Modular connector with injection molded seal

Abstract

A modular connector comprising a housing having at least two seats for receiving contact terminal modules; characterized in that the housing comprises: a first injection molded seal, wherein the seal is molded directly onto the connector housing for sealing the housing with respect to a corresponding mating connector housing; and a second injection molded seal, wherein the seal is molded directly onto the at least two seats for sealing the housing with respect to the inserted contact terminal modules.

Description

Technical Field

[0001] This disclosure relates to a modular connector and a method for manufacturing the modular connector. Specifically, this disclosure relates to a connector having seals for a housing and a module base, thereby ensuring an effective seal to the mating connector housing and the inserted contact terminal module. Background Technology

[0002] In the field of modular connectors, individual sealing elements are commonly used to ensure proper sealing between the connector housing and the contact terminal module. Known systems typically involve the use of gaskets, O-rings, or other discrete sealing components that must be assembled into the connector housing. These individual sealing elements are often held in place by retainers, which increases the complexity of the assembly process and may increase the likelihood of incorrect installation or seal failure. Additionally, these seals can easily shift or be damaged during handling and use, compromising the integrity of the connection.

[0003] Based on known modular connector systems, the sealing process can be cumbersome and time-consuming. The need to insert and secure individual seals into the connector housing can lead to variations in seal quality and the possibility of human or machine errors. Furthermore, reliance on multiple components for sealing increases the number of parts that must be managed, stored, and assembled, potentially complicating inventory management and increasing production costs. The use of individual seals also requires additional design considerations to accommodate retaining elements and ensure the seal remains in place during operation.

[0004] Despite substantial progress in the field of modular connectors, there remains a need for an improved sealing solution that simplifies the assembly process, reduces the risk of seal failure, and enhances the overall reliability of the connection. Therefore, the fundamental technical problem of this invention is to provide a modular connector system that at least partially overcomes the shortcomings of known systems. Summary of the Invention

[0005] The object of this invention is to provide a modular connector that overcomes one or more of the shortcomings of known systems. This is achieved by the modular connector according to claim 1.

[0006] A first aspect of the invention provides a modular connector comprising a housing having at least two seats for receiving contact terminal modules; characterized in that the housing comprises: a first injection-molded seal, wherein the seal is directly molded onto the connector housing for sealing the housing relative to a corresponding mating connector housing; and a second injection-molded seal, wherein the seal is directly molded onto the at least two seats for sealing the housing relative to an inserted contact terminal module.

[0007] The described subject matter relates to a modular connector designed to improve sealing efficiency and reduce the number of parts required for assembly. The modular connector includes a housing having at least two seats intended for receiving contact terminal modules. The housing is equipped with a first injection-molded seal directly molded into the connector housing itself. This seal serves to seal the housing relative to the corresponding mating connector housing, thereby ensuring a strong and leak-proof connection between the two housings. Furthermore, the housing includes a second injection-molded seal directly molded into the seats within the housing. This second seal is designed to seal the housing relative to the inserted contact terminal modules, thereby providing an independent seal for each module and enhancing the overall integrity of the connector.

[0008] The term "modular connector" refers to a connector capable of accommodating multiple contact terminal modules, allowing for flexibility and customization in its use. "House" refers to the connector body that holds the contact terminal modules. "Socket" is the specific location within the house where the contact terminal modules are inserted. "Injection-molded seal" refers to a seal formed by directly injecting a sealing material such as silicone onto the house or socket, creating a permanent and integrated seal.

[0009] The advantages of this design include a reduced number of parts required for the connector, as the seal is integrally formed with the housing and seat, rather than being a separate component that needs to be assembled. This integration also protects the modular seal within the housing, reducing the risk of damage or misalignment. The design allows for a more compact package because no additional seal holder is required. Furthermore, the injection molding process ensures a secure connection between the seal and the housing, eliminating the need for pressure to hold the seal in place compared to conventional sealing methods and reducing space requirements. A distribution system for the sealing material ensures uniform filling of the sealing cavity, thereby enhancing the quality and reliability of the seal.

[0010] In a first embodiment of the modular connector according to the first aspect, the housing includes channels for distributing sealing material.

