Electrical assembly and connector therefor

Abstract: An electrical assembly (10) comprises an electrical connector (12) and an electrical device (14) such as a sensor that are connected directly to each other. The electrical connector has a one-piece connector body (16) of mouldable, thermoplastic electrically insulative material that has a socket (18) at one end for receiving a mating electrical connector, and a platform (20) at the other end supporting the electrical device. One-piece terminals (35) are insert moulded in the connector body so that the insert moulded terminals have exposed contacts (36) at one end that project into the socket and exposed contacts (38) at the other end that project outwardly of the platform. The electrical device is fastened to the platform mechanically and has prongs (44) that engage the exposed contacts at the other end of the insert moulded terminals. The electrical assembly may also include a second electrical device such as a diode (32) that is fastened to the front of the platform and electrically connected to the exposed contacts at the other end of the insert moulded terminals.

Description: This invention relates generally to electrical assemblies and more particularly to electrical assemblies comprising an electrical connector and an electrical device such as a sensor. US-A-4,894,017 discloses an electrical assembly comprising an electrical connector and a sensor that is disposed in a protective metal casing that is filled with a potting compound. The electrical connector and the sensor are mechanically and electrically connected by means of a printed circuit board. Both components have plastic pins that are heat staked for fastening the components to the printed circuit board and both components have terminal prongs that are plugged in and soldered to apertured contacts of the printed circuit board. The housing of the electrical connector also includes a narrow peripheral groove for mounting the electrical header connector on a slotted panel wall of the protective metal casing. US-A-4 430 983 discloses an electrical assembly and connector in accordance with the preamble of Claims 1 and 4 respectively. The object of this invention is to provide an improved electrical assembly of the above noted type and an improved electrical connector for such an electrical assembly. To this end, an electrical assembly and an electrical connector therefor are characterised over US-A-4 430 983 by the features specified in the characterising portions of Claims 1 and 4 respectively. A feature of the improved electrical assembly is that the electrical connector and the electrical device are connected to each other directly both mechanically and electrically. This eliminates the need for a printed circuit board and reduces cost. This also reduces the number of electrical interfaces between the electrical connector and the electrical device from two to one. The reduction of electrical interfaces increases electrical reliability and performance and further reduces cost. Elimination of the printed circuit board also reduces the number of mechanical connections which also increases reliability and reduces cost. A feature of the improved electrical connector is that the electrical connector has a connector body and terminals that are configured for supporting an electrical device and for connecting directly to the supported electrical device mechanically and electrically thereby eliminating the need for a printed circuit board or any other intervening element. The present invention will now be described, by way of example, with reference to the following description, taken in conjunction with the accompanying drawings, in which:- Figure 1 is a side view of an electrical assembly in accordance with the invention; Figure 2 is a section taken substantially along the line 2-2 of Figure 1 looking in the direction of the arrows and showing a front view of the electrical connector that is used in the electrical assembly of Figure 1; Figure 3 is a rear view of the electrical assembly taken substantially along the line 3-3 of Figure 1 looking in the direction of the arrows; and Figure 4 is a section taken substantially along the line 4-4 of Figure 3 looking in the direction of the arrows. Referring now to the drawings an electrical assembly 10 of this invention comprises an electrical connector 12 and an electrical device 14 such as a sensor that is used in automotive systems. The electrical connector 12 and the electrical device 14 are connected to each other both mechanically and electrically without an intervening element such as a printed circuit board that is commonly used in prior art electrical assemblies of this type. The electrical connector 12 is configured to support the electrical device 14 and make direct mechanical and electrical connections with the supported electrical device 14. More specifically the electrical connector 12 has a one-piece connector body 16 of mouldable, thermoplastic electrically insulative material. The connector body 16 has an upright socket 18 at one end for receiving a mating electrical connector (not shown), and a cantilevered platform 20 at the other end for supporting the electrical device 14 in an upright position near the socket 18. The connector body 16 has a narrow peripheral groove defined by confronting flanges 22 that are disposed between the socket 18 and the platform 20. The narrow peripheral groove is used to mount the electrical assembly on a slotted panel wall of a protective metal casing as shown in Figure 6 of US-A-4,894,017 that is discussed in the introduction, and that is incorporated in this patent specification by reference. The cantilevered platform 20 has a curved rib 24 adjacent the flanges 22, a straight rib 26 at its free end and two holes 28 between the ribs for securing the electrical device 14 on the platform 20. The ribs 24 and 26 strengthen the platform 20 and also help locate the electrical device 14 for fastening to the platform. The platform 20 also has two laterally spaced bifurcated fingers 30 that project from the free end for optionally holding a second electrical device such as a diode 32 or other similar electrical device that has axial lead wires 33 extending from each end. The electrical connector 12 also has two one-piece terminals 34 and 35 that are insert moulded in the connector body 16. The insert moulded terminals 34 and 35 have exposed, upright contacts 36 at one end of generally L-shaped stampings that project into the socket 18. The terminals 34 and 35 have exposed contacts 38 at the other end of generally L-shaped stampings that project outwardly of the platform 20 in the lateral direction. The upright contacts 36 are in the from of double thickness blades that are formed by folding the one end of the stampings back over onto itself. The one end of the terminal 35 is bifurcated to form two upright contacts 36 at the one end. The contacts 38 are flanged to provide upright walls 40 that are laterally spaced from the side edges of the platform 20. The walls 40 are slit to provide integral straps 42 that are raised outwardly of the walls 40 to form sockets for receiving flat prongs 44 of the electrical device 14 that is mounted on the platform. The walls 40 also have T-shaped slots 45 for receiving the ends of the lead wires 33 of the diode 32. The electrical device 14 comprises a round housing 46 of thermoplastic material that has a circular lip 48 at the bottom. The housing also has two depending pins 50 that fit into the holes 28 when the electrical device 14 is plugged onto the platform 20. As indicated above, the electrical device 14 has two flat prongs 44 that project from the bottom of the housing 46. These flat prongs 44 are connected to electrical componentry within the housing 46 and project from the bottom of the housing 46 to connect the internal electrical componentry with external electrical devices via the electrical connector 12. The electrical device 14 is plugged onto the platform 20 of the electrical connector 12 so that the flat prongs 44 plug into the sockets of the contacts 38 and the plastic pins fit 50 into the holes 28. The plastic pins 50 are then heat staked to fasten the electrical device 14 and the electrical connector 12 together. If desired another electrical device such as a diode 32 may be incorporated in the electrical assembly 10. This diode 32 is mechanically fastened and electrically connected to the electrical connector 12 by the lead wires 33 of the diode. The lead wires 33 are wedged in the bifurcated fingers 30 as shown in Figures 2, 3 and 4 to fasten the diode 32 to the front of the platform 20 while the ends of the lead wires 33 are wedged in the T-shaped slots 45 of the contacts 38 to connect the diode 32 to the electrical connector 12 electrically.

