EP3281256B1 - Waterproof electrical connector and method to assemble the same - Google Patents

Description

The invention relates to a method for producing a watertight connector, wherein at least one electrical conductor is inserted via a side opening in a guide channel of an insulator part for holding the conductor, the insulator part is arranged with the conductor in a connector housing, and then at least an inner volume of the connector housing partially poured with a sealant.

The at least one electrical conductor can in the form of a wire, a wire, a strand, a cable or the like. be formed. The insulator part preferably has a plurality of guide channels running side by side, into each of which a conductor is introduced from the side. For example. the conductors are inserted or clipped over the side opening in the respective guide channel in such a way that they emerge from the isolator part or from the guide channel at a cable-side end.

On the one hand, the insulator part has a plug-in end with a plug-in interface carrying a plurality of contact elements, which is set up for coupling to a mating plug connector in a plug-in direction S, and, on the other hand, has the cable-side end on which the conductors emerge from the insulator part. in the Inside the insulator part, the conductors can be electrically connected to the contact elements of the plug-in interface.

By pouring the inner volume of the connector housing with the insulator portion disposed therein, on the one hand, the insulator portion is fastened together with the conductors in the connector housing and integrally connected thereto, so that an overall stable and durable connector results. On the other hand, if the sealant is made fluid-tight, the ingress of water or other liquids into the interior of the connector housing is prevented so that no water can penetrate to the conductors inside the connector housing and potentially cause damage.

As a sealant, for example, a curable adhesive such as a polymer resin composition or the like. be used.

The publication US 2004/008532 A1 relates to a power supply assembly having an internal mounting structure having a power supply circuit and both primary side and secondary side connecting elements electrically connected to the power supply circuit, wherein the insert-type internal structure is made such that the outer surface of the internal structure body is coated with a synthetic resin varnish which is also an integral part of the internal body. The inner structure body may be formed by a hemispherical hollow body and an inner housing cover, so that a cavity for the power supply and the primary side and secondary side connecting elements are integrated or sealed in the inner housing.

The publication US 2007/232140 A1 relates to an electrical connector for connection to a mating connector. The electrical connector has a housing; a wire coating, which is centrally connected to the housing and a sliding closure. The sliding latch is provided at the front with a hole for receiving the snap closure, which is centrally connected to the wire cover and slidably connected to the housing. The sliding tab has a hole on the front for the snap-in connection with the closure receptacle on the mating connector. The housing comprises at least one Bearing surface for the displacement of the front of the slide fastener in the ramp surface along the housing.

The publication EP 2 458 691 A1 refers to a plug-in power supply for supplying a consumer with a low voltage. The power supply comprises at least one power plug contact which is connectable to a mains voltage, at least one output terminal for outputting the low voltage, and a voltage converter unit with at least one electronic component for converting the mains voltage into the low voltage. The power supply has a housing with a housing base element and a cover element, wherein the power plug contact is held on the housing. The voltage converter unit is mounted on a circuit carrier which is in a plug-in direction of the power plug contact. is arranged in the housing base element, that a defined to be insulated first region of the circuit substrate is received in a housing enclosed by walls of the housing base Vergussraum which is filled with an electrically insulating potting compound, so that to be isolated first region of the circuit substrate of the potting compound is covered, while a second region of the circuit substrate, on which the at least one electronic component is arranged, is non-poured.

The publication EP 1 587 176 A1 discloses a connection device for the sealed connection of conductors of a cable, in particular to an electronic assembly in a housing, which is provided with at least one or more openings, wherein the conductors of the cable are respectively connected to a male or a female part, which for mating with a corresponding Socket or plug part is designed on the electronic module, and wherein the male or female part to which the conductors of the cable are connected, projecting at least partially out of the opening of the housing to the outside. In this case, at least one latchable at the respective opening of the housing housing is provided, which is pushed over the out of the housing (1) projecting portion of the male or female part and having a first and a second sealing ring, one of which the transition region between the Outer casing and the breakthrough seals and the other the area of the passage of the cable or its conductor in the Outer housing seals. However, it has been found that the course of the at least one conductor in the guide channel of the insulator part can change due to the pouring out of the connector housing, which can adversely affect the electrical and mechanical properties of the connector and the signal transmission by means of the connector.

In view of the described problems, it is the object of the present invention to provide a waterproof connector with an insulator part molded into a connector housing which, in spite of the pouring, provides optimum mechanical and electrical properties.

This object is achieved by a development of the method described in the introduction with the method steps indicated in claim 1. In the manufacturing method according to the invention, the side opening of the guide channel of the insulator part is at least partially closed after the insertion of the at least one conductor into the guide channel prior to the pouring out of the connector housing.

