Patent Abstract:
An electrical connector includes a terminal body defining at least two openings therein. Electrical terminals positioned in each of the at least two openings defined by the terminal body include respective crimp sections that extend beyond an end of the terminal body. A separator fin attached to the end of the terminal body extends beyond the crimp sections of the electrical terminals and is located between the at least two openings in the terminal body so that the separator fin defines a structure that is closed on an inner side to physically separate the crimp sections of the electrical terminals and open on an outer side so that the crimp sections of the electrical terminals are exposed.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This is a continuation of co-pending U.S. patent application Ser. No. 11/748,946, filed May 15, 2007, now allowed, which is hereby incorporated herein by reference for all that it discloses. 
     
    
     TECHNICAL FIELD 
       [0002]    This invention relates to electrical connectors in general and more specifically to environmentally-resistant electrical connectors. 
       BACKGROUND 
       [0003]    Numerous types of electrical connectors exist and have been used for decades to provide a removable electrical connection between various types of electrical components and devices. One type of removable electrical connector is known as a bayonet connector. Bayonet connectors were developed decades ago and are commonly used to innerconnect single conductor cables, typically in low power, low voltage applications, such as those commonly used in truck and automotive electrical systems. However, bayonet connectors may be used in other applications as well. 
         [0004]    A typical bayonet connector assembly may comprise a male terminal and a female terminal that are designed to be engaged and disengaged with one another. Both the male and female terminals are typically electrically and mechanically attached to an electrical conductor (e.g., a wire) by crimping, although they may also be soldered. Both types of terminals (e.g., the male and female terminals) are typically mounted within a housing or connector body that supports the terminals and electrically insulates them from one another and from their surroundings. However, most connector bodies do not seal the terminals from the environment, thereby subjecting the terminals to corrosion and other deleterious effects due to exposure to the surrounding environment. Of course, such environmental exposure is undesirable in applications where the environment contains corrosive agents (e.g., salts), such as, for example, in external automotive and commercial vehicle applications. 
         [0005]    While several types of electrical connectors have been developed in an effort to protect the terminals from exposure to the environment, none are without their problems. For example, while some types of connectors are highly effective from a sealing standpoint, i.e., they are good at protecting the electrical terminals from exposure to the environment, such connectors tend to be expensive to produce or are difficult and/or time-consuming to connect and disconnect in service. Other types of connectors, while being of lower cost and easier to use, often fail to protect the electrical terminals from the deleterious effects of the environment. Still other types of connectors may work well when new, but tend to deteriorate rapidly and may be subject to in-service corrosion, which may lead to erratic performance. 
       SUMMARY OF THE INVENTION 
       [0006]    An embodiment of an electrical connector includes a terminal body defining at least two openings therein. Electrical terminals positioned in each of the at least two openings defined by the terminal body include respective crimp sections that extend beyond an end of the terminal body. A separator fin attached to the end of the terminal body extends beyond the crimp sections of the electrical terminals and is located between the at least two openings in the terminal body so that the separator fin defines a structure that is closed on an inner side to physically separate the crimp sections of the electrical terminals and open on an outer side so that the crimp sections of the electrical terminals are exposed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    Illustrative and presently preferred exemplary embodiments of the invention are shown in the drawings in which: 
           [0008]      FIG. 1  is an exploded perspective view of a mating electrical connector pair according to one embodiment of the invention; 
           [0009]      FIG. 2  is a connector-end view of a male portion of a terminal body; 
           [0010]      FIG. 3  is a cross-sectional view in elevation of the male terminal body taken along the line  3 - 3  of  FIG. 2 ; 
           [0011]      FIG. 4  is a partial sectional view of the male terminal body; 
           [0012]      FIG. 5  is a terminal-end view of the male terminal body; 
           [0013]      FIG. 6  is a connector-end view of a female portion of a terminal body; 
           [0014]      FIG. 7  is a cross-sectional view in elevation of the female terminal body taken along the line  7 - 7  of  FIG. 6 ; 
           [0015]      FIG. 8  is a terminal-end view of the female terminal body; 
           [0016]      FIG. 9  is an end view of a locking collar; 
           [0017]      FIG. 10  is a cross-sectional view in elevation of the locking collar taken along the line  10 - 10  of  FIG. 9 ; 
           [0018]      FIG. 11  is a side view of a male electrical terminal; and 
           [0019]      FIG. 12  is a side view of a female electrical terminal. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0020]    An electrical connector  10  according to one embodiment of the present invention is illustrated in  FIG. 1  and may comprise both connector portions of a mating electrical connector pair  12 . More specifically, a first electrical connector  10  of the mating electrical connector pair  12  may comprise a male portion  14 , whereas a second electrical connector of the mating electrical connector pair  12  may comprise a female portion  16 . The electrical connector  10 , i.e., either the male portion  14  or the female portion  16 , may comprise a terminal body (e.g.,  18 ,  18 ′) that defines at least one opening (e.g.,  20 ,  20 ′) therein sized to receive an electrical terminal (e.g.,  22 ,  22 ′). 
