Abstract:
The present invention provides a solenoid and electrical connector assembly which includes a solenoid body having a pair of electrical terminals disposed on opposite sides of a plunger component and a connector having two corresponding electrical terminals and a non-conductive blade or tongue disposed therebetween. When assembled, the tongue of the connector seats between the terminals on the solenoid body and inhibits corrosion and ingress of foreign matter in the region between the terminals of the solenoid.

Description:
FIELD 
       [0001]    The present disclosure relates to electrical connectors and electrical devices and more particularly to an assembly of an electrical device such as a motor or solenoid and an electrical connector having improved reliability. 
       BACKGROUND 
       [0002]    The statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art. 
         [0003]    Compact electrical devices such as motors and solenoids are often housed in cylindrical housings which correspond generally to the active components of the device: a rotor surrounded by a cylindrical stator in the case of a motor or a plunger surrounded by a cylindrical coil in the case of a solenoid. Such cylindrical housings are efficient packages for such devices as they generally require a minimum of material and result in a package having minimum dimensions. 
         [0004]    Since one end of a typical motor or solenoid will include an output feature, either a shaft or a plunger, it is frequently convenient to arrange the electrical input or terminals on the opposite end. Input connections or terminals so located also maintain the cylindrical symmetry of the housing. 
         [0005]    A problem may develop with such an arrangement, however, especially in smaller devices in which the spacing between the motor shaft, solenoid plunger or other electrically components associated with them and the electrical terminals is limited. In such situations, conductive foreign matter may bridge the gap between an electrical terminal and the shaft or plunger and intermittently or permanently short circuit the device. 
         [0006]    This problem can be especially acute in motors and solenoids for automotive applications because of the constant demand for weight saving which generally encourages lighter and therefore smaller devices and the fact that they are often exposed to deleterious atmospheric conditions such as dirt, metallic debris and other contaminants and particulates. Furthermore, a failure of the motor or solenoid due to a short circuit to ground may cause consequential failure of related components or controllers. The present invention addresses this difficulty with motors, solenoids and other similar electrical devices. 
       SUMMARY 
       [0007]    The present invention provides a solenoid and electrical connector assembly which includes a solenoid body having a pair of electrical terminals disposed on opposite sides of a plunger component and a connector having two corresponding electrical terminals and a non-conductive blade or tongue disposed therebetween. When assembled, the tongue of the connector seats between the terminals on the solenoid body and inhibits ingress of foreign matter in the region between the terminals of the solenoid. The service life and reliability of the solenoid are thus greatly improved. 
         [0008]    The invention is also suitable for and may be utilized with a motor having a bearing at one end and a pair of electrical terminals disposed on opposite sides of the bearing. The electrical connector includes a pair of electrical terminals correspondingly arranged and a blade or tongue which seats between the terminals of the motor and protects the bearing from foreign matter thereby reducing the likelihood of a short circuit. 
         [0009]    Thus it is an object of the present invention to provide a solenoid and connector assembly having a tongue disposed between a pair of terminals. 
         [0010]    It is a further object of the present invention to provide a solenoid having a pair of terminals on opposite sides of a plunger component and a connector having a corresponding pair of terminals and a tongue between the terminals which protects the plunger component when the solenoid and connector are assembled. 
         [0011]    It is a still further object of the present invention to provide a solenoid having a pair of terminals on opposite sides of a plunger and a connector having a corresponding pair of terminals and a tongue between the terminals which covers the plunger when the solenoid and connector are assembled to inhibit ingress of foreign matter. 
         [0012]    It is a still further object of the present invention to provide a motor having a pair of terminals on opposite sides of a bearing and a connector having a corresponding pair of terminals and a tongue between the terminals which protects the bearing when the motor and connector are assembled. 
         [0013]    It is a still further object of the present invention to provide a motor having a pair of terminals on opposite sides of a bearing and a connector having a corresponding pair of terminals and a tongue between the terminals which covers the bearing when the motor and connector are assembled to inhibit ingress of foreign matter. 
         [0014]    Further objects, advantages and areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       DRAWINGS 
         [0015]    The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
           [0016]      FIG. 1  is a perspective view of a first embodiment of a solenoid and an electrical connector according to the present invention in pre-assembly configuration; 
           [0017]      FIG. 2  is a full, sectional view of a first embodiment of a solenoid and an electrical connector assembly according to the present invention; 
           [0018]      FIG. 3  is a full, sectional view of a first embodiment of an electrical connector according to the present invention taken along line  3 - 3  of  FIG. 2 ; 
           [0019]      FIG. 4  is a perspective view of a first embodiment of an electrical connector according to the present invention; 
           [0020]      FIG. 5  is a perspective view of a second embodiment of a motor and an electrical connector according to the present invention in pre-assembly configuration; and 
           [0021]      FIG. 6  is a full, sectional view of a second embodiment of a motor and an electrical connector assembly according to the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. 
