Patent Publication Number: US-10777934-B2

Title: Electrical connector which accepts different seal configurations

Description:
FIELD OF THE INVENTION 
     The present invention relates to sealed electrical connectors. More specifically, the present invention relates to electrical connectors which accept different seal configurations. 
     BACKGROUND OF THE INVENTION 
     Electric connectors that prevent moisture from entering a housing of the electrical connector are commonly used in many industries. Generally, these sealed or waterproof connectors have a seal member formed of an elastomer arranged at a wire receiving opening of the housing where electric wires are connected to a contact or a fitting component of a mating connector. The seal member seals the entrance for the electric wires, which are connected to contacts inside the housing to prevent the influx of water therein. The seal member may either be an individual seal member where the seal member is individually attached to each of a plurality of the electric wires or a collective or gang seal member where the seal member is attached to the plurality of the electric wires as a group. 
     Typical individual wire seals are formed with flanges around an outside circumference of the seal member. The individual wire seals are positioned proximate the terminals provided at the ends of the wires and are inserted into terminal receiving passages of the housing of the connector. The flanges press against inside walls of the passages to seal the housing. The passages are thereby individually sealed to prevent the ingress of moisture. 
     Typical collective or gang seals are made from an elastomer and are formed to have a plurality of wire receiving through-holes. Terminals provided at the ends of the wires are inserted through the wire receiving through-holes and are inserted into terminal receiving passages of the housing of the connector. End walls or flanges of the collective or gang seal engage inside walls of a seal receiving cavity of the housing of the connector to seal the housing. The seal receiving cavity is thereby sealed to prevent the ingress of moisture. 
     While both individual wire seals and collective seals are effective, each seal has required a different housing in order to provide and maintain an effective seal. The need for multiple housings requires multiple tooling and increase inventory, as multiple parts are required, thereby increasing the cost of such part. 
     It would, therefore, be beneficial to provide a housing which provides and maintains an effective seal using either individual wire seals or collective seals. It would also be beneficial if the same housing could accept the wires and terminals in applications in which sealing is not required. 
     SUMMARY OF THE INVENTION 
     An embodiment is directed to an electrical connector having a housing with a mating face and a wire-receiving face. Terminal-receiving cavities extend from the mating face toward the wire-receiving face. A receiving cavity extends from the wire-receiving face to an end wall provided at an end of the terminal-receiving cavities. The receiving cavity has a first section provided proximate the wire-receiving face and a second section provided proximate the end wall at the end of the terminal-receiving cavities. A transition wall is provided between the first section and the second section. Terminals are positioned in the terminal-receiving cavities. The terminals are physically and electrically connected to wires which extend through the receiving cavity and the wire-receiving face. A rear cover member is provided proximate the wire-receiving face. The receiving cavity is configured to receive a gang sealing member in the first section or individual wire sealing members in the second section to form a seal between the housing and the respective gang sealing member or the individual wire sealing members. 
     An embodiment is directed to an electrical connector having a housing with a mating face and a wire-receiving face. Terminal-receiving cavities extend from the mating face toward the wire-receiving face. A seal-receiving cavity extends from the wire-receiving face to an end wall provided at an end of the terminal-receiving cavities. The seal-receiving cavity has a first section provided proximate the wire-receiving face and a second section provided proximate the end wall at the end of the terminal-receiving cavities. The second section has cylindrical seal-receiving passages which extend from the terminal-receiving cavities to the first section. A transition wall is provided between the first section and the second section. Terminals are positioned in the terminal-receiving cavities. The terminals are physically and electrically connected to wires which extend through the seal-receiving cavity and the wire-receiving face. One or more sealing members are provided in the seal-receiving cavities. The one or more sealing members cooperate with the housing and the wires to form a seal between the housing, the wires and the one or more sealing members. A rear cover member is provided proximate the wire-receiving face and extends across the wire-receiving face. The rear cover member engages the one or more sealing members to maintain the one or more sealing members in the seal-receiving cavity. 
     Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative embodiment of an electrical connector according to the present invention. 
         FIG. 2  is an exploded perspective view of an illustrative electrical connector of  FIG. 1 , the electrical connector includes a collective or gang seal. 
         FIG. 3  is an exploded perspective view of an illustrative electrical connector of  FIG. 1 , the electrical connector includes individual wire seals. 