         [0021]    Referring now primarily to  FIGS. 3 and 7 , each opening  20 ,  20 ′ defined by the terminal body  18 ,  18 ′ may be provided with a plurality of alignment ribs  24 ,  24 ′. As will be described in further detail below, the alignment ribs  24 ,  24 ′ help to align the electrical terminals  22 ,  22 ′ within the openings  20 ,  20 ′ defined by the terminal bodies  18 ,  18 ′. The improved terminal alignment provided by the alignment ribs  24 ,  24 ′ enhances the engagement of the two electrical connectors  10 , i.e., the male portion  14  and the female portion  16 , that comprise the mating electrical connector pair  12 . 
         [0022]    As will be described in further detail below, each terminal body  18 ,  18 ′ may also be provided with additional features and elements that may be used to enhance or achieve the various objects and advantages described herein. For example, each opening  20 ,  20 ′ in the terminal body  18 ,  18 ′ may also be provided with a tapered portion  26 ,  26 ′ comprising a wide end  48 ,  48 ′ and a narrow end  50 ,  50 ′. The tapered portion  26 ,  26 ′ is sized so that it receives a corresponding tapered section  74 ,  74 ′ ( FIGS. 11 and 12 ) provided on the electrical terminal  22 ,  22 ′ when the terminal  22 ,  22 ′ is positioned in the opening  20 ,  20 ′. Tapered portion  26 ,  26 ′ also helps to center the electrical terminal  22 ,  22 ′ within the opening  20 ,  20 ′. The openings  20 ,  20 ′ may also be provided with a shoulder  28 ,  28 ′ sized to engage a tang  30 ,  30 ′ ( FIGS. 11 and 12 ) that may be provided on the electrical terminals  22 ,  22 ′. 
         [0023]    Each terminal body  18 ,  18 ′ may also be provided with one or more separator fins  32 ,  32 ′, as best seen in  FIG. 1 . The separator fins  32 ,  32 ′ prevent the electrical terminals  22 ,  22 ′ from contacting one another when in terminal body  18 ,  18 ′, thereby preventing an electrical short circuit from developing between the electrical terminals  22 ,  22 ′. 
         [0024]    In one embodiment, the mating electrical connector pair  12 , which may comprise two electrical connectors  10  (i.e., the male portion  14  and the female portion  16 ), may be provided with a locking collar  34 . As will be described in further detail below, one or more locking tabs  46  ( FIGS. 9 and 10 ) provided on locking collar  34  are sized to engage one or more grooved portions  36  provided on the mating electrical connector  10  (e.g., the male portion  14 ), thereby securely locking together the two connector portions  14  and  16  of mating electrical connector pair  12 . In addition, each terminal body  18 ,  18 ′ may be covered or encapsulated (e.g., by an overmolding process described in greater detail below) by a sleeve  38 ,  38 ′, as best seen in  FIGS. 3 and 7 . As will be described in greater detail below, the provision of an overmolded sleeve  38 ,  38 ′ helps to provide a good physical bond and a gas- and liquid-tight seal between sleeve  38 ,  38 ′ and terminal body  18 ,  18 ′. 
