Patent Publication Number: US-2020287328-A1

Title: Electrical connector with flexible bellows

Description:
TECHNICAL FIELD OF THE INVENTION 
     The invention generally relates to an electrical connector, particularly an electrical connector with an integral flexible bellows. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
       The present invention will now be described, by way of example with reference to the accompanying drawings, in which: 
         FIG. 1  is a perspective view of an electrical connector assembly, according to an embodiment of the invention; 
         FIG. 2  is an end view of the electrical connector assembly of  FIG. 1 , according to an embodiment of the invention; and 
         FIG. 3  is a cross section view of the electrical connector assembly of  FIG. 1 , according to an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments. 
     Manufacturing processes have variations that affect a product&#39;s shape and dimensions. This implies no two parts are the same, making fitment a complex requirement when assembling parts, such as electrical connector assemblies, due to dimensional tolerances that need to be maintained. Especially with rigid materials, such as engineered plastics, there are often trade-offs between function and manufacturability. 
     A proposed innovative solution to the issues associated with dimensional tolerances can be provided by adding geometric compliance to a connector by replacing part of the connector body with a bellows or bellow-like feature. This flexible bellows can aid fitment to different geometries and sizes. Having a flexible bellows with the appropriate geometry can also lead to higher adaptability and provide varying levels of environmental sealing. Higher adaptability in the connector assembly can also lead to better performance regardless of some of the mating part&#39;s conditions. Utilizing additive manufacturing methods, the bellows can be integrally fabricated with the rest of the connector body. Conventional plastic molding technology cannot provide an economically viable means of producing such a product. 
       FIG. 1  illustrates an electrical connector assembly, hereinafter referred to as the assembly  10 , according to an embodiment of this invention. The assembly  10  includes a connector body  12  that is formed of a polymeric dielectric material, such as polyamide (PA) or polybutylene terephthalate (PBT). The connector body  12  defines a plurality of terminal cavities  14  that extend longitudinally through the connector body  12 . The terminal cavities  14  are each configured to receive and retain an electrical terminal (not shown). The electrical terminal may terminate a wire cable (not shown) or may be directly attached to a connective trace on a printed circuit board assembly (not shown). Each terminal cavity defines an opening  16  that is configured to receive a corresponding mating electrical terminal (not shown) therethrough. The assembly  10  also includes a collapsible bellows  18  that longitudinally surrounds the opening  16 . This bellows  18  is integrally formed with the connector body  12 . The bellows  18  is a folding bellows type that includes flexible linear hinge features  20  that are located intermediate less flexible planar web features  22 . The bellows  18  is configured to contact a corresponding connector assembly (not shown) containing the corresponding mating terminals. As the bellows  18  contacts the corresponding connector assembly, the hinge features  20  bend, thereby allowing the bellows  18  to compress as the assembly  10  is mated with the corresponding connector assembly. The compression of the bellows  18  allows for larger dimensional tolerance between the assembly  10  and the corresponding connector assembly. The bellows  18  may also provide protection of the terminal interface from environmental contaminants, such as dust or water, by inhibiting the intrusion of these contaminants into the terminal cavities  14 . The assembly  10  should have an ingress protection rating according to International Electrotechnical Commission (IEC) Standard 60529 of at least IP50 and could have an IP rating up to IP52 depending on the particular application in which the assembly  10  is used. 
     The connector body  12  and the bellows  18  of the illustrated embodiment are integrally formed using an additive manufacturing process, such as stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selecting heat sintering, multi-jet modeling, multi-jet fusion, electronic beam melting, laminated object manufacturing, or 3D printing. 
     According to the embodiment illustrated in  FIG. 3 , the bellows  18  is formed of the same polymeric dielectric material as the connector body  12 . 
     While the illustrated embodiment presented herein includes a folding bellows feature, the bellows may alternatively be configured as a corrugated bellows feature. Additionally, while the illustrated embodiment is directed to an electrical connector assembly, other embodiments may be envisioned that are adapted for use with other types of connector assemblies for fiber optic cables, pneumatic tubes, hydraulic tubes, or a hybrid connector assembly including two or more of the items listed above. 
     While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to configure a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely prototypical embodiments. 
     Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the following claims, along with the full scope of equivalents to which such claims are entitled. 
     As used herein, ‘one or more’ includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above. 
     It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact. 
     The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
     As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context. 
     Additionally, while terms of ordinance or orientation may be used herein these elements should not be limited by these terms. All terms of ordinance or orientation, unless stated otherwise, are used for purposes distinguishing one element from another, and do not denote any particular order, order of operations, direction or orientation unless stated otherwise.