Abstract:
An electrical connector assembly has an overmolded housing which is preferably injection-molded of thermoplastic resilient or elastic material onto a base housing containing an electrical connector. A strain relief is preferably integral with the overmolded housing. A pre-mold housing is preferably molded onto the base housing before the overmold housing.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to electrical connector housing construction. 
     2. Description of the Prior Art 
     A drawback of the electrical connectors of the prior art is that metallic outer connector housings have been made with strain reliefs and cable terminations that are fastened onto the rigid metal housing using hardware. The hardware typically consists of a threaded adapter and nut, a washer, and a rubber grommet. Tightening the nut compresses the grommet around the cable and provides a strain relief. This requires many parts and results in a heavy outer housing. In addition, the nut can come loose, allowing foreign contamination to enter and pulling the cable from the housing. 
     SUMMARY OF THE INVENTION 
     To overcome the deficiencies in the prior art as discussed above, the present invention provides an electrical connector comprised of a base housing which is overmolded in a plastic material to form an overmold housing. Preferably, the base housing is made of metal and the overmolding is cast around it in resilient plastic material that seals and provides a strain relief. A pre-mold housing is preferably applied to a portion of the base housing before the overmold housing is formed. 
     Other features of the invention may include: cable strain relief fittings to prevent damage to the plug-cord connection; use of special construction materials (i.e., die cast metal and plastics) that withstand chemical and high/low temperature environments; and audible and/or tactile confirmation that a latch is engaged. 
     With these and other objects, advantages and features of the invention that may become hereinafter apparent, the nature of the invention may be more clearly understood by reference to the following detailed description of the invention, the appended claims and to the several drawings attached herein. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of an electrical connector cable assembly in accordance with the invention. 
     FIG. 2 is a perspective view of the base housing of the electrical connector of the invention. 
     FIG. 3 is a perspective view of the base housing with a pre-mold housing formed thereon; 
     FIG. 4 is a partial cross-sectional view along lines IV—IV of FIG.  3 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 shows the electrical connector of the invention. The connector  1  is comprised of three main parts, a base housing  3 , a pre-mold housing  5  molded onto a rear portion of the base housing (see, FIG. 3) and an overmolded housing  7 , which is molded over the pre-mold housing, as described in more detail below. 
     The overmolded housing  7  is preferably molded of plastic material with resilience or elasticity, such as a thermoplastic elastomeric material, although hardened plastic, such as thermosetting material, may be also used. The overmolded housing  7  preferably includes a strain relief extension  9  molded around the cable  11  which supplies the wires  13  which enter the rear of the base housing  3  and are attached to the contacts  15  of internal connector  21 . 
     FIG. 2 shows base housing  3  which includes internal connector  21  disposed in passageway  17  having electrical contacts  15  which are attached to wires  13  which enter through an open rear of base housing  3  from cable  11 . The rear portion of base housing  23  includes a circumferential groove  25  and flange  27 , which aid in the attachment of the pre-mold housing as discussed below. 
     FIG. 3 shows base housing  3  with pre-mold housing  5 , molded thereon. Pre-mold housing  5  may be molded from any of the thermoplastic or thermosetting plastic materials used for the overmolded housing. To attach the pre-mold housing  5  to the base housing  3 , the base housing with attached cable is placed in a mold and the pre-mold housing is molded thereon, covering the rear portion of the base housing  23 , wires  13  and a portion of cable  11 , as shown in FIG.  3 . 
     The pre-mold and overmold housing are preferably made by injection molding plastic material into the mold to form the structures shown in FIGS. 1 and 3. 
     To facilitate attachment of the pre-mold housing to the rear of the base housing, a circumferential groove  25  and flange  27  are preferably provided on the rear of the base housing. As shown in FIG. 4, the material which forms the pre-mold housing is held in groove  25 , locking the pre-mold housing to the base housing. 
     Overmolded housing  7  is then molded over the pre-mold housing and central portion  29  of base housing  3  to form the connector of the invention shown in FIG.  1 . Overmold housing  7  is, preferably, molded such that its outer surface is flushed with the outer surface of the exposed front portion of base housing  31 . The surface of the overmold housing may contain ribs  33  to facilitate gripping of the connector. 
     In a preferred embodiment, the front portion  31  of the base housing  3  is provided with lug ridge  41 . The lug ridge  41  is an optional feature that is preferably cast into base housing  3 . It includes two rounded ends  43 , reinforcement members  45 , and a reinforcement extension  47 . The mating connector (not shown) includes two latches having detents, on swing arms, that catch onto the rounded ends  43 . The latches are shown in the co-pending application entitled “General Motion Connector,” Ser. No. 09/805,330, filed Mar. 14, 2001, the contents of which are entirely incorporated herein by reference. The rounded ends  43  take the place of cylindrical lug pins, which are prone to break under the high forces exerted by the latches. 
     The reinforcement members  45  are preferably of the same height above the surface of the housing as is the rounded ends  43 , but may be of a different height. The same is true of the extension  47 . 
     Although certain presently preferred embodiments of the present invention have been specifically described herein, it will be apparent to those skilled in the art to which the invention pertains that variations and modifications of the various embodiments shown and described herein may be made without departing from the spirit and scope of the invention. Accordingly, it is intended that the invention be limited only to the extent required by the appended claims and the applicable rules of law.