         [0025]    Referring now to  FIGS. 11 and 12 , in one embodiment, the electrical terminals  22 ,  22 ′ may comprise plug and socket terminals having a configuration that is similar to that of conventional plug and socket connectors. However, unlike conventional connectors, the plug and socket electrical terminals  22 ,  22 ′ that may be utilized in one embodiment of the present invention are provided with a tab portion  40 ,  40 ′ that substantially closes a proximal end  42 ,  42 ′ of the electrical terminal  22 ,  22 ′. The tab portion  40 ,  40 ′ prevents the material from migrating into the hollow portion of the electrical terminal  22 ,  22 ′, such as, for example, molten sleeve material during the sleeve overmolding process. 
         [0026]    One significant feature of the electrical connector  10  of the present invention is that the alignment ribs  24 ,  24 ′ provided in the openings  20 ,  20 ′ defined by the terminal bodies  18 ,  18 ′ help to properly align the electrical terminals  22 ,  22 ′ within the terminal bodies  18 ,  18 ′, thereby making it easier to engage the two portions (e.g., the male and female portions  14  and  16 ) of the electrical connectors  10  comprising the mating electrical connector pair  12 . The enhanced alignment of the electrical terminals  22 ,  22 ′ provided by the alignment ribs  24 ,  24 ′ is particularly advantageous in multiple-terminal configurations, i.e., where the electrical connector  10  comprises a plurality of individual electrical terminals  22 ,  22 ′. 
         [0027]    Still other advantages are associated with the various configurations and elements comprising the claimed invention. For example, the tapered portions  26 ,  26 ′ provided in the openings  20 ,  20 ′ enhance the alignment of the electrical terminals  22 ,  22 ′ when they are inserted into the terminal body  18 ,  18 ′ during the assembly process. That is, the tapered portions  26 ,  26 ′ provide a generous “lead-in” for the terminals  22 ,  22 ′. In addition, the tapered portions  26 ,  26 ′ provide for improved alignment of the electrical terminals  22 ,  22 ′ when they are fully inserted into the terminal bodies  18 ,  18 ′. The cooperative engagement of the tangs  30 ,  30 ′ provided on the electrical terminals  22 ,  22 ′ with the shoulders  28 ,  28 ′ provided in the terminal body  18 ,  18 ′ helps to positively retain the electrical terminals  22 ,  22 ′ within the terminal body  18 ,  18 ′, helping to prevent the electrical terminals  22 ,  22 ′ from becoming dislodged during subsequent connector use. Moreover, the separator fins  32 ,  32 ′ provided on the terminal body  18 ,  18 ′ prevent the various electrical terminals  22 ,  22 ′ from contacting one another, thereby preventing electrical short circuits from developing between the electrical terminals  22 ,  22 ′ contained in the terminal bodies  18 ,  18 ′. 
         [0028]    As already briefly described, the mating electrical connector pair  12  may also be provided with a locking collar or ring  34 . In one embodiment, the locking collar  34  may be used to draw together the two portions (e.g.,  14  and  16 ) of the mating connector pair  12  to ensure a secure connection and a tight seal between the male and female portions  14  and  16 , particularly where a gasket  44  ( FIG. 1 ) is positioned between the two connector portions  14  and  16 . In addition, the locking collar  34  covers the joint or interface between the electrical terminals  22 ,  22 ′ of the two connector portions  14  and  16 , thereby further reducing the likelihood that environmental contaminants will find their way into the interface between the two connector portions  14  and  16 . 
         [0029]    Having briefly described one embodiment of the electrical connector  10 , how it may comprise a portion of a mating electrical connector pair  12 , as well as some of its more significant features and advantages, various embodiments and variations of the present invention will now be described in detail. 