[0011] These channels facilitate the effective distribution of sealing material, ensuring a consistent and reliable seal throughout the housing. This feature enhances the overall integrity and performance of the modular connector by providing a more uniform application of the sealing material, thereby improving its ability to prevent contaminant ingress and maintain electrical connection. The inclusion of channels for distributing sealing material represents an advancement in modular connector design, contributing to its durability and reliability in a wide range of applications.

[0012] In another embodiment of the modular connector, the housing seal is made of a different material than the module seal.

[0013] This difference in material composition brings several advantages, including the ability to optimize the sealing characteristics of each seal based on its specific function and location within the modular connector. Housing seals, directly molded onto the connector housing, are designed to ensure a robust seal relative to the corresponding mating connector housing, potentially requiring materials with high durability and resistance to environmental factors such as moisture, temperature variations, and mechanical stress. On the other hand, modular seals, directly molded onto the sockets for contact terminal modules, may require materials that provide a more flexible and adaptable seal to accommodate the insertion and removal of the contact terminal modules, ensuring a reliable connection while allowing for easy maintenance and replacement.

[0014] In another embodiment of the modular connector, the seal is made of a two-component sealing material, particularly a two-component silicone material.

[0015] This embodiment introduces a feature where the seal is made of a two-component sealing material, specifically a two-component silicone material. This feature enhances the sealing properties of the connector by utilizing a material known for its durability and flexibility, thereby ensuring a more reliable and robust seal. The use of a two-component silicone material improves resistance to environmental factors such as temperature variations and chemical exposure, thus extending the connector's lifespan and performance. This material selection also allows for better adhesion to the housing and seat, ensuring the seal remains firmly in place and maintains its integrity over time.

[0016] In another embodiment of the modular connector, the connector housing includes ribs designed to prevent silicone spillage during the injection molding process.

[0017] These ribs ensure that the silicone used for the seal does not spill or contaminate other parts of the connector during manufacturing, thus maintaining the integrity and functionality of the seal and the connector as a whole. Preferably, the ribs conform to the shape and form of the injection seal, allowing the sealing material to flow along the ribs, thus forming a barrier for the injection sealing material.

[0018] In another embodiment of the modular connector, the housing includes an overflow opening to allow inspection of the integrity and quality of the sealant injection.

[0019] The overflow opening serves as a mechanism for communication between internal components and the external environment, allowing for visual or instrumental inspection of the seals. This new feature introduced by the overflow opening ensures that the injection-molded seals are correctly formed and adhered to the housing and seat, thereby enhancing connector reliability and performance by preventing incomplete or defective seals. This inspection capability helps maintain the integrity of the modular connector, ensuring that it provides an effective seal relative to the corresponding mating connector housing and the inserted contact terminal module.

[0020] In another embodiment of the modular connector, the housing includes at least two distribution channels, wherein the at least two channels have different diameters, such that the outer sealing cavity and the inner cavity closer to the injection port are filled with sealant material almost simultaneously.

[0021] This feature enhances the efficiency and uniformity of the sealing process, ensuring that both the inner and outer cavities are adequately sealed simultaneously. The varying channel diameters facilitate uniform distribution of the sealant material, preventing any delays or uneven filling that could compromise seal integrity. This connection mechanism between the distribution channels and the sealing cavity ensures a reliable and robust seal, thereby improving the overall performance and durability of the modular connector.

[0022] In another embodiment of the modular connector, all module seals are formed by a single injection process starting from the same injection port.

[0023] This implementation introduces a specific mechanism for forming modular seals within a modular connector. It specifies that all modular seals are formed through a single injection process originating from the same injection port. This feature brings efficiency and uniformity to the manufacturing process, ensuring that seals are produced continuously in a single operation, rather than through multiple separate injections. By using a single injection port, the process reduces complexity and potential failure points, resulting in more reliable seals and potentially lower production costs. This method also enhances the structural integrity of the seals, as they are formed simultaneously and are therefore more likely to possess uniform characteristics and performance properties. The single-injection process simplifies the design and assembly of modular connectors, helps streamline the production workflow, and potentially reduces manufacturing time.

[0024] In another embodiment of the modular connector, the modular connector does not include a separate sealing element.

[0025] This feature enhances the design of the modular connector by eliminating the need for additional components required for sealing applications. By stating that the modular connector does not include a separate sealing element, this embodiment emphasizes the integral formation and efficiency of the sealing mechanism of the invention. This simplifies the design and makes it more compact, thereby reducing the complexity and potential failure points associated with separate sealing elements. The absence of a separate sealing element also indicates a reduction in the materials used and the required parts, contributing to environmental benefits and cost savings.