         [0023]    With reference now to  FIGS. 1 and 2 , a first embodiment of a solenoid and electrical connector assembly is illustrated and generally designated by the reference number  10 . The first embodiment solenoid and electrical connector assembly  10  includes a solenoid  12  having a generally cylindrical body or housing  14  which is preferably fabricated of metal, for example, steel, aluminum or an alloy of these or other metals. The cylindrical housing  14  locates, supports and protects an electrical coil  16 . The electrical coil  16  generally surrounds a bi-directionally translatable armature or plunger  18 . The plunger  18  cooperates with a first axial guide or bearing  22  and a second axial guide, pole piece or stop  24  which together define the axis of motion or translation of the plunger  18 . A portion of the plunger  18  extends through the first axial guide or bearing  22  and activates or controls an associated device (not illustrated). If desired, a compression spring  26  and an adjusting screw  28  may be disposed between the plunger  18  and the second axial guide, pole piece or stop  24  for adjusting the travel of the plunger  18   
         [0024]    At the end of the cylindrical housing  14  adjacent the second axial guide, pole piece or stop  24  is disposed a terminal assembly  30 . The terminal assembly  30  is fabricated of a plastic, insulating material, for example, ABS or nylon, and is shaped to generally conform to the housing  14  of the solenoid  12  and includes a flat, chordal surface  32  flanked by two smaller perpendicular surfaces  34   a  and  34   b . The terminal assembly  30  defines a pair of rectangular slots  34   a  and  34   b  parallel to and adjacent the surfaces  34   a  and  34   b . The terminal assembly  30  is secured to the housing  14  by a positioning or register pin  38  which is received within a suitably sized and appropriately located opening  42  and a resilient or flexible latch  44  which is releasably received within a second opening  46  having a flat or chordal edge which is engageable by the flexible latch  44 . 
         [0025]    The terminal assembly  30  includes a centrally disposed aperture  48  which receives a portion of the second guide, pole piece or stop  24 . The terminal assembly  30  also includes a pair of spaced apart electrical terminals  50   a  and  50   b  disposed adjacent and on opposite sides of the center aperture  48 . Each of the terminals  50   a  and  50   b  is connected by one of a pair of electrical leads or wires  52  to the electrical coil  16 . 
         [0026]    Referring now to  FIGS. 1 ,  2 ,  3  and  4 , an electrical connector  60 , also fabricated of an insulating material, for example, ABS or nylon, includes a complexly configured connector body  62  which receives, supports and positions a pair of electrical terminals  64   a  and  64   b  and a cover  66  which is removably retained on the body  62  by a latch assembly  68 . The connector body  62  includes a pair of parallel, spaced-apart outer ears or flanges  72   a  and  72   b  which are each reinforced by pairs of gussets  74  and a center flange or tongue  76  perpendicular to and offset from the outer flanges  72   a  and  72   b  which is also strengthened by a pair of gussets  78 . As indicated by the arrows in  FIG. 1 , when the electrical connector  60  is assembled to the terminal assembly  30 , each of the pair of ears or flanges  72   a  and  72   b  is received within a respective one of the pair of rectangular slots  34   a  and  34   b . Also, as illustrated in  FIG. 2 , when the electrical connector  60  is assembled to the terminal assembly  30 , the center flange or tongue  76  is in intimate contact with the surface of the terminal assembly  30  around the aperture  48  and closes and seals it off. 
         [0027]    The pair of electrical terminals  64   a  and  64   b  in the electrical connector  60  are flat, resilient, blade-like components which may be crimped to respective electrical leads  84  and which may be molded in-situ in the electrical connector  60  or secured there by other conventional, for example, mechanical, means. Generally aligned with the center flange  76  is a resilient latch member  86  which releasably engages a cross member  88  of the terminal assembly  30 , as illustrated in  FIG. 2 , to retain the electrical connector  60  on the terminal assembly  30 . A U-shaped bridge  94 , aligned with the center flange  76  and the resilient latch member  86  reinforces the electrical connector  60 , protects and acts as a locating reference for the latch member  86  and facilitates installation of the electrical connector  60  on the terminal assembly  30 . 
         [0028]    Referring now to  FIGS. 5 and 6 , a second embodiment of the invention having an electric motor and an electrical connector assembly according to the present invention is illustrated and generally designated by the reference number  100 . The second embodiment motor and electrical connector assembly  100  is similar to the first embodiment assembly  10  except that the solenoid  12  is replaced by an electric motor  102  and an electrical connector  150  includes electrical leads  172  which extend from the connector  150  in an opposite direction. It should be appreciated that these various components may be interchanged and that the solenoid  12  of the first embodiment assembly  10  may be utilized with the electrical connector  150  of the second embodiment assembly  100  and that the electric motor  102  of the second embodiment assembly  100  may be utilized with the electrical connector  60  of the first embodiment assembly  10 . 