         FIG. 4  is an exploded perspective view of an illustrative electrical connector of  FIG. 1 , the electrical connector does not include any seals. 
         FIG. 5  is a cross-sectional view of the assembled connector of  FIG. 2 . 
         FIG. 6  is a cross-sectional view of the assembled connector of  FIG. 3 . 
         FIG. 7  is a cross-sectional view of the assembled connector of  FIG. 4 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. 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 preferred 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. 
     Referring to the embodiment shown in  FIG. 1 , an illustrative electrical connector  10  is shown. In the embodiment shown, a male electrical connector is shown. However, a female electrical connector may also be used without departing from the scope of the invention. 
     Referring to  FIGS. 2 through 7 , the connector  10  has housing  12  with a top surface or wall  20 , an oppositely facing bottom surface or wall  22  and side surfaces or walls  24  which extend between the top wall  20  and the bottom wall  22 . A forward mating face  26  extends between top wall  20 , bottom wall  22  and side walls  24 . Terminal-receiving cavities  28  extend from the mating face  26  toward a wire-receiving face  30 . 
     A seal-receiving cavity  40  extends from the wire-receiving face  30  to the terminal-receiving cavities  28 . As best shown in  FIGS. 5 through 7 , the seal-receiving cavity  40  has a first section  44  and a second section  46 . The first section  44  is positioned proximate to the wire-receiving face  30 . The first section  44  of the seal-receiving cavity  40  extends from the top surface or wall  20  to the bottom surface or wall  22  and from the one side surface or wall  24  to the opposed side surface or wall  24 . The second section  46  extends between the terminal-receiving cavities  28  and the first section  44 . The second section  46  has a plurality of cylindrical seal-receiving passages  42 . The first section  44  has a larger height and width than the cylindrical seal-receiving passages  42  of the second section  46 . A transition wall  48  extends between the first section  44  and the second section  46 . In the illustrative embodiment shown, the transition wall  48  extends from the top surface or wall  20 , the bottom surface or wall  22  and the side surfaces or walls  24 . 
     A mating connector latching area  32  extends from the top wall  20 . In the illustrative embodiment shown, the mating connector latching area  32  is positioned between the mating face  26  and the wire-receiving face  30 . However, the mating connector latching area  32  may be positioned in other locations along the top wall  20 . In the illustrative embodiment shown, the mating connector latching area  32  includes a mating connector engagement arm  36 . The engagement arm  36  extends in a direction which is essentially parallel to the top wall  20 . However, other configurations of the engagement arm  36  may be used. The mating connector latching area  32  is configured to cooperate with a latching area of a mating connector (not shown). 
     As best shown in  FIGS. 5 through 7 , terminals  52 , which are physically and electrically connected to wires or conductors  54 , are inserted into the terminal-receiving cavities  28  and are retained therein by resilient terminal latching arms  56 . The particular configuration of the terminals  52  and the resilient terminal latching arms  56  are shown for illustrative purposes but may vary. The wires or conductors  54  extend from the terminal-receiving cavities  28  through the seal-receiving cavity  40  and the wire-receiving face  30 . 
     In various embodiments, a peripheral seal  58  may be provided proximate the mating face  26 . The peripheral seal  58  cooperates with the mating connector, as is known in the art. 
     In the embodiment shown in  FIGS. 2 and 5 , a collective or gang sealing member  60  is provided proximate the rear wire-receiving face  30 . The gang sealing member  60  has a top surface  62 , an oppositely facing bottom surface  64  and side surfaces  66 . Wire-receiving openings  68  extend through the collective or gang sealing member  60  from an outwardly facing first surface  70  to an inwardly facing second surface  72 . The wire-receiving openings  68  are dimensioned to allow the wires or conductors  54  to be inserted therein. However, the wire-receiving openings  68  have inside diameters which are slightly smaller than outside diameters of the wires or conductors  54 , allowing the wire-receiving openings  68  to form seals with the wires or conductors  54 . 
     The wire-receiving openings  68  may also have ribs or projections  73  which extend inward from the walls of the wire-receiving openings  68 . The number and dimension of the ribs or projections  73  may vary. 
     Ribs or projections  74  extend from the top surface  62 , the bottom surface  64  and side surfaces  66 . The number and dimension of the ribs or projections  74  may vary. 
