Method of forming a sealed electrical connector

Abstract: An electrical connector (2) having an insulating housing (4) has a rear face (8) with a plurality of electrical terminals (50) extending therethrough. A sealant material (70) in the form of a hotmelt material is placed over the ends of the terminals (50) and the connector, including the sealing material, is thereafter heated to melt the material (70). The sealing material flows around the terminals and partially into the apertures (10) of the housing (4) to provide for a sealed atmosphere on the interior of the connector housing (4).

Description: The present invention relates to a method of sealing electrical connectors, particularly those connectors which are used on printed circuit boards. Electrical connectors are mounted to printed circuit boards for a variety of applications in the electronics industry, for such uses varying from modems for personal computers to sockets for integrated circuit packages, for example the so-called "DIP sockets" and the like. After placing the connectors onto the boards, but prior to soldering of these connectors to the boards, the boards and the connector terminals undergo a cleaning process, where a cleansing fluid, typically referred to as flux, is passed over the connection area to prepare and treat the surfaces for soldering. A problem which results from this process is that, due to the natural surface tension of the flux material, the flux wicks up the terminals and can flow into the area where the electrical connection is made. This flux material can actually cause an electrical isolation between the terminals and the mating electrical component even when the two mating components are fully mated. DE-U-8702517.5 describes an electrical connector for printed circuit boards, including a housing mounting a plurality of terminal pins, in which the apertures in the housing receiving the pins are sealed against the ingress of flux by a sealing foil fitted over the pins. According to the present invention, the aforementioned problem is alleviated by a sealing method which is characterized by the steps of providing a sealant material for the electrical connector having a melting temperature which is less than that of the insulating housing of the connector; placing the sealant material adjacent to a rear face of the connector with end portions of the terminals extending through the sealant material; heating the sealant material to the point where the sealant material melts and flows around the terminals; and cooling the sealant material to cure the sealant material. In a preferred embodiment of the method, the heating step is undertaken in a convection oven. The connector may be rotated within the oven so as uniformly to heat the sealant material. In the preferred embodiment, the heating step includes the heat transfer equivalent of an oven temperature of 180° C for a duration of one minute. Furthermore, prior to placing the sealant material adjacent to the rear face, the sealant material is cut, or stamped to include apertures extending therethrough to match the terminal pattern. Preferably, the sealant or sealing material is a hot melt material. It should be noted that the inventive method is useful with all types of electrical connectors. An embodiment of the invention will now be described by way of example with reference to the accompanying drawings, in which:- Figure 1 is an isometric view showing the progression of the method, Figure 2 is an isometric view showing the electrical connector prior to the placement of the sealant material adjacent to the rear face of the housing, Figure 3 is an isometric view showing the sealant material placed over the terminals, and placed adjacent to the rear face of the electrical connector, and Figure 4 is a cross sectional view showing diagrammatically, the progression of the inventive method. Figure 2 shows a typical electrical connector for use with the inventive method where the electrical connector 2 includes an insulating housing 4 including a plate portion 6 having a platform 12 extending perpendicularly therefrom, the platform being used for mounting on a printed circuit board. Above the platform 12 is a rear face 8 which includes a plurality of apertures 10 therein which extend through the rear face 8 to the front mating face 14. A plurality of electrical terminals 50 are positioned within the apertures 10 and include contact portions adjacent to the front mating face 14. A shield, such as 30, is also included which has tabs 32 and 34 to retain the shield member 30 to the plate portion 6 and further comprises feet 36 for an integral interconnection to ground traces on the printed circuit board. With the connector configured as shown in Figure 2, the electrical connector can then receive the sealing material to form the sealed connector. As shown in Figure 1, the electrical connector 2 can be preassembled to a position where the terminals 50 are inserted within, and the shield member 30 are mounted to, the electrical connectors, although the end portions of legs 52 of the terminals 50 stand vertically to receive the sealing material. A roll of the sealing material, such as 70, can be moved in a direction transverse to the direction of the connectors and the sealing material can be stamped to conform to the rear face 8 of the electrical connector. In the preferred embodiment of the invention, a stamping die, such as 80, stamps a plurality of apertures 74 into the sealing material 70 while a knife, such as 82, shears the sealing material 70 into individual sealing members 72. The individual sealing members 72 are then placed over the top of the upstanding terminal legs 52 and can be moved downwardly to lie adjacent to the rear face 8 of the electrical connector 2. The terminal legs 52 can then be formed into the desired right angle feature to include perpendicular sections 56 having printed circuit board tab portions 58. The electrical connectors can then be moved to an oven where the sealing material is heated to a temperature which causes the material to melt and partially flow into the apertures 10 which extend beyond the rear face 8. Due to the natural surface tension of the flowing material, the molten material adheres to the exterior surfaces of the terminal legs 52 and to the interior portions of the apertures 10. It is important to note that the movement or flowing of the material 70 can be controlled by temperature and time duration such that the desired flow is achieved. For example, in the connector shown herein, the material is allowed to flow into the apertures 10 to form a face 76 of the material. The material is not allowed to flow further into the apertures 10, as this would cause the sealing material to flow into the contact area of the terminals. Advantageously, as the desired amount of flow of the molten material is achieved, the connectors are removed from the oven and the molten material quickly cures and solidifies, preventing further flowing of the material. In the preferred embodiment of the invention, the material which is used as the sealing material is a hot melt thermoplastic which is commercially available from the Chemische Fabrik G.m.b.H. and Company KG as type BS 610 material. Also in the preferred embodiment of the invention, the oven temperature is maintained at approximately 180°C and the electrical connectors are placed in the oven for approximately one minute. Furthermore, in the preferred method, the oven includes a turntable which rotates the connectors to ensure uniform heating to the sealing material. As shown above, the method is advantageously very easy to accomplish and can be easily incorporated into an existing manufacturing process. The desired material can be obtained in rolled or sheet form and can be automatically inserted over the terminal end portions, without a labor intensive process such as placing discrete seals over the terminals. The connectors can also be automatically transferred into and out of the ovens.

Claims: A method of sealing a connector (2) of the type comprising an insulating housing (4) and a plurality of electrical terminals (50), the insulating housing having a rear face (8) having a plurality of apertures (10) extending therethrough for the receipt of the terminals, with end portions (52) of the terminals extending beyond the rear face (8), the method being characterized by the steps of: providing a sealant material (70) having a melting temperature which is less than that of the insulating housing (4); placing the sealant material adjacent to the rear face (8) of the connector (2) with the end portions (52) of the terminals (50) extending through the sealant material; heating the sealant material to the point where the sealant material melts and flows around the terminals; and cooling the sealant material to cure the sealant material. The method of claim 1, characterized in that the heating step is undertaken in a convection oven. The method of claim 2, characterized by the step of rotating the connector (2) within the oven uniformly to heat the sealant material (70). The method of claim 1,2 or 3, characterized in that the heating step includes the heat transfer equivalent of an oven temperature of 180° C for a duration of approximately one minute. The method of claim 1,2,3 or 4, characterized in that prior to placing the sealant material (70) adjacent to the rear face (8), the sealant material is formed to include apertures (74) extending therethrough to match the terminal (50) pattern. The method of any preceding claim, characterized in that the sealant material (70) is a hot melt material.

Inventors: WEIGERT FIDELO, WEIGERT, FIDELO
Applicants: WHITAKER CORP, THE WHITAKER CORPORATION
Application year: 1989
Main classification: H01R43
IPC codes: H01R43, H05K3