[0026] In another embodiment of the modular connector, the module seal is protected inside the housing.

[0027] This implementation introduces a feature where the modular seal is protected within the housing, eliminating the need for separate seal holders. This new feature ensures the seal is protected within the housing structure, thereby enhancing its durability and reliability by preventing external damage or displacement. Furthermore, the elimination of separate seal holders simplifies the design and assembly process of the modular connector, potentially reducing manufacturing costs and improving ease of use.

[0028] In another embodiment of the modular connector, the housing has exactly two, four, five, six, or eight module seats.

[0029] This implementation introduces a specification regarding the number of module sockets within the housing of the modular connector. Specifically, the housing is defined as having exactly two, four, five, six, or eight module sockets. This feature brings a degree of flexibility to modular connector design, allowing it to be adapted to different configurations based on the specific requirements of the application. This feature also potentially simplifies the manufacturing process by standardizing housing designs to accommodate these specific socket numbers, thereby improving efficiency and reducing costs.

[0030] In another embodiment of the modular connector, a contact terminal module is mounted in each module housing of the connector housing.

[0031] This arrangement ensures that the modular connector maintains a structured and organized construction. This feature enhances the connector's modularity by ensuring that each module is independently supported and isolated within its own housing, thereby reducing the risk of interference or misalignment with adjacent modules. This aspect outlines the presence of injection-molded seals directly molded onto the connector housing and housing, providing a robust sealing mechanism relative to the corresponding mating connector housing and the inserted contact terminal module.

[0032] A second aspect of the invention provides a modular connector system comprising two modular connectors according to any one of the embodiments, wherein the two modular connectors are corresponding male and female connectors adapted to be mounted on each other.

[0033] The advantages of this design include: reducing the number of parts required for the female connector, protecting the module seals inside the housing, and achieving a more compact package without the need for seal holders.

[0034] A third aspect of the invention provides a method for manufacturing a modular connector, comprising: providing a connector housing having at least two module seats; injecting a sealing material directly onto the connector housing for sealing the housing relative to a corresponding mating connector housing; injecting the sealing material directly into at least two seats for sealing the housing relative to inserted contact terminal modules, and distributing the sealing material through channels in the housing; and allowing the sealing material to cure to form a molded seal directly connected to the housing.

[0035] The method for manufacturing modular connectors involves several steps. First, a connector housing with at least two module sockets is provided. Then, a sealing material is injected directly onto the connector housing to seal it relative to the corresponding mating connector housing. Additionally, before, after, or simultaneously with sealing the housing, the sealing material is injected directly into the module sockets to seal the housing relative to the inserted contact terminal modules. The sealing material is distributed through channels in the housing. Finally, the sealing material is allowed to cure, thereby forming a molded seal that is directly connected to the housing.

[0036] This embodiment preferably uses different injection ports for the sealing material used for the housing seal and the sealing material used for the module seal. This difference in injection ports allows for more controlled and precise application of the sealing material, thereby improving seal effectiveness and reliability. By utilizing separate injection ports, this method ensures that the sealing material is properly distributed to the intended areas, thus minimizing the risk of cross-contamination or accidental material mixing. The use of different injection ports for the housing seal and the module seal also facilitates accommodating different sealing materials or formulations suitable for the specific needs of each sealing area, thereby optimizing the connector's performance and durability. Attached Figure Description

[0037] In the following description, various aspects of the subject matter of this disclosure are described in detail with reference to the accompanying drawings, in which: Figure 1 An exploded view of a prior art connector housing assembly is shown.

[0038] Figure 2 Figure (a) illustrates an embodiment of a modular connector having an injection port and a channel for distributing sealing material for the module seat.

[0039] Figure 2 Figure (b) is shown in cross-section and rotated 90°. Figure 2 Example of Figure (a).

[0040] Figure 3 Figure (a) shows a rotation of 180° Figure 2The embodiment of Figure (a) indicates the injection port and the channel for distributing the sealing material for the housing.

[0041] Figure 3 Figure (b) is shown in cross-section and rotated 90°. Figure 3 Example of Figure (a).