         [0030]    However, before proceeding with the detailed description, it should be noted that while the present invention is shown and described herein as it could be used in conjunction with the plug and socket type of electrical terminals, it could be utilized with other types of electrical terminals, either now known in the art or that may be developed in the future, as would become apparent to persons having ordinary skill in the art after having become familiar with the teachings provided herein. Consequently, the present invention should not be regarded as limited to the particular type of electrical terminals shown and described herein. 
         [0031]    In addition, while the electrical connector shown and described herein comprises seven (7) separate mating electrical terminal pairs  22 ,  22 ′, any number of electrical terminal pairs could be used, again as would become apparent to persons having ordinary skill in the art after having become familiar with the teachings provided herein. Consequently, the present invention should not be regarded as limited to the particular configurations and applications shown and described herein. 
         [0032]    Referring back now to  FIG. 1 , one embodiment of an electrical connector  10  is shown and described herein as it could be used in conjunction with the so-called plug and socket type of electrical terminals  22 ,  22 ′. More specifically, the plug and socket type of electrical terminals may comprise two mating portions: A male terminal  22  and a female terminal  22 ′. See also  FIGS. 11 and 12 . As described herein, the electrical connector  10  that receives the male electrical terminal  22  may be referred to herein as the male portion  14 , whereas the electrical connector  10  that receives the female electrical terminal  22 ′ may be referred to herein as the female portion  16 . Both the male portion  14  and the female portion  16  may be referred to herein in the alternative as simply “electrical connector  10 .” Because the male portion  14  is designed to mate with the female portion  16 , the combination of the male and female portions  14  and  16  also may be referred to herein as the mating electrical connector pair  12 . 
         [0033]    Referring now primarily to  FIGS. 2-5 , the male portion  14  of the electrical connector may comprise a terminal body  18  that defines at least one opening  20  therein sized to receive electrical terminal  22 . The terminal body  18  may be configured to provide electrical connections for any number of electrical terminals  22 . By way of example, in the embodiment shown and described herein, the terminal body  18  defines seven (7) openings  20 , thereby allowing the electrical connector  10  to provide seven (7) discrete electrical connections. Alternatively, of course, a greater or fewer number of openings  20  may be provided, depending on the desired number of electrical connections to be provided. Consequently, the present invention should not be regarded as limited to a terminal body  18  defining any particular number of openings  20 . 
         [0034]    Each opening  20  in terminal body  18  may be provided with a plurality of alignment ribs  24  sized and positioned so that they will position the electrical terminal  22  at the desired location (e.g., concentrically) within the opening  20 . In the embodiment shown and described herein four (4) alignment ribs  24  are provided at substantially diametrically opposed locations within the opening  20 , as best seen in  FIG. 2 . Alternatively, a greater or fewer number of alignment ribs  24  may be used and may be located at different positions depending on the number of alignment ribs  24  to be provided. For example, in another embodiment (not shown), three (3) separate alignment ribs  24  may be provided. However, instead of being diametrically opposed, the three (3) separate alignment ribs  24  may be spaced substantially evenly around the opening  20  (e.g., at 120° intervals). 
         [0035]    Each opening  20  may also be provided with a tapered section  26  ( FIG. 3 ). Tapered section  26  may comprise a wide end  48  and a narrow end  50 . Electrical terminal  22  may be provided with a corresponding tapered section  74 , as best seen in  FIG. 11 . Thus, when the electrical terminal  22  is inserted into the terminal body  18 , the wide end  48  of tapered section  26  will serve as a lead-in for the distal end  52  ( FIG. 11 ) of electrical terminal  22 . When the electrical terminal  22  is fully inserted into terminal body  18 , the narrow end  50  will contact the electrical terminal  22 , thereby helping to properly locate the electrical terminal  22  within terminal body  18 . 
         [0036]    Each opening  20  may also be provided with a shoulder  28  sized to engage a tang  30  ( FIG. 11 ) provided on the electrical terminal  22 . More specifically, shoulder  28  will engage tang  30  when the electrical terminal  22  is fully inserted into terminal body  18 . The engagement of shoulder  28  and tang  30  will also prevent the electrical terminal  22  from being pushed back out from terminal body  18  during service. 
