Electrical connectors – Metallic connector or contact having part permanently...
Reexamination Certificate
1999-07-30
2001-04-17
Abrams, Neil (Department: 2839)
Electrical connectors
Metallic connector or contact having part permanently...
C439S593000
Reexamination Certificate
active
06217397
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to an electric connector for creating a permanent, electrically conductive connection, having a connector part and a male connector, in which at least one conductive contact of the male connector is arranged on a conductive contact of the connector part and a fusion bond is provided between the two contacts. The present invention also relates to a method of producing the connector according to the present invention and its use according to the present invention.
BACKGROUND INFORMATION
Conventional detachable plug-in connectors include at least one connector part formed on a housing and into which a mating connector, connected to a conductor, can be inserted. Electronic components of the electric device are thus connected to other devices or to the power supply via the detachable plug-in connector and the conductor connected thereto. In particular in mass production, for example, in the automobile industry, it is often required that a detachable connection be provided in one application and that a permanent connection, which is secured by a fusion bond, i.e., a solder or weld, and can no longer be subsequently separated by removing the mating connector, be provided in another application.
In the conventional connectors, a connector part must be provided for the detachable electric connector and another connector part must be connected to the same housing for the permanent connector. This entails considerable expense, since different manufacturing methods and manufacturing tools are required for the alternative connectors in order to produce the different male connector geometries.
SUMMARY OF THE INVENTION
An object of the present invention is to improve the electric connector so that a connector part that is permanently connected to a device housing is suitable for both a detachable and a permanent electric connection without necessitating the formation of separate connector parts on the device housing.
This object is achieved according to the present invention concerning an electric connector by designing a permanently connectable connector part, for example, so that it can also be used for a detachable electrically conductive connection, and the male connector having a molded body designed to fit the connector part.
It has been recognized according to the present invention that the same connector part can be used for a detachable connection and for a permanent fused bond. The connector part, which is designed to have standard geometry featuring tabs, can be assembled as a detachable, electrically conductive connection. To produce the permanent electrically conductive connection, only the mating connector is replaced by the male connector according to the present invention, which is insertable into the connector part and whose molded body is designed to fit the geometry of the connector part. Thus, the male connector can be advantageously inserted in the connector part, so that the contact of the male connector is on the contact of the connector part and then a permanent bond can be created between the two contacts using a special fusing method.
The decisive advantage of the electric connector according to the present invention is that a single connector part, which is mechanically attached to the device housing, can be used for the different connector versions. Different electric connectors can be obtained simply by using a conventional mating connector for the detachable connection and a male connector for the permanent connection. Since the same connector part is molded or formed on the device housing for the different connectors, considerable cost savings can be achieved. In the context of the present invention, the term permanent means a connection that can only be separated by destroying the fused bond, for example, at very high temperatures.
The connector part is preferably mechanically attached to the device housing. The connector part can be a standard component with tabs having standard geometry. Thus, a uniform basic body composed of the device housing and the connector part is obtained, i.e., a cost-effective version for fully automatic manufacturing. The design of the connector versions is obtained by a separate plastic injection process to produce the male connectors to fit the connector part. The contacts of the male connector are then borded to the contacts of the connector part using a special fusion bond.
In a particularly advantageous embodiment according to the present invention, the connector part has a receptacle, into which the mating connector of the detachable connection, in particular, a plug and socket, clamp or threaded connection, can be inserted. This receptacle can have a predefined standard geometry for large-scale manufacture. The male connector can then be inserted in this receptacle to form the permanent fusion bond. The male connector, connected to a conductor, for example, a cable, is initially simply inserted in the receptacle and is held fast there in a form-fitting manner.
The receptacle is preferably designed as a socket, in particular, with an annular shoulder as a stop for the mating connector or the male connector. Thus, the male connector is in a fixed position within the connector part prior to the fusion bonding procedure and a seal can be provided on the annular shoulder in order to protect the conductors within the electric connector from environmental influences.
The actual electric contact of the male connector can be designed as a plug and socket contact or as a contact socket. Distinction should be made between the receptacle designed as a socket, which can be made of plastic and can be brought into engagement with the molded body of the male connector, and the metal contact of the connector part, which can be designed as a plug-in connector or as a contact socket.
The contact of the male connector is preferably designed as a cable clamp contact, on which a conductor, in particular, a cable, can be fixedly clamped prior to fusion bonding. The cable clamp contact can be provided with a tab at one end, and with at least one clip to secure the conductor, in particular, the cable, at the other end. The cable is then preferably secured at the cable clamp contact using the clip, and the other end of the cable clamp contact projecting from the molded body of the male connector or freely positioned there is provided as a tab to engage with the contact of the connector part.
The male connector has a molded body made, in particular, of plastic, which fits the receptacle of the connector part. The molded body is advantageously produced by injecting plastic around the cable connected to the cable clamp contact, using an injection mold allowing a molded body fitting the connector part to be produced.
In a particularly advantageous embodiment according to the present invention, the molded body has one or more support elements, which press the contact of the connector part against the contact of the male connector. For this purpose, the contact of the male connector can be arranged on a plastic projection, and a support element positioned opposite the contact and separated from it by a small distance can be provided, so that the contact of the connector part can be inserted and pressed between the contact and the plastic projection. In either case, standard contacts can also be used.
The molded body preferably has a stop, in particular, an annular shoulder, for limiting movement. The annular shoulder can be in close contact with another annular shoulder or edge of the contact part receptacle, forming a seal in particular.
A conductor or a cable is preferably connected to the cable element. The cable element, in turn, is connected to the connector part via a fusion bond. A weld or a solder is provided as a fusion bond. Induction or reflow soldering is advantageously used for soldering.
An object of the present invention concerning a method is also achieved, for example, by providing a method of producing a permanent, electrically conductive connection, in which a cable or conductor is co
Abrams Neil
Dinh Phuong KT
Kenyon & Kenyon
Robert & Bosch GmbH
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