         [0029]    The second embodiment motor and electrical connector assembly  100  includes the electric motor  102  which may be either uni-or bi-directional and which has a generally cylindrical housing  104  which is preferably fabricated of metal, for example, steel, aluminum or an alloy of these or other metals. The cylindrical housing  104  locates, supports and protects a stator and electrical coil  106 . The stator and electrical coil  106  generally surrounds a rotatable armature  108  having a shaft  110  which defines an axis of rotation. The armature  108  cooperates with and is supported by a first guide or bearing  112  and a second guide or bearing  114  which together define the axis of motion or rotation of the armature  108 . 
         [0030]    At the end of the cylindrical housing  104  opposite the first guide or bearing  112  is disposed a terminal assembly  120 . The terminal assembly  120  is fabricated of a plastic, insulating material, for example, ABS or nylon, and is shaped to generally conform to the housing  104  of the electric motor  102  and includes a flat, chordal surface  122  flanked by two smaller perpendicular surfaces  124   a  and  124   b . The terminal assembly  120  defines a pair of rectangular slots  126   a  and  126   b  parallel to and adjacent the surfaces  124   a  and  124   b , respectively. The terminal assembly  120  is secured to the cylindrical housing  104  by a positioning or register pin  128  which is received within a suitably sized and appropriately located opening  132  and a resilient latch  134  which is releasably received within a second opening  136  having a flat or chordal edge which is engageable by the latch  134 . 
         [0031]    The terminal assembly  120  includes a centrally disposed aperture  140  which receives a portion of the second guide or bearing  114 . The terminal assembly  120  also includes a pair of spaced apart electrical terminals  142   a  and  142   b  disposed adjacent and on opposite sides of the center aperture  140 . Each of the terminals  142   a  and  142   b  is connected to a respective one of the electrical leads or wires  144  of the electric coil  106  of the electric motor  102 . 
         [0032]    An electrical connector  150 , also fabricated of an insulating material, for example, ABS or nylon, includes a complexly configured body  152  which receives, supports and positions a pair of electrical terminals  154   a  and  154   b  and a cover  156  which is removably retained on the body  152  by a latch assembly  68  (illustrated in  FIG. 3 ). The connector body  152  includes a pair of parallel, spaced-apart outer ears or flanges  162   a  and  162   b  which are reinforced by pairs of gussets  74  (illustrated in  FIG. 4 ) and a center flange or tongue  166  perpendicular to and offset from the outer ears or flanges  162   a  and  162   b . The center flange or tongue  166  is strengthened by a pair of gussets  78  (illustrated in  FIG. 4 ). As indicated by the arrows in  FIG. 5 , when the electrical connector  150  is assembled to the terminal assembly  120 , each of the pair of ears or flanges  162   a  and  162   b  is received within a respective one of the pair of rectangular slots  126   a  and  126   b . Also, as illustrated in  FIG. 6 , when the electrical connector  150  is assembled to the terminal assembly  120 , the center flange or tongue  166  is in intimate contact with the terminal assembly  120  around the aperture  140  and closes and seals it off. 
         [0033]    The pair of electrical terminals  154   a  and  154   b  in the electrical connector  150  are flat, resilient, blade-like components which may be crimped to respective electrical leads  172  and which may be molded in-situ in the electrical connector  150  or secured there by other conventional, for example, mechanical, means. Generally aligned with the center flange  166  is a resilient latch member  176  which engages, as illustrated in  FIG. 6 , a cross member  178  of the terminal assembly  120  to retain the electrical connector  150  on the terminal assembly  120 . 
         [0034]    It will be appreciated that in the first embodiment solenoid and electrical connector assembly  10 , the center flange or tongue  76  effectively covers and protects the center aperture  48  inhibiting the ingress of foreign material which could cause a short circuit between one of the electrical terminals  50   a  and  50   b  and the chassis ground through the second guide, pole piece or stop  24  when the electrical connector  60  is assembled to the terminal assembly  30 . Likewise, in the second embodiment motor and electrical connector assembly  100 , the center flange or tongue  166  effectively covers and protects the center aperture  140  inhibiting the ingress of foreign material which could cause a short circuit between one of the electrical terminals  142   a  and  142   b  and the chassis ground through the second guide or bearing  114  when the electrical connector  150  is assembled to the terminal assembly  120 . 
         [0035]    The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.