[0042] Figure 4 A modular connector housing is shown in a bottom view, wherein the modular connector housing has multiple sockets for receiving contact terminal modules.

[0043] Figure 5 An embodiment of a female modular connector housing with an injection port and a seal is shown.

[0044] Figure 6 An embodiment of a male modular connector housing is shown, which corresponds to Figure 5 The mother housing has a module seat and an injection port for the seal.

[0045] Figure 7 Various embodiments of modular connectors with different numbers of module seats and injection ports are shown. Detailed Implementation

[0046] Figure 1 This diagram illustrates a prior art connector assembly comprising several components. A housing 1 forms the central structure of the connector, providing a primary enclosure for other components. A gasket seal 2 is positioned above the housing 1, providing a sealing function to ensure the connector remains impermeable to external elements. A housing seal 3 is located below the housing 1, acting as an additional sealing layer to enhance the connector's integrity against environmental factors. A housing seal retainer 4 is located at the bottom of the assembly and is designed to hold the housing seal 3 in place, preventing displacement or misalignment during operation. Finally, a gasket seal retainer 5 is positioned at the top of the assembly, ensuring the gasket seal 2 remains securely attached to the housing 1, thus maintaining its sealing effectiveness. This construction illustrates a layered approach used in the prior art to achieve robust sealing and structural stability in connector assemblies.

[0047] Figure 2 A modular connector 20 according to the invention is shown, comprising a housing 21 having various integrally formed components for sealing and receiving contact terminal modules. Figure 2In Figure (a), housing 21 is depicted as having an injection port 22 for the module seal. Channel 23 distributes sealant from injection port 22 to a designated area within the housing. Overflow opening 27 is visible, allowing inspection of the integrity and quality of the sealant injection process. Housing seal 34 is directly molded onto housing 21, thereby ensuring a robust seal relative to the corresponding mating connector housing.

[0048] Figure 2 Figure (b) shows a cross-sectional view of the modular connector 20, highlighting the housing 25 for receiving contact terminal modules. Module seal 24 is molded directly to the housing 25, providing a seal against any inserted contact terminal modules. Channel 23 facilitates the distribution of sealing material to the housing 25, ensuring a consistent seal throughout the housing.

[0049] The injection port 22 is strategically positioned to allow for efficient injection of sealing material into the channel 23. The channel 23 is designed to distribute the sealing material evenly across the module seat 25, thereby ensuring uniform formation of the module seal 24.

[0050] The modular connector 20 is designed to accommodate multiple contact terminal modules, wherein each module housing 25 receives a module and is sealed by a module seal 24. A housing seal 34 provides an additional sealing layer, thereby ensuring a robust seal between the connector housing 21 and the corresponding mating connector housing.

[0051] Figure 3 (a) diagram from and Figure 2 The opposite side of Figure (a) shows the same modular connector 20 (i.e., rotated 180°). The housing 21 includes an injection port 32 for a housing seal 34. The housing seal 34 is molded directly onto the housing 21, thereby providing a seal relative to the corresponding mating connector housing. The injection port 32 connects to a channel 33 that distributes the sealant material throughout the housing 21. An overflow opening 27 is included in the housing 21 to allow inspection of the integrity and quality of the sealant injection.

[0052] Figure 3 Figure (b) shows the relative to Figure 3 (a) is a cross-sectional view of the modular connector 20 rotated 90°. Figure 3 Figure (b) shows the internal distribution of the sealing material and the formation of the housing seal 34.

[0053] Figure 4The modular connector 20 is shown as viewed from the bottom. Multiple (four) sockets 25, each designed to accommodate a contact terminal module, can be seen. The housing 21 has a rectangular structure, providing a robust frame for the modular connector 20. The sockets are arranged symmetrically, thus optimizing the space distribution within the housing 21.

[0054] A key feature is the presence of injection-molded seals 24 and 34. Seal 24 is directly molded onto each module seat 25, thereby ensuring a tight seal between the housing 21 and any inserted contact terminal module. This seal helps maintain connection integrity and prevents the ingress of any contaminants or moisture that could impair the electrical performance of the connector.

[0055] Furthermore, the housing seal 34 serves to seal the housing 21 relative to the corresponding mating connector housing, thereby ensuring a strong and reliable connection between the modular connector 20 and its mating part. The housing seal 34 is strategically positioned along the outer edge of the housing 21 to provide a continuous barrier that enhances the connector's resistance to environmental factors.

