Patent ID: 12237747

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.

Referring toFIG.1, an electrical connector10has a housing12with a front surface14, a rear surface16, and side surfaces18. A first wall20extends between the front surface14, the rear surface16and the side surfaces18. Depending upon the type of mating connector and the assembly to which the mating connectors are attached, the size and shape of each of the side surfaces18may vary. The first wall20has a first reference surface22. In the illustrative embodiment shown, the first reference surface22is a planar surface. A second wall24extends between the front surface14, the rear surface16and the side surfaces18. The second wall24has a second reference surface26. In the illustrative embodiment shown, the second reference surface26is a radiused surface.

One or more terminal receiving cavities30extend from a front surface16to a rear surface18. In the illustrative embodiment shown, three terminal receiving cavities30are provided. However, other numbers and configurations of terminal receiving cavities30may be provided.

In the illustrative embodiment shown, the terminal receiving cavities30are spaced from the second reference surface26by cavities32. The terminal receiving cavities30are spaced from the first reference surface22by cavities34. This allows the terminal receiving cavities30to be properly positioned to mate with a mating connector (not shown). Depending upon the type of mating connector and the assembly to which the mating connectors are attached, the size and shape of the cavities32,34may vary, or one or more of them may not be needed.

A registration shoulder or projection36is provided on the second wall24and extends from the second reference surface26in a direction away from the first wall20. The registration projection36is provided proximate the front surface14. In the illustrative embodiment shown, the registration projection36extends from one side surface18to the opposite side surface18, but other configurations of the registration projection36may be used.

An alignment rib or projection38is provided on the second wall24and extends from the second reference surface26in a direction away from the first wall20. In the illustrative embodiment shown, the alignment projection38extends from the front surface14to the rear surface16, but other configurations of the alignment projection38may be used.

Compression clips40extend from the side surfaces18. Each compression clip40has a base42, a beam44and a latching projection48. The base42extends at approximately 90 degrees from the side surface18. The base42is integrally molded to the housing12. In various embodiments, the thickness of the material of the base42is thicker than that material of the first wall20and second wall24. The increased thickness provides the strength needed to allow the base42to bend, without breaking, as the beam44is compressed, as will be more fully discussed.

Each beam44extends from the base42. The beam44extend from the base42at an angle, for example, but not limited to, between 90 degrees and 120 degrees. Each beam44may be straight or have a first portion50, which extend from a free end56of the beam44, and a second portion52, which extend from the bas44. A transition portion54is provided between the first portion50and the second portion52. The transition portion54has a larger cross-sectional area than the first portion50and/or the second portion52to provide additional strength and stability to the beam44. The first portion50extends at an angle relative to a lower portion52.

The latching projections48are provided at the free ends56of the beams44. The latching projections48extend at approximately 90 degrees to the longitudinal axis of the beams44. Each latching projection48has a latching shoulder58.

The connector10is mounted on a radiused surface60, as shown inFIGS.2and5. In the illustrative embodiment shown, the radiused surface60is an inside radiused surface of an electrical motor stator62. The radius of the radiused surface60is the same or approximately the same as the radius of the second reference surface26of second wall24of the connector10. In other embodiments, the positioning of the radiused surface may vary and the configuration of the radiused surface60and the second reference surface26may also vary.

The stator62includes slots64which are spaced about the inside circumference of the stator62. The slots64extend in a direction which is parallel to a longitudinal axis of the stator62. As shown inFIG.5, the slots64have tubular members or windings66which are positioned therein. Slot openings68extend from the radiused surface60to the slots64. Tooth tips70are provided at the intersection of the slot openings68with the slots64. Both slots64and slot openings68may be precisely positioned features of stator62.

During assembly, the connector10is moved into the inside opening72(FIG.2) of the stator62, as shown inFIG.3. In this position, the front surface14and the registration projection26of the connector10are positioned proximate to, but above a top surface74of the stator62. The connector10is positioned proximate the leads76(FIG.2) of the stator62.

The beams44of the compression clips40are moved inward or compressed to a stressed position, as indicated by arrows78ofFIG.3. As this occurs, the connector10is moved toward the radiused surface60of the stator62, as indicated by arrow80.

As the connector10is moved, the alignment projection38is moved into a respective slot opening68aof the stator62. The insertion of the alignment projection38in the respective slot opening68aof the stator62facilitates the proper positioning of the connector10on the radiused surface60of the stator62. In addition, as the alignment projection38extends along the length of the connector10, the engagement of the alignment projection38with the respective slot opening68aprovides stability to the connector10when fully mounted, minimizing the movement of the connector in a direction perpendicular to the longitudinal axis of the slot opening68a. The distance that the alignment projection38extends from the second reference surface26of the second wall24is dimensioned to allow the alignment projection38to be retained in the respective slot opening68awithout extending into the slot64.

As the connector10is moved, the latching projections48of the compression clips40are moved into respective slot openings68bof the stator62. The insertion of the latching projections48into the respective slot opening68bof the stator62facilitates the proper positioning of the connector10on the radiused surface60of the stator62. In addition, as the latching projections48extend along the length of the connector10, the engagement of the latching projections48with the respective slot openings68bprovides stability to the connector10when fully mounted, minimizing the movement of the connector in a direction perpendicular to the longitudinal axis of the slot openings68b. The length of the beams44is dimensioned to allow the latching projections48to extend through the respective slot openings68band into the slots64. However, the beams44are dimensioned to allow the latching projections48to extend into the slots64without interfering with the tubular members or windings66positioned in the slots64.

With the radiused second reference surface26of the second wall24positioned in engagement with the radiused surface60of the stator60, the alignment projection30positioned in the respective slot opening68a, and the latching projections48of the compression clips40properly positioned in the respective slot openings68b, the force on the compression clips40is released, allowing the compression clips40to return toward an unstressed position, as represented by arrows82inFIG.4. In this position, the latching shoulders58of the latching projections48of the compression clips40are moved into engagement with the tooth tips70of the stator62, thereby preventing unwanted removal of the connector10from the stator62.

With the latching shoulders58of the latching projections48of the compression clips40positioned in engagement with the tooth tips70of the stator62, the connector10is moved downward, as indicated by arrow84inFIG.5. The movement continues until the registration projection36is moved into engagement with the top surface74of the stator62. With the registration projection36moved into engagement with the top surface74of the stator62, the connector10is properly and precisely positioned relative to the stator62, thereby allowing the leads76to be properly positioned in the connector10.

In addition, as the connector10is precisely positioned, the first reference surface22of the first wall20can be used as a reference surface for a mating connector (not shown). This allows for the controlled and accurate positioning of the mating connector relative to the connector10and the stator62. The size and configuration of the cavities32,34may be varied to properly position the first reference surface22to accommodate different mating connectors and their positioning.

The radiused second reference surface26allows for a good bearing surface contact between the connector10and the radiused surface60of the stator62. The alignment projection38ensures proper alignment and orientation of the connector10during mating to the stator62. The registration projection36can be manually biased against the top surface74of the stator62to ensure proper positioning of the connector20relative to the stator62. The operation of the compression clips40, which are manually squeezed during installation and released when properly positioned, securely locks the connector10to the stator62.

The electrical connector10can be precisely mounted to a radiused surface60, such as the inside surface of an electric motor stator62. This allows the leads76of the motor stator62to be secured in a common location for shipment to final assembly. This helps to prevent damage to the leads76during shipment. In addition, the use of the connector10enables automated removal and final connection of the connector10during the final assembly process. Among other advantages, automation may provide labor savings, reduces connection failures, and avoids operator injury.

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 as defined in the accompanying claims. 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.