         [0037]    Terminal body  18  may also be provided with one or more separator fins  32  that extend generally rearwardly from terminal body  18 , as best seen in FIGS.  1  and  3 - 5 . The separator fins  32  may be generally co-extensive with the electrical terminals  22  when they are fully inserted into the terminal body  18 , so as to prevent the electrical terminals  22  from contacting one another. 
         [0038]    The separator fins  32  are arranged so that they are located generally between adjacent ones of the openings  20  defined in terminal body  18 , as best seen in  FIGS. 1 and 5 . In the embodiment shown and described herein wherein the terminal body  18  is provided with seven (7) openings  20 , the separator fins  32  are arranged so that they define a central opening  33  that is substantially aligned (e.g., concentric with) with the center opening  20 . See  FIG. 5 . 
         [0039]    Terminal body  18  may also be provided with other features to provide the electrical connector  10  with additional advantages. For example, in one embodiment, the terminal body  18  and separator fins  32  are provided with notched sections  54  to provide a more secure attachment to the sleeve  38 , as best seen in  FIGS. 3 and 4 . The terminal body  18  may also be provided with a recessed face portion  56 . Recessed face portion  56  causes the seam or interface between the two connector portions  14  and  16  to be located within the recessed face portion  56  of the mating electrical connector pair  12 , thereby reducing the likelihood that interface between the two portions  14  and  16  will be exposed to environmental contaminants. In addition, the recessed face portion  56  provides a convenient location for gasket  44  ( FIG. 1 ) if such a gasket is desired. 
         [0040]    Recessed face portion  56  may be provided with an index feature, such as a V-shaped projection  58  ( FIGS. 2 and 3 ) sized to receive a corresponding V-shaped notch  64  ( FIGS. 6 and 7 ) which may be provided in the mating electrical connector  10  (e.g., female portion  16 ). The index feature provides a convenient way to align the connectors to ensure proper connection of the electrical terminals  22 ,  22 ′. 
         [0041]    Terminal body  18  of electrical connector  10  may also be provided with one or more grooves or grooved sections  36  sized to engage a locking collar  34  that may be provided on the mating terminal body. See  FIGS. 1-4 . In the embodiment shown and described herein, three (3) separate grooved sections  36  are provided around the exterior or outer periphery of terminal body  18  at 120° intervals, as best seen in  FIGS. 1 and 2 . Alternatively, a greater or fewer number of grooved sections  36  may be used and may be provided at different spacings or intervals. The grooved sections  36  are sized to receive corresponding locking tabs  46  ( FIG. 9 ) provided on locking collar  34 . In addition, one or more of the grooved sections  36  may be provided with a detent  60  ( FIG. 4 ) configured to engage the locking tabs  46  provided on locking collar  34 . The engagement of the locking tabs  46  with the detents  60  provides a positive locking action for the locking collar  34 . That is, the detents  60  help to secure the locking collar  34  in the fully engaged or locked position. 
         [0042]    The terminal body  18  and the various features and components thereof may be fabricated from any of a wide range of materials, such as plastics or other non-conductive materials, that would be suitable for the intended application. Consequently, the present invention should not be regarded as limited to a terminal body  18  fabricated from any particular type of material. However, by way of example, in one embodiment, the terminal body  18  is molded as a single, unitary piece from nylon “66.” 
         [0043]    Referring now primarily to  FIGS. 6-8 , a female portion  16  of an electrical connector  10  may be designed to engage or mate with the male portion  14  of the electrical connector just described. The female portion  16  may comprise a terminal body  18 ′ that defines one or more openings  20 ′ therein. The numbers, sizes, and spacings of the openings  20 ′ may be configured to correspond to the numbers, sizes, and spacings of the openings  20  provided in the terminal body  18  for the male portion  14  of electrical connector  10 . For example, in the embodiment shown and described herein, the terminal body  18 ′ defines seven (7) openings  20 ′ therein in the manner illustrated in FIGS.  1  and  6 - 8 . 