[0056] The figure also highlights the ribs 28 present within the housing 21. These ribs are designed to prevent silicone overflow during the injection molding process, thereby ensuring precise distribution and containment of the sealing material within designated areas. The ribs 28 follow the flow and arrangement of the housing seal 34 and form a barrier for the sealing material.

[0057] Figure 5 Two views of the modular connector 50, specifically the female modular connector housing 51, are shown from different perspectives (rotated 180°). The housing 51 is designed to house contact terminal modules within its (six) module seats 55. The housing 51 has an injection port 52 for module seals and another injection port 532 for housing seals. A module sealing channel 53 is visible, distributing sealing material from the injection port 52 to the module seat 55. A housing sealing channel 533 is also shown, distributing sealing material from the injection port 532 to the housing seal 534. The housing seal 534 is directly molded onto the connector housing 51, thereby providing a seal relative to the corresponding mating connector housing. The module seats 55 are designed to receive contact terminal modules, and the module seals are directly molded onto these seats to ensure a robust seal relative to the inserted contact terminal modules. The modular connector 50 does not include individual sealing elements because all seals are directly molded onto the housing 51.

[0058] Figure 6An embodiment of the modular connector 60 is shown, specifically focusing on the male connector housing 61, which is shown from two perspectives (rotated 180°). The connector housing 61 is the mating member of the female housing 51, such that the two housings together form a modular connector system. Housing 61 also includes six module holders 65, designed to accommodate contact terminal modules. In the mated state of the male housing 61 and female housing 51, the corresponding module holders are aligned to allow electrical connection between contact terminals assigned to corresponding modules arranged in holders 55, 65.

[0059] Figure 6 The right-hand view highlights injection port 62, a critical component in the connector manufacturing process. This port is used to inject sealing material for sealing the module housing. The sealing process is further supported by distribution channels 63, visible in the figure. These channels facilitate the uniform distribution of sealing material throughout the housing, ensuring a uniform seal that enhances connector reliability and performance.

[0060] The connector housing 61 is also equipped with overflow openings 67, which serve a dual purpose. First, these openings allow inspection of the integrity and quality of the sealant injection, providing visual confirmation that the seal has been correctly formed. Second, they act as a safety feature, preventing excessive sealant buildup within the housing, which could potentially compromise the integrity of the seal.

[0061] Figure 7 Various embodiments of modular connectors with different module base configurations are shown. The figure illustrates six different modular connectors, each designated by reference numerals 70a, 70b, 70c, 70d, 70e, and 70f. These connectors are distinguished by the number of module bases 75 they possess, ranging from two to eight bases.

[0062] The top row of the figure shows a top view of the connectors, highlighting the module bases 75. Each connector housing is designed to accommodate a specific number of contact terminal modules. For example, connector 70a has three module bases 75, while connector 70b has two module bases 75. Connector 70c includes four module bases 75 in a rectangular configuration, connector 70d has six module bases 75, connector 70e includes eight module bases 75, and connector 70f is equipped with five module bases 75 arranged linearly.

[0063] The bottom row of the figure presents a side view of the connector, highlighting the injection port 72 and the distribution channel 73. The injection port 72 serves as the entry point for the sealing material, which is then distributed through the channel 73 to form a seal around the module base 75.

[0064] Each connector housing is equipped with channels 73 of different diameters and lengths, thereby ensuring that the outer sealing cavity and the inner cavity closer to the injection port 72 are filled with sealant material almost simultaneously.

[0065] Figure 7 The modular connector depicted is designed to be universal and adaptable, accommodating contact terminal modules with different constructions. Seals formed through an injection molding process are directly molded onto the connector housing and module base, providing a robust and reliable sealing solution independent of the number of module bases incorporated into the respective housing. This eliminates the need for separate sealing elements and seal holders, thus simplifying connector assembly and maintenance.

