving portion122and the mating terminal receiving portion126.

The wire receiving portion122has a diameter F which is large enough to receive the terminal therethrough. The mating terminal receiving portion126has a diameter G which is smaller than the diameter F of the wire receiving portion122. The diameter G is dimensioned to be large enough to allow a mating contact or pin to be inserted therethrough. However, the diameter G is sufficiently small to prevent the terminal inserted through the mating terminal receiving portion126to be removed through the wire receiving portion122.

The securing portion124has resilient securing arms130provided therein. In the illustrative embodiment shown inFIGS. 6 through 10, three resilient securing arms130are provided in each terminal receiving cavity20. However, other numbers of resilient securing may be provided. The securing arms130have a fixed portion132which extends from and is integrally attached to base member or projection member138which extends from and is integrally attached to a side wall134of the terminal receiving cavity120. The securing arms130are made from the same material and are made in the same process that forms the other parts of the housing110. The fixed portion132is positioned proximate to or offset from the wire receiving face114of the housing110. In the illustrative embodiment shown inFIGS. 6 through 9, the length of the securing portion124is greater than the length of the securing arms130.

The resilient securing arms130extend from the fixed ends132toward the mating face112of the housing110. The resilient securing arms130terminate at free ends136which are spaced from the side wall134of the terminal receiving cavity120. The resilient securing arms130are configured to cooperate with the terminal inserted therein to maintain the terminal in the terminal receiving cavity120. The free ends136of the resilient securing arms130tilt into the terminal receiving cavity further than the fixed ends132, such that the diameter H of passage formed by the fixed ends132is greater than the diameter I of passage formed by the free ends136.

The number, size, shape and positioning of the resilient securing arms130may vary. The length of the resilient securing arms130as measured from the fixed ends132to the free ends136may vary, as may the length of the terminal receiving cavity120. The thickness of the resilient securing arms130may vary from one embodiment to another. In addition, the thickness of the resilient securing arms130may vary from the fixed ends132to the free ends136. The amount of tilt of the free ends136may also be varied. While the free ends136of the resilient securing arms130in the embodiment shown are curved slightly inward relatively straight, the resilient securing arms130may have a helical configuration. The resilient securing arms130may be curved outward or be straight depending upon the resiliency needed to maintain the terminal in position in the terminal receiving cavity120.

Although the fixed ends132are fixed to base members or projection members138which extend from side wall134of the terminal receiving cavity120, the fixed ends132are spaced from the side wall134by a gap140. The size of the gap can be varied. As the resilient securing arms130are formed in the same process as the housing110, and as tooling cannot be inserted into the terminal receiving cavity120to properly form the resilient securing arms130, the housing110and resilient securing arms130must be formed by an additive manufacturing process, such as, but not limited to 3D printing. Consequently, it is imperative that excess material or unwanted material be able to be cleaned out or removed from the terminal receiving cavity120upon completion of the formation of the housing120and the resilient securing arms130. Providing gaps140between the resilient securing arms130and the side wall134facilitates the cleaning or removal of the excess material.

In order to properly maintain the position of the free ends136prior to the insertion of the terminal in the terminal receiving cavity120, holders or tabs142extend between the free ends136of adjacent resilient securing arms130, as best shown inFIG. 10. The holders or tabs142are integrally formed with the free ends136to maintain the free ends136in position relative to each other as the connector housing110and the resilient securing arms130are cleaned and thermally cured. The holders or tabs142are configured to break as the mating terminal is inserted into the terminal receiving cavity120to allow the resilient securing arms130to act independently to secure the terminal in position.

Referring toFIGS. 6, 8 and 9, mating terminal receiving openings158extend through the mating face112of the connector housing110. The mating terminal receiving openings158extend into the mating terminal receiving portions126of the terminal receiving cavities120and are dimensioned to receive the mating terminals of the mating connector therein. Cleaning openings160are provided on the mating face112of the connector housing110. The cleaning openings160are positioned proximate to the mating terminal receiving openings158and extend through the mating face112and into the mating terminal receiving portions126of the terminal receiving cavities120.

The cleaning openings160are smaller in size than the mating terminal receiving openings158, whereby the mating terminals cannot be inserted into the cleaning openings160. In this illustrative embodiment, three cleaning openings160extend into each terminal receiving cavity120, with the cleaning openings160positioned in approximate alignment with the securing arms130of the respective terminal receiving cavity120. However, other numbers and positioning of the cleaning openings160may be used. The cleaning openings160facilitates the removal of the excess material or unwanted material from the terminal receiving cavity120upon completion of the formation of the housing120and the resilient securing arms130.

In various illustrative embodiments, the gap40,140may be, but is not limited to, 0.15 mm, 0.20 mm, 0.30 mm, between 0.15 mm and 0.30 mm, greater than 0.30 mm. In various illustrative embodiments, the securing arms30,130may have, but are not limited to, a thickness of 0.35 mm, 0.37 mm, between 0.30 mm and 0.40 mm. In various illustrative embodiments, the securing arms30,130may have, but are not limited to, 4 spring arms with a range about the circumference of the terminal receiving cavity20,120of 75 degrees and a gap between the spring arms of 15 degrees, 5 spring arms with a range about the circumference of the terminal receiving cavity20,120of 65 degrees and a gap between the spring arms of 15 degrees, 6 spring arms with a range about the circumference of the terminal receiving cavity20,120of 45 degrees and a gap between the spring arms of 15 degrees.