The invention is based on the knowledge that after the introduction of the conductor into the guide channel of the insulator part via a side opening the pasty or viscous sealant can penetrate the pouring through the open side opening in the interior of the insulator part up to the guide channel, whereby the course of Ladder can be changed in the guide channel. For example. the sealing compound which has penetrated into the guide channel undergoes a change in volume in the course of hardening, whereby the conductor can be pressed mechanically against a wall of the guide channel or against the adjacent conductors. A change in the dielectric between multiple conductors and / or a change in the mutual distance through the sealant influences the characteristic impedance and other electrical properties. Furthermore, the contact points between the conductors and the contact elements in the interior of the insulator part by the penetrated sealant mechanically, for example. Mechanically loaded on train, which can reduce the durability of the connector.

The step of closing the side opening after insertion of the at least one conductor minimizes penetration of sealing compound into the interior of the insulator part and preferably completely prevents it. The side opening does not necessarily have to be sealed watertight or gas-tight. If necessary, a significantly lower degree of impermeability is sufficient since the viscous sealant can not penetrate through small cracks or gaps.

The side opening of the insulator part can be closed in any manner. In view of a good tightness and ease of installation, it has proven to be expedient that the side opening is covered with a lid. The cover may be formed as a separate cover for lateral laying and connecting to the insulator part. Alternatively, the cover may be adjustably attached to the insulator member so as to be adjustable from an open position in which it releases the side opening for insertion of the conductors to a closed position in which it closes the side opening.

Preferably, at the cable-side end of the insulator part, on which the conductors emerge from the insulator part, a flexible contact region of the insulator part under pressure seals laterally against the conductors, so that penetration of sealant into the guide channel is prevented even at the cable end of the insulator part , For this purpose, the lid may have a pressure area for pressing the abutment area of the insulator part against the conductors in the closed position, between which the conductors are made.

The side opening to be closed according to the invention preferably bounds the guide channel at least in sections laterally and not necessarily (but possibly additionally) at its cable-side end, at which the conductors exit from the insulator part.

According to a particularly preferred embodiment of the invention, the lid is mounted pivotably about a pivot axis on the insulator part and is pivoted into a closed position in which it at least partially and preferably completely closes the side opening. In other words, the lid is a hinged lid. For example. the lid is in the closed position preferably circumferentially at an edge of the side opening, so that no sealant between the edge and the adjoining lid can penetrate.

In order to prevent that the cover can be released again from the closed position, it is preferably locked in the closed position, for which purpose a locking mechanism can be provided between the cover and the insulator part.

A good and reliable closure of the side opening can be achieved in that the cover has a covering surface for covering the side opening. A good and reliable locking of the lid can be achieved by projecting from the cover surface at least one, preferably two locking elements with engagement portions which are each clipped into an engagement recess such as a Einclipsöffnung the insulator part.

The locking elements preferably project substantially perpendicularly from the covering surface and are formed in the form of flexible struts or rods. The flexible struts or rods may protrude on two sides of the cover surface of the lid so that they include in the closed position of the lid, the conductor at the cable end of the insulator part between them and press after clipping into the respective Einclipsöffnungen a contact portion of the insulator member against the head , In this way, penetration of sealant at the cable end of the guide channels can be reliably prevented.

By pressing the two flexible struts or rods toward each other in the direction of the insulator part, the engaging portions each having a widening are each clipped into the associated clip-in opening of the insulator part.

According to a particularly preferred embodiment, the connector produced according to the invention is an angle connector, wherein the plugging direction extends at an angle of preferably 90 ° to the exit direction of the conductor from the connector housing. In other words, the guide channel with angle connectors a curve or curvature of preferably about 90 °. In an angle connector, it is not possible to linearly introduce the conductor via the cable-side opening of the guide channels in the connector, but the Due to the curved course of the guide channels, conductors must at least partially be introduced into the guide channels via a side opening, which makes the insulator part particularly susceptible to the penetration of sealing compound during pouring.

According to the inventive method, the at least one conductor is preferably inserted into the insulating part substantially in the plugging direction of the connector through the side opening, and has such a curved course or is bent such that it extends at an angle on the cable side, in particular approximately perpendicular to the plugging direction exits the insulator part. Subsequently, the side opening can be closed with the lid.

With regard to the transmission of multiple signals and / or currents, it is advantageous that more than one conductor, in particular two, three, four or more conductors such as wires or strands are introduced via the side opening in each case an associated guide channel of the insulator part and the side opening then closed with the lid. In cross-section preferably four guide channels in an approximately square arrangement in the interior of the insulator part run side by side.