         [0044]    Each opening  20 ′ may be provided with features similar to those provided in openings  20  of terminal body  18 . For example, and with reference now to  FIG. 7 , each opening  20 ′ may be provided with a plurality of alignment ribs  24 ′. Alignment ribs  24 ′ may be substantially identical to the alignment ribs  24 , thus will not be described in further detail herein. 
         [0045]    Each opening  20 ′ may also be provided with a tapered section  26 ′ having a wide end  48 ′ and a narrow end  50 ′ that are sized to receive a tapered section  74 ′ ( FIG. 12 ) provided on the mating (e.g., female) electrical terminal  22 ′ in a manner similar to that already described for the tapered section  26 . Opening  20 ′ may also be provided with a shoulder  28 ′ sized to engage a tang  30 ′ provided on female electrical terminal  22 ′. 
         [0046]    As was the case for the male portion  14  of the electrical connector  10 , the terminal body  18 ′ of female portion  16  of electrical connector  10  may be provided with one or more separator fins  32 ′. The separator fins  32 ′ may extend generally rearwardly from the terminal body  18 ′ so that the are co-extensive with the electrical terminals  22 ′ when the electrical terminals  22 ′ are fully inserted in terminal body  18 ′. In the embodiment shown and described herein wherein the terminal body  18 ′ is configured with seven (7) openings  20 ′, the separator fins  32 ′ are arranged so that they define a central opening  33 ′ that is substantially aligned with the opening  20 ′ provided at or near the center of the terminal body  18 ′. See  FIGS. 1 and 8 . 
         [0047]    With reference now primarily to  FIG. 7 , the terminal body  18 ′ and separator fins  32 ′ may be provided with notched areas or sections  54 ′ to provide a more secure attachment for sleeve  38 ′. Terminal body  18 ′ may also be provided with a raised or extended face section  62  that is sized to be received by the recessed face portion  56  of terminal body  18 , as best seen in  FIG. 1 . The raised face section  62  and recessed face  56  may be configured to interface with gasket  44 , as best seen in  FIG. 1 . In addition, the raised face section  62  may be provided with an index feature, such as a V-shaped notch  64  ( FIG. 6 ) that is sized to mate with or engage the corresponding index feature (e.g., the V-shaped projection  58 ) provided on the mating terminal body  18 . 
         [0048]    Terminal body  18 ′ may also be provided with a raised shoulder or boss  66  that engages with a similar shoulder  68  provided on locking collar  34 . The engagement of the two shoulders  66  and  68  allows the locking collar  34  to securely hold together the two connector portions  14  and  16  when they are engaged with one another and when the locking collar  34  is rotated to the locked position. 
         [0049]    Terminal body  18 ′ may be fabricated from any of a wide range of materials, such as plastics or other non-conductive materials, that would be suitable for the intended application. Consequently, the present invention should not be regarded as limited to any particular type of material. However, by way of example, in one embodiment, terminal body  18 ′ is molded as a single, unitary piece from nylon “66.” 
         [0050]    As already discussed herein, it may be generally desirable to provide each terminal body  18 ,  18 ′ with a sleeve  38 ,  38 ′. Sleeves  38 ,  38 ′ may provide a good physical bond as well as a gas- and liquid-tight seal with the terminal bodies  18 ,  18 ′ and wires  70 ,  70 ′ thereby providing for enhanced protection against environmental encroachment. In addition, sleeves  38 ,  38 ′ may be configured or shaped to provide an enhanced gripping area for a user. While the sleeves  38 ,  38 ′ may comprise a separate component or element that is fitted over the terminal bodies  18 ,  18 ′, in many applications it will be generally desirable to form or mold the sleeves  38 ,  38 ′ directly on the terminal bodies  18 ,  18 ′ after the terminal bodies  18 ,  18 ′ have been assembled, i.e., after the various electrical terminals  22 ,  22 ′ have been inserted into the openings  20 ,  20 ′ provided in terminal bodies  18 ,  18 ′. 
