Electrical connectors – With insulation other than conductor sheath – Insulating body with spaced – electrically interconnected,...
Reexamination Certificate
2000-02-29
2001-09-18
Ta, Tho D. (Department: 2833)
Electrical connectors
With insulation other than conductor sheath
Insulating body with spaced, electrically interconnected,...
C029S876000
Reexamination Certificate
active
06290551
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to electrical connectors and, more particularly, to ultrasonically welded housing pieces.
2. Prior Art
U.S. Pat. No. 5,380,226 discloses a housing for an electrical connector which comprises two housing pieces that are ultrasonically welded to each other. Ultrasonic welding is not without posing some problems. Efficient welding and sealing at the welds are not easy to obtain without taking some precautions before welding. There is a need for more efficient welding and sealing that has heretofore not been provided.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention, an electrical connector is provided comprising at least one electrical contact; and a housing connected to the contact. The housing has at least two housing pieces comprised of ultrasonically weldable material. A first one of the housing pieces has grooves. A second one of the housing pieces has projections located in the grooves. At least one of the projections comprise an energy director leading section which has a general cross-sectional wedge shape before ultrasonic welding of the first and second housing pieces to each other for use in directing energy during ultrasonic welding.
In accordance with another embodiment of the present invention, an electrical connector is provided comprising at least one electrical contact; and a housing connected to the contact. The housing has at least two housing pieces which are ultrasonically welded to each other. A first one of the housing pieces has grooves which receive projections of a second one of the housing pieces. At least one of the grooves comprise an outer perimeter groove facing an outer lateral side and a bottom side of the first housing piece. The outer perimeter groove comprises a flash director at an outer side of the outer perimeter groove.
In accordance with one method of the present invention, a method for ultrasonically welding two electrical connector housing pieces to each other is provided. The method comprises steps of positioning projections of a first one of the housing pieces into grooves of a second one of the housing pieces, wherein the projections including energy director leading ends which have general cross-sectional wedge shapes, and wherein the grooves include an outer groove facing an outer lateral side and a bottom side of the second housing piece which comprises a flash director at an outer side of the outer groove; ultrasonically welding the two housing pieces to each other; and automatically aligning the first and second housing pieces relative to each other during the step of ultrasonically welding, wherein the wedge shaped leading ends of the projections and the flash director of the outer groove cause self-alignment to a predetermined position of the two pieces with each other.
REFERENCES:
patent: 4301343 (1981-11-01), Jonelis
patent: 4828509 (1989-05-01), Vogel
patent: 5380226 (1995-01-01), Anderson
patent: 5569050 (1996-10-01), Lloyd
FCI USA Inc.
Perman & Green LLP
Ta Tho D.
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