The connector housing, in which the insulating member is poured, preferably has a fixing portion for attaching the plug-side end of the insulator member and a main body of the insulator member receiving trough portion which is filled during pouring with the sealant. After pouring, the sealant may preferably be cured by means of UV radiation and the connector housing subsequently closed.

In another aspect, the present invention relates to a waterproof connector as can be made according to the method of the invention. An inventive connector has an integrally molded in a connector housing insulator part with at least one guide channel, in which an electrical conductor is held. The conductor exits the guide channel at a cable end. A side opening of the guide channel of the insulator part is closed by means of a lid. Due to the lid can penetrate the viscous sealant in the pouring of the connector housing Inside of the insulator part are prevented by the side opening. Consequently, the interior of the insulator part of the connector according to the invention is preferably completely free of sealant, which leads to advantageous mechanical and electrical properties of the connector.

Preferably, the cast-insulator part has four side-by-side guide channels, in each of which a conductor is held, wherein the four conductors emerge from the insulator part at the cable end. Through the closed side opening with the lid all four conductors have been inserted from the side into the insulator part.

The connector according to the invention may alternatively or additionally comprise some or all of the features described above in any combination, reference being made to the above description paragraphs to avoid repetition.

According to a particularly preferred embodiment, the lid is connected via a pivot joint to the insulator part and pivoted in the finished connector in a closed position in which it rests against the side opening at least partially encircling edge of the insulator part such that no sealant between the edge of the side opening and can penetrate the lid.

The connector according to the invention preferably has a locking mechanism which holds the cover in the closed position in order to prevent an automatic opening of the cover during pouring out. For this purpose, the cover may, on the one hand, have a covering surface which covers an outer boundary surface of the insulator part which has the side opening and, on the other hand, locking elements which project from the covering surface and have engagement sections which engage in engagement sections, such as clip-in openings of the insulator part.

By clipping in the engagement sections of the locking elements, a contact section of the insulator part can additionally be pressed on the cable-side end of the insulator part from both sides against the exiting conductor, so that no sealing compound can penetrate into the guide channel even at the cable-side end of the insulator part.

According to a further aspect, the present invention relates to an insulator part of a connector according to the invention. The insulator member preferably includes a plurality of juxtaposed guide channels for receiving conductors such as wires or strands which exit the insulator portion at a cable end. The conductors can be inserted through a side opening in the guide channel. Furthermore, the insulator part has a cover, such as a lid for closing the side opening, so that during pouring no sealant can penetrate into the interior of the insulator part.

The insulator part is preferably set up to provide an angle plug connector and has a plug-in end which can be plugged in the direction of a mating plug connector in a plugging direction. The plug-in direction extends at an angle (preferably 90 °) to the outlet direction of the conductor from the guide channel.

Fig. 1a bis 1d:

vier Schritte bei der Herstellung eines Steckverbinders gemäß dem erfindungsgemäßen Verfahren, wobei jeweils zwei Seitenansichten dargestellt sind,

Fig. 2:

eine Seitenansicht eines erfindungsgemäßen Steckverbinders, und

Fig. 3:

eine perspektivische Ansicht eines erfindungsgemäßen Steckverbinders vor dem Ausgießen.

The lid can be locked by means of a locking mechanism in a closed position in which it closes the side opening. Reference is made to the above statements.
In the following description, the invention will be described with reference to the accompanying drawings. Show:

1a to 1d:

Four steps in the production of a connector according to the method of the invention, wherein two side views are shown,

Fig. 2:

a side view of a connector according to the invention, and

3:

a perspective view of a connector according to the invention before pouring.

In the FIGS. 1a to 1d are four steps of the inventive method for producing an angle connector 100 with a plug-side end 110 for coupling with a mating connector and a cable-side end 120 at which a plurality of (four example here) conductors emerge from the connector shown.

In each case, the four conductors 30 and an insulator part 20 for holding the four conductors 30 are shown, on the one hand with a view of the cable end of the insulator part (left) and on the other in a side view (right). The four conductors 30 are received in four guide channels 12 of the insulator part 20. Subsequently, the insulator portion 20 is poured with the four inserted conductors 30 in a connector housing 40, to prevent in this way the ingress of water into the interior of the connector 100.