         [0051]    In one embodiment, the sleeves  38 ,  38 ′ are formed over the terminal bodies  18 ,  18 ′ by an “overmolding” process of the type known in the art. So forming the sleeves  38 ,  38 ′ by such an overmolding process allows a robust seal (e.g., a gas- and liquid-tight seal) to be established between the terminal bodies  18 ,  18 ′, the electrical conductors or wires  70 ,  70 ′, and the sleeves  38 ,  38 ′. 
         [0052]    More specifically, after the terminal bodies  18 ,  18 ′ have been assembled, they may be positioned in a form or mold (not shown) suitable for defining or forming the sleeves  38 ,  38 ′. Material (e.g., molten material) that will comprise the sleeves  38 ,  38 ′ may then be injected under pressure into the form or mold. During the molding process, the injected material will flow around the various components of the assembled terminal bodies  18 ,  18 ′, substantially encapsulating portions of the terminal bodies  18 ,  18 ′, portions of the electrical conductors (i.e., wires)  70 ,  70 ′, and portions of the electrical terminals  22 ,  22 ′, such as, for example, the crimp sections  76 ,  76 ′ thereof, as best seen in  FIGS. 3 and 4 . Significantly, the closed proximal ends  42 ,  42 ′ of electrical terminals  22 ,  22 ′ (e.g., formed by the respective tab portions  40 ,  40 ′ thereof), prevent molten sleeve material from flowing or migrating into the hollow portions of the electrical terminals  22 ,  22 ′ during the molding process. In addition, the engagement of the tapered sections  74 ,  74 ′ of the electrical terminals  22 ,  22 ′ with the corresponding tapered portions  26 ,  26 ′ of terminal bodies  18 ,  18 ′ also prevents molten sleeve material from flowing or migrating beyond the narrow ends  50 ,  50 ′ to tapered portions  26 ,  26 ′ during the molding process. 
         [0053]    Sleeves  38 ,  38 ′ may be fabricated from any of a wide range of materials (e.g., plastics) suitable for the particular application and for the particular process (e.g., overmolding) used to form the sleeves  38 ,  38 ′. Consequently, the present invention should not be regarded as limited to sleeves  38 ,  38 ′ formed from any particular type of material. However, by way of example, in one embodiment, sleeves  38  and  38 ′ are formed from a PVC (polyvinylchloride) plastic material. 
         [0054]    Turning now to  FIGS. 1 ,  9 , and  10 , locking collar  34  may be used to securely hold together the male and female portions  14  and  16  of the mating electrical connector pair  12 . In the embodiment shown and described herein, locking collar  34  may comprise a generally hollow, cylindrically shaped member having one or more locking tabs  46  provided thereon. Locking collar  34  may also be provided with a shoulder section  68  sized to engage a similar shoulder or boss  66  provided on terminal body  18 ′, as already described. Once the male and female portions  14  and  16  are fully mated together, locking collar  34  may be rotated as necessary to align the locking tabs  46  with the with the grooves  36  provided on the mating terminal body (e.g., terminal body  18 ). Locking collar  34  is then moved axially toward the mating terminal body  18  until the locking tabs  46  engage the inclined sections  72  ( FIG. 4 ) of grooves  36 . Locking collar  34  is then rotated. The engagement of the locking tabs  46  with the inclined sections  72  of grooves  36  causes the two connector portions  14  and  16  to be drawn together as the locking collar is rotated toward the locked position. When rotated to the locked position, the connector portions  14  and  16  will be fully drawn together and the locking tabs  46  will engage the detents  60  provided on grooves  36 , thereby holding the locking collar  34  in the locked position. 
         [0055]    Locking collar  34  may be fabricated from any of a wide range of materials, such as metals or plastics, suitable for the intended application. By way of example, in one embodiment, locking collar  34  is fabricated from nylon “66,” although other materials could be used as well. 