     The gang sealing member  60  is made of any material which prevents moisture or contaminants from entering the housing  12  of the connector  10  through gaps where the wires or conductors  54  enter the rear wire-receiving face  30  of the connector  10 . For example, the gang sealing member  60  may be made from elastomeric material such as silicon rubber. 
     When inserted into the seal-receiving cavity  40 , the inwardly facing second surface  72  of the gang sealing member  60  engages the transition wall  48  to position and maintain the gang sealing member  60  in the first section  44  and prevent the gang sealing member  60  from moving to the second section  46 . In this position, the ribs or projections  74  and the gang sealing member  60  are compressed to form a seal between the ribs or projections  74  and the first section  44  of the seal-receiving cavity  40 . The compression of the gang sealing member  60  also causes the wire-receiving openings  68  and the ribs or projections  73  to further compress around the wires or conductors  54  to enhance the seal between the wire-receiving openings  68  and the wires or conductors  54 . 
     A rear seal cover member  80  is positioned proximate the rear wire-receiving face  30 . The rear seal cover member  80  is a separate molded member with conductor receiving cavities  82 , a seal engaging portion  84  and two resilient latching arms  86  which extend from either side of the seal engaging portion  84 . When moved into position proximate the rear wire-receiving face  30 , the seal engaging portion  84  spans the rear wire-receiving face  30  and engages the outwardly facing surface  70  of the gang sealing member  60 . The resilient latching arms  86  are configured to engage and cooperate with the cover latching members  88  positioned on the side walls  24  of the housing  12  of the connector  10 . The rear seal cover member  80  is positioned over the rear wire-receiving face  30  after the terminals  52  have been inserted into the terminal-receiving cavities  28  and the gang sealing member  60  have been inserted into the first section  44  of the seal-receiving cavity  40 . The rear seal cover member  80  maintains the gang sealing member  60  in position in the connector  10 . 
     In the embodiment shown in  FIGS. 3 and 6 , multiple individual sealing members  160  are provided proximate the rear wire-receiving face  30 . Each individual seal member  160  cooperates with a respective conductor  54 . The individual sealing members  160  have generally cylindrical configurations with outer walls  162 . Wire-receiving openings  168  extend through the individual wire seals  160  from outwardly facing first surfaces  170  to inwardly facing second surfaces  172 . The wire-receiving openings  168  are dimensioned to allow the wires or conductors  54  to be inserted therein. However, each of the wire-receiving openings  168  has an inside diameter which is slightly smaller than an outside diameter of a respective wire or conductor  54 , allowing each of the wire-receiving openings  168  to form a seal with its respective wire or conductor  54 . The wire-receiving openings  168  may also have ribs or projections  173  which extend inward from the walls of the wire-receiving openings  168 . The number and dimension of the ribs or projections  173  may vary. 
     Ribs or projections  174  extend from the outer walls  162  of the individual sealing members  160 . The number and dimension of the ribs or projections  174  may vary. 
     The individual sealing members  160  are made of any material which prevents moisture or contaminants from entering the housing  12  of the connector  10  through gaps where the wires or conductors  54  enter the rear wire-receiving face  30  of the connector  10 . For example, the individual sealing members  160  may be made from elastomeric material such as silicon rubber. 
     When inserted into the seal-receiving cavity  40 , the individual sealing members  160  are inserted into the cylindrical seal-receiving passages  42  such that the inwardly facing second surfaces  172  of the individual sealing members  160  are positioned proximate the terminal-receiving cavities  28 . In this position, the ribs or projections  174  and the individual sealing members  160  are compressed to form a seal between the ribs or projections  174  and the walls of the cylindrical seal-receiving passages  42  of the second section  46  of the seal-receiving cavity  40 . The compression of the individual sealing members  160  also causes the wire-receiving openings  168  and the ribs or projections  173  to further compress around the wires or conductors  54  to enhance the seal between the wire-receiving openings  168  and the wires or conductors  54 . In the illustrative embodiment shown, the individual sealing members  160  extend from the terminal-receiving cavities  28  to proximate the wire-receiving face  30 . In this position, the individual sealing members  160  extend through the first section  44  and the cylindrical seal-receiving passages  42  of the second section  46 . 
     As the individual sealing members  160  are positioned on the wires or conductors  54  prior to the terminals  52  being crimped to the wires or conductors  54 , the sharp edges of the terminals do not tear or distort the wire-receiving openings  168 . Consequently, the individual sealing members  160  properly conform to the wires or conductors  54  and to the cylindrical seal-receiving passages  42  of the second section  46  of the seal-receiving cavity  40 , thereby allowing the individual sealing members  160  to have a higher seal rating than the gang sealing member  60 . 