FIG. 1a shows the four conductors 30 before insertion into the guide channels 12 of the insulator part 20 through a side opening 25. The conductors 30 embodied as strands are introduced in the insertion direction S through the side opening 25 into the guide channels 12 until they are in the interior of the insulator part 20 contact elements of Contact connector. Subsequently, the four conductors 30 are bent (see Fig. 1b ) that they emerge at the cable-side end of the insulator part 20 in an exit direction from the insulator part 20, which extends substantially perpendicular to the insertion direction S. When the conductors 30 are introduced, flexibly formed abutment sections 14 of the insulator part 20 deflect slightly outwards and then snap back into their starting position so that the abutment sections 14 fit snugly against the conductors 30 (see FIG Fig. 1b ).

In FIG. 1b is clearly the upwardly open side opening 25 of the guide channels 12 and a pivotally mounted on the insulator part 20 lid 22 shown, which is in an open position in which it releases the side opening 25.

As in Figure 1c is shown, the lid 22 can be pivoted about a pivot axis A in a closed position in which it covers the side opening 25 and closes. In the closed position, a covering surface 24 of the lid lies flat against an edge of the side opening 25. Two locking elements 26 in the form of elastic struts project vertically from the covering surface 24 in such a way that the conductors 30 are arranged on the cable-side end of the insulator part 20 between the locking elements 26. Engagement sections 28 attached to the locking elements 26 do not yet engage in clip-in openings of the insulator part 20 (see FIG Fig. 1c , Left).

To lock the lid 22, the two locking elements 26 are pressed towards each other, whereby the engaging portions 28 each engage in the associated Einclipsöffnung (see Fig. 1d , Left). The lid 22 can not be solved now.

In addition, the lid is pressed by the locking elements 26 fixed to the edge of the side opening 25. Furthermore, the locking elements 26 press the abutment region 14 of the insulator part from both sides against the conductors 30 and in this way seal the cable-side end of the guide channels against the ingress of sealing compound.

As in Fig. 3 is shown, the closed and locked insulator portion 20 is disposed in a trough portion of a connector housing 40, wherein the trough portion has a pourable inner volume 42. This inner volume 42 is filled with a curable sealing compound which, due to the cover 22, can not penetrate into the interior of the insulator part 20 or into the guide channels 12.

An inventive connector 100 with a connector housing 40 with molded insulator part 20 with closed cover 22 is in Fig. 2 shown in a side view. The position of the insulator part 20 with the conductors 30, which emerge from the insulator part 20 at the cable end, inside the connector housing 40 is partially shown for clarity.

Claims (10)

1. Method for producing a water-tight plug connector (100) in which at least one electric conductor (30) such as a wire is introduced into a guide channel (12) of an insulator part (20) via a lateral opening (25) in order to hold the conductor, the insulator part (20) with the introduced conductor is arranged in a plug connector housing (40), and an internal volume (42) of the plug connector housing is then at least partially filled with a sealing compound, characterised in that the lateral opening (25) is closed prior to filling.
2. Method according to claim 1, characterised in that the lateral opening (25) is covered with a cover (22).
3. Method according to claim 2, characterised in that the cover (22), attached to the insulator part (20) so as to swivel around a swivel axis (A), is swivelled into a closed position in which it lies against an at least partially peripheral edge of the lateral opening (25).
4. Method according to claim 2 or 3, characterised in that the cover (22) is locked, in particular clipped, into a closed position.
5. Method according to one of the preceding claims, characterised in that the cover (22) has a cover surface (24) for covering the lateral opening (25) and at least two locking elements (26) projecting transversely, in particular roughly perpendicular, to the cover surface, with engaging sections (28) which are each clipped into a clip-in opening of the insulator part (20).
6. Method according to one of the preceding claims, wherein the plug connector (100) is an angle plug connector, characterised in that the at least one conductor (30) is substantially introduced into the insulator part (20) through the lateral opening (25) in a plugging direction (S) of the plug connector and runs in such a curve that it emerges from the insulator part on the cable side at an angle, in particular roughly perpendicular to the plugging direction (S).
7. Water-tight plug connector (100), manufactured by means of the method according to one of the preceding claims, with an insulator part (20) cast into a plug connector housing (40) with a guide channel within which at least one electrical conductor (30) is held, characterised in that a lateral opening of the guide channel of the insulator part (20) is closed with a cover (22).
8. Plug connector according to claim 7, characterised in that the cover (22) is connected with the insulator part (20) via a hinged joint and is swivelled into a closed position in which it lies against an edge of the insulator part (20) which at least partially surrounds the lateral opening (25).
9. Plug connector according to claim 7 or 8, characterised by a locking mechanism holding the cover (22) in a closed position with locking elements (26) projecting from a cover surface (24) of the cover with engaging sections (28) which engage in clip-in openings of the insulator part (20).
10. Insulator part (20) of a plug connector (100) according to one of the claims 7 to 9.

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