Patent Publication Number: US-2003224649-A1

Title: Protector for an overmolded connector

Description:
FIELD OF THE INVENTION  
       [0001] The present invention relates to connectors in general and, more particularly, to an overmolded connector assembly having a protector enclosing the connector for protection during the overmolding process.  
       BACKGROUND OF THE INVENTION  
       [0002] There are numerous electronic, low-voltage devices which are commonly in use. Such devices typically need a supply of power for either charging an internal battery or for continuous operation. Power is typically supplied to the low voltage devices through electrical cords which are terminated with a connector. In many applications, the connectors are overmolded connectors. Overmolded connectors are characterized by a connector enclosed or encased within a shell. Such self-contained connectors are particularly attractive because they may be manufactured at a relatively low cost.  
       [0003] In a typical overmolded connector, one or a number of electrical terminals of the connector are soldered to a direct current (DC) cable. The solder joints are then typically covered by molding a small amount of resin over the solder joints. The premold material also serves as an initial layer to prevent molding defects when the overmold is applied. The soldered assembly is then overmolded with polyvinylchloride (PVC), which serves as the external enclosure for the connector assembly.  
       [0004] In a conventional overmold process, the overmolding process may warp the walls of the connector due the injection pressure. When the connector walls are pushed inward, they may interfere with the internal contact spring, inhibiting of free movement on the spring and possibly causing a malfunction of the connector. The deformation of the walls may also allow for some plastic resin to seep into the connector body and touch the spring terminals, causing the spring terminals to be further inhibited from moving freely.  
       [0005] Thus, there is a need for an overmolded connector which sufficiently protects the internal parts of the connector during the overmolding process.  
       SUMMARY OF THE INVENTION  
       [0006] This invention is directed to a connector assembly including a connector. The assembly also includes an upper protector disposed above the connector and a lower protector disposed below the connector. The upper and lower protectors cooperate to seal the connector and structurally protect the connector. An overmolded portion of the connector assembly encases the protector, and the overmolded portion is sealed from the connector by the upper and lower protectors.  
       [0007] This invention is also directed to a method of forming a connector assembly comprising the steps of providing a connector and enclosing the connector within a protective shell defined by an upper portion and a lower portion. The upper and lower portions are arranged to protect and seal the connector. Next the connector and protective shell are overmolded. The protective shell protects the connector from mechanical deformation during the overmolding process and seals the connector during the overmolding process  
       [0008] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0009] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:  
     [0010]FIG. 1 depicts an assembled view of an overmolded connector arranged in accordance with the principles of the present invention;  
     [0011]FIG. 2 depicts an exploded view of the overmolded connector assembly of the present invention;  
     [0012]FIG. 3 depicts a longitudinal cross-sectional view of the overmolded connector assembly of the present invention; and  
     [0013]FIG. 3 is a partial cut away view of the overmolded connector assembly of the present invention.  
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
     [0014] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.  
     [0015] With reference to FIGS.  1 - 4 , FIG. 1- 4  depict various views of the overmolded connector assembly  10  of the present invention. Connector assembly  10  includes an overmolded portion  12  which encases a connector  14 , such as a DC connector. It will be understood by those skilled in the art, however, that the connector  14  of connector assembly  10  may be any of a number of connectors other than DC connectors.  
     [0016] Connector  14  includes a housing  16 , which is typically formed of plastic, but may be formed of other suitable materials. Housing  16  encloses electrically conductive springs  18  which terminate at spring contacts  20 . Housing  16  also typically is formed to include an integral retainer  22  which engages a mating connector (not shown). As best seen in FIG. 4, springs  18  includes a second pair of terminals  24  opposite that of spring contacts  20 .  
     [0017] An upper protector  30  encases housing  16  on an upper side of housing  16 . Similarly, a lower protector  32  encases housing  16  on a lower side of housing  16 . Protectors  30  and  32  cooperate to protect housing  16  as well as contacts  24 . In particular, connectors  30  and  32  are matingly sized and engaged to prevent an inflow of resin during the overmolding process. Further, protectors  30  and  32  are suitably formed and engaged so as to provide structural protection for housing  16 . Thus, during the overmolding process, the injection pressure exerted upon upper protector  30  and lower protector  32  does not deform protectors  30 ,  32 , rather than being absorbed by housing  16  cannot thereby leading to be possible deformation.  
     [0018] As described above, protectors  30  and  32  are formed so as to be engaged to protect housing  16 . As can be at best be seen in FIG. 2, protector  32  includes a projection  36  which engages a correspondingly formed female counterpart (not shown) of upper protector  30 . A plurality of tabs  38  formed in lower protector  30  to cooperate to engage upper protector  30  in order to maintain engagement between upper protector  30  and lower protector  32 .  
     [0019] In order to manufacture connector assembly  10 , wires  26  are soldered to terminals  24  of connector  16 . The connector is then enclosed by upper protector  30  and lower protector  32 , which are engaged as described above in order to maintain a structural and injection mold resistant seal. The protector and connector subassembly are then placed in an injection molding. Overmolded portion  12  is then formed by injection molding.  
     [0020] The connector assembly  10  described herein and provides several benefits and advantages over the prior art. In particular, upper protector  30  and lower protector  32  cooperate to provide both a structural seal to protect housing  16  during the overmolding process. In addition to structural support provided by upper protector  30  and lower protector  32 , the protectors  30 ,  32  cooperate to provide a fluid seal during the overmolding process in order to protect the solder joints  24  which interconnect wires  26  and terminals  24 .  
     [0021] The description of the invention is merely exemplary in nature and, thus, 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.