         [0056]    The electrical terminals  22 ,  22 ′ that may be utilized in one embodiment of the invention are best seen in  FIGS. 1 ,  11 , and  12 . In one embodiment, the electrical terminals  22 ,  22 ′ may comprise a size and configuration that is consistent with the connector standard that is well-known in the art. Alternatively, other types of electrical terminals, either now known in the art or that may be developed in the future, may be used. Referring now primarily to  FIG. 11 , a male-type electrical terminal  22  may comprise a generally elongate, hollow structure having a proximal end  42  and a distal end  52 . The proximal end  42  of male electrical terminal  22  may be provided with a tapered section  74  sized to be received by the tapered portion  26  provided in the opening  20  of terminal body  18  ( FIG. 3 ) in the manner already described. Electrical terminal  22  may also be provided with a tang  30  sized and positioned to engage the shoulder  28  provided in the opening  20  of terminal body  18 . Proximal end  42  of male electrical terminal  22  may also be provided with a suitable crimp section  76  for allowing the electrical conductor of a wire  70  ( FIG. 1 ) to be crimped (i.e., connected) to the electrical terminal  22 . 
         [0057]    The proximal end  42  of male electrical terminal  22  is also provided with a tab  40  that substantially closes the proximal end  42  of the electrical terminal  22 . The tab  40  prevents unwanted material from migrating into the hollow portion of the electrical terminal  22 , thereby enhancing the reliability and durability of the electrical connector. The presence of the tab  40  is particularly beneficial in situations wherein the sleeve  38  is formed by the overmolding process already described. That is, tab  40  prevents molten sleeve material from migrating into the hollow portion of the electrical terminal  22 . 
         [0058]    A female type of electrical terminal  22 ′ is best seen in  FIGS. 1 and 12  and may comprise a generally elongate, hollow structure having a proximal end  42 ′ and a distal end  52 ′. The proximal end  42 ′ of female electrical terminal  22 ′ may be provided with a tapered section  74 ′ sized to be received by the tapered portion  26 ′ provided in the opening  20 ′ of terminal body  18 ′ ( FIG. 7 ). Electrical terminal  22 ′ may also be provided with a tang  30 ′ sized and positioned to engage the shoulder  28 ′ provided in the opening  20 ′ of terminal body  18 ′. Proximal end  42 ′ of female electrical terminal  22 ′ may also be provided with a suitable crimp section  76 ′ for allowing the electrical conductor of a wire  70 ′ ( FIG. 1 ) to be connected to the electrical terminal  22 ′. 
         [0059]    The proximal end  42 ′ of female electrical terminal  22 ′ is also provided with a tab  40 ′ that substantially closes the proximal end  42 ′ of the electrical terminal  22 ′. The tab portion  40 ′ prevents unwanted material from migrating into the hollow portion of the electrical terminal  22 ′, thereby enhancing the durability and reliability of the electrical connector. The presence of the tab  40 ′ is particularly beneficial in situations wherein the sleeve  38 ′ is formed by the overmolding process already described. That is, tab  40 ′ prevents molten sleeve material from migrating into the hollow portion of the electrical terminal  22 ′. 
         [0060]    The male and female electrical terminals  22  and  22 ′ may be fabricated from any of a wide range of electrically conductive materials and in accordance with any of a wide range of fabrication processes, as would become apparent to persons having ordinary skill in the art after having become familiar with the teachings provided herein. However, by way of example, in one embodiment, each electrical terminal  22 ,  22 ′ may be fabricated from a generally flat sheet of material (e.g., metal) that includes features and elements that, when elastically deformed or bent, will form the generally elongate hollow terminal having the desired configuration. In addition, the sheet of material may comprise a tab portion (e.g.,  40 ,  40 ′) that can be bent or elastically deformed so as to substantially close the proximal end of the electrical terminal  22 ,  22 ′ in the manner already described and best seen in  FIGS. 11 and 12 . 
         [0061]    Having herein set forth preferred embodiments of the present invention, it is anticipated that suitable modifications can be made thereto which will nonetheless remain within the scope of the invention. The invention shall therefore only be construed in accordance with the following claims:

Technology Classification (CPC): 8