Claims: An electrical assembly (10) comprising an electrical device (14); an electrical connector (12) having a one-piece connector body (16) of mouldable, thermoplastic electrically insulative material, the connector body (16) having a socket (18) at one end for receiving a mating electrical connector, and a platform (20) at the other end for supporting the electrical device (14), the electrical connector (12) having a plurality of one-piece terminals (34,35) that are insert moulded in the connector body (16), the terminals (34,35) having exposed contacts (36) at one end that project into the socket (18) and exposed contacts (38) at the other end that project outwardly of the platform (20); means (28,50) for fastening the electrical device (14) to the platform (20) mechanically; and the electrical device (14) having prongs (44) engaging the exposed contacts (38) at the other end of the terminals (34,35) to connect the electrical device (14) to the electrical connector (12) electrically; characterised in that the platform (20) has a curved rib (24) toward the socket (18), a straight rib (26) at its free end and at least one hole (28) between the ribs for securing the electrical device (14) on the platform; the exposed contacts (36) at one end of the terminals (34,35) are generally L-shaped stampings that project into the socket; the exposed contacts (38) at the other end of the terminals are generally L-shaped stampings that project outwardly of the platform in the lateral direction and are flanged to provide upright walls (40) that are laterally spaced from the side edges of the platform and that are slit to provide integral straps (42) that are raised outwardly of the upright walls to form sockets for receiving the prongs (44) of the electrical device; and the electrical device has a housing (46) of thermoplastic material that has a circular lip (48) and at least one depending pin (50) that fits into the hole when the electrical device is plugged onto the platform and which can be heat staked to fasten the electrical device and the electrical connector together. An electrical assembly as claimed in claim 1, further comprising a second electrical device (32) having lead wires (33) extending axially from opposite ends of the second electrical device; the platform (20) having means (30) at the free end holding the second electrical device; and the exposed contacts (38) at the other end of the terminals (34,35) having slots (45) that receive respective ends of the lead wires of the second electrical device. An electrical assembly as claimed in claim 2, wherein the means on the platform (20) comprises two laterally spaced bifurcated fingers (30) that project from the free end and receive the respective lead wires (33) of the second electrical device (32) to hold the second electrical device; and the slots (45) are T-shaped. An electrical connector (12) for an electrical assembly (10) as claimed in any one of claims 1 to 3, comprising a one-piece connector body (16) having a socket (18) at one end for receiving a mating electrical connector, and a platform (20) at the other end for supporting an electrical device (14); and a plurality of one-piece terminals (34,35) that are insert moulded in the connector body, the terminals having exposed contacts (36) at one end that project into the socket and exposed contacts (38) at the other end that project outwardly of the platform for engaging prongs (44) of the electrical device when it is mounted on the platform; the platform having means (28) for fastening the electrical device to the platform mechanically; characterised in that the platform (20) has a curved rib (24) toward the socket (18), a straight rib (26) at its free end and at least one hole (28) between the ribs for securing the electrical device (14) on the platform; the exposed contacts (36) at one end of the terminals (34,35) are generally L-shaped stampings; the exposed contacts (38) at the other end of the terminals are generally L-shaped stampings and project outwardly in the lateral direction, and are flanged to provide upright walls (40) that are laterally spaced from the side edges of the platform and that are slit to provide integral straps (42) that are raised outwardly of the walls to form sockets for receiving the prongs (44) of the electrical device (14) when it is secured on the platform. An electrical connector as claimed in claim 4, wherein the platform (20) has means (30) at the free end for holding a second electrical device (32); and the exposed contacts (38) at the other end of the terminals (34,35) have slots (45) for receiving respective ends of lead wires (33) of the second electrical device. An electrical connector as claimed in claim 5, wherein the means on the platform (20) comprises two laterally spaced bifurcated fingers (30) that project from the free end for receiving respective lead wires (33) of the second electrical device (32) to hold the second electrical device mechanically; and the slots (45) are T-shaped slots. An electrical connector as claimed in claim 5 or claim 6, wherein the exposed contacts (36) at the one end of the terminals (34,35) are in the form of double thickness blades that are formed by folding the one end of the stampings back over onto itself; with the one end being bifurcated to form two upright contacts at the one end.

Inventors: MARGRAVE CHRISTOPHER ADRIAN, STEVENS KENNETH CHARLES, MARGRAVE, CHRISTOPHER ADRIAN, STEVENS, KENNETH CHARLES
Applicants: GEN MOTORS CORP, GENERAL MOTORS CORPORATION
Application year: 1993
Main classification: H01R13
IPC codes: H01R13