     A rear seal cover member  80  is positioned proximate the rear wire-receiving face  30 . The rear seal cover member  80  is a separate molded member with conductor receiving cavities  82 , a seal engaging portion  84  and two resilient latching arms  86 . When moved into position proximate the rear wire-receiving face  30 , the seal engaging portion  84  spans the rear wire-receiving face  30 . The seal engaging portion  84  cooperates with the outwardly facing first surfaces  170  of the individual sealing members  160  to facilitate the proper position of the individual sealing members  160  in the second section  46  of the seal-receiving cavity  40 . 
     The resilient latching arms  86  are configured to engage and cooperate with the cover latching members  88  positioned on the side walls  24  of the housing  12  of the connector  10 . The rear seal cover member  80  is positioned over the rear wire-receiving face  30  after the terminals  52  and the individual sealing members  160  have been inserted into the terminal-receiving cavities  28  to maintain the individual sealing members  160  and terminals  52  in position in the connector  10 . If any terminal  52  is not fully seated into its respective terminal-receiving cavity  28 , the individual sealing member  160  which cooperates with the unseated terminal  52  may, in some instances, prevent the seal engaging portion  84  from being fully inserted, which may prevent the resilient latching arms  86  of the rear seal cover member  80  from engaging or latching to cover latching members  88 . Consequently, under certain circumstances, the cover member  80  may help alert the assembler to check for one or more unseated terminals. 
     In the embodiment shown in  FIGS. 4 and 7 , no type of multiple sealing members  160  is provided in the seal-receiving cavity  40 . In such embodiments, a rear cover member  280  is positioned proximate the rear wire-receiving face  30 . The rear cover member  280  is a separate molded member with conductor receiving cavities  282 , a back wall  284  and two resilient latching arms  286 . When moved into position proximate the rear wire-receiving face  30 , the back wall  284  spans the rear wire-receiving face  30  and has terminal engaging arms  285  which are dimensioned to extend through the first section  44  and the second section  46  of the seal-receiving cavity  40 . The terminal engaging arms  285  engage a back surface of the terminals  52  to facilitate the proper position of the terminals  52  in the terminal-receiving cavities  28 , thereby providing terminal position assurance. The terminal engaging arms  285  extend from the back wall  284  at a distance to allow the terminal engaging arms  285  to move past the transition wall  48  between the first section  44  and the second section  46  to position free ends  287  of the terminal engaging arms  285  in the cylindrical seal-receiving passages  42  of the second section  46 . 
     The resilient latching arms  286  are configured to engage and cooperate with the cover latching members  88  positioned on the side walls  24  of the housing  12  of the connector  10 . The rear cover member  280  is positioned over the rear wire-receiving face  30  after the terminals  52  have been inserted into the terminal-receiving cavities  28  to maintain the individual terminals  52  in position in the connector  10 . If any terminal  52  is not fully seated into its respective terminal-receiving cavity  28 , the terminal engaging arms  285  will engage the unseated terminal  52  and move it into position. Alternatively, if the unseated terminals  52  cannot be properly positioned, the terminal engaging arms  285  cannot be properly inserted into the housing  12 , preventing the resilient latching arms  286  of the rear cover member  280  from engaging or latching to cover latching members  88 , thereby alerting the assembler to check for one or more unseated terminals. 
     The housing  12  of the connector  10  is configured to properly receive and maintain either a gang sealing member  60  or individual sealing members  160  or terminal engaging arms  285  therein. As one housing can be manufactured to accommodate different sealing members, the costs associated with the connector  10  are reduced, as manufacturing and inventory costs are reduced. In addition, end users or installers benefit as the gang sealing members  60  or individual sealing members  160  can be used in the same connector  10 , thereby allowing the installers to use the same connector in different applications or environments. 
     While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted for elements thereof without departing from the spirit and scope of the invention of the invention as defined in the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other specific forms, structures, arrangements, proportions, sizes, and with other elements, materials and components, without departing from the spirit or essential characteristics thereof. One skilled in the art will appreciate that the invention may be used with many modifications of structure, arrangement, proportions, sizes, materials and components and otherwise used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being defined by the appended claims, and not limited to the foregoing description or embodiments.