[0066] List of reference numerals in the attached diagram: 1. Existing connector housing 2. Gasket seal 3. Housing seals 4. Housing seal retention parts 5. Gasket Seal Retention Components 20 Modular Connectors 50 female modular connector 21, 51, 61 Casing 22, 52, 62, 72 are injection ports used for module seals. Channels 23, 53, 63, and 73 (for module seals) Module seals for 24 and 54 25, 55, 65, 75 are sockets for receiving contact terminal modules. 26 latch arms 27 Overflow opening 28 Ribs to prevent silicone leakage 32, 532 Injection ports for housing seals Channels 33 and 533 (for housing seals) 34, 534 Housing seals 60mm modular connector 70a Modular connector with three module sockets 70b Modular connector with two module sockets 70c Modular connector with four module sockets 70d Modular connector with six module sockets 70e Modular connector with eight module sockets 70F Modular connector with five module sockets

Claims

1. A modular connector (20; 50; 60; 70) comprising a housing (21; 51; 61) having at least two sockets (25; 55; 65; 75) for receiving contact terminal modules; characterized in that, The housing includes a first injection-molded seal (34; 534), wherein the seal is directly molded onto the connector housing (21; 51; 61) for sealing the housing (21; 51; 61) relative to a corresponding mating connector housing; and A second injection-molded seal (24; 54) is directly molded to the at least two seats for sealing the housing (21; 51; 61) relative to the inserted contact terminal module.

2. The modular connector (20; 50; 60; 70) according to claim 1, characterized in that, The housing (21; 51; 61) includes channels (23; 53; 63; 73) for distributing sealing material.

3. The modular connector (20; 50; 60; 70) according to claim 1 or 2, characterized in that, The housing seal is made of a different material than the module seals (24, 54).

4. The modular connector (20; 50; 60; 70) according to any one of the preceding claims, characterized in that, The seals (24; 54; 34; 534) are made of two-component (2K) sealing materials, particularly two-component silicone materials.

5. The modular connector (20; 50; 60; 70) according to any one of the preceding claims, characterized in that, The connector housing (21; 51; 61) includes ribs (28) designed to prevent silicone spillage during the injection molding process.

6. The modular connector (20; 50; 60; 70) according to any one of the preceding claims, characterized in that, The housing (21; 51; 61) includes an overflow opening (27) to allow inspection of the integrity and quality of the sealant injection.

7. The modular connector (20; 50; 60; 70) according to any one of the preceding claims, characterized in that, The housing (21; 51; 61) includes at least two distribution channels (23; 53; 63; 73), wherein the at least two channels have different diameters, such that the outer sealing cavity and the inner cavity closer to the injection port (22; 52; 62; 72; 32; 532) are filled with sealant material almost simultaneously.

8. The modular connector (20; 50; 60; 70) according to any one of the preceding claims, characterized in that, All module seals (24; 54) are formed by a single injection process starting from the same injection port (22; 52; 62; 72).

9. The modular connector (20; 50; 60; 70) according to any one of the preceding claims, characterized in that, The modular connectors (20; 50; 60; 70) do not include independent sealing elements.

10. The modular connector (20; 50; 60; 70) according to any one of the preceding claims, characterized in that, The module seals (24, 54) are protected inside the housing (21; 51; 61), thereby eliminating the need for separate seal holders.

11. The modular connector (20; 50; 60; 70) according to any one of the preceding claims, characterized in that, The housing has exactly two, four, five, six or eight module seats (25; 55; 65; 75).

12. The modular connector (20; 50; 60; 70) according to any one of the preceding claims, characterized in that, A contact terminal module is installed in each module holder (25; 55; 65; 75) of the connector housing (21; 51; 61).

13. A modular connector system comprising two modular connectors (50; 60) according to any one of claims 1 to 10, characterized in that, The two modular connectors are corresponding male connectors (60) and female connectors (50) adapted to be installed onto each other.

14. A method of manufacturing a modular connector (20), comprising: Provides at least two module sockets (25; 55; 65； 75) connector housing (21; 51; 61）； The sealing material is injected directly onto the connector housing (21; 51; 61) to seal the housing relative to the corresponding mating connector housing; The sealing material is injected directly into the at least two seats (25; 55; 65; 75) to seal the housing (21; 51; 61) relative to the inserted contact terminal module, and the sealing material is distributed through channels (23; 53; 63; 73) in the housing (21; 51; 61); The sealing material is allowed to cure, thereby forming a molded seal that is directly connected to the housing.

15. The method according to claim 14, characterized in that, The sealing material for the housing seal (34; 534) is injected at a different injection port than that for the module seal (24, 54).

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