Electrical connector and manufacturing process of an electrical connector

Abstract

The invention relates to an electrical connector (100) configured to be paired with a complementary electrical connector (501), the electrical connector (100) comprising a housing element (101), an electrical terminal (300) housed in a corresponding terminal cavity (107) of the housing element (101), and an anti-vibration element (103). The electrical connector (100) is characterized in that the housing element (101) further comprises a through groove (117) which passes through the housing element (101) from an external surface of the housing element (109) to an internal surface of the housing element (301) which defines the corresponding terminal cavity (107), and the anti-vibration element (103) is arranged in the through groove (117).The invention also relates to an assembly of electrical connectors (500) comprising the electrical connector (100) and a complementary electrical connector (501), a method for assembling the assembly of electrical connectors (500), and a method for manufacturing an electrical connector (100), in particular the electrical connector (100) of the invention. Figure 1.

Description

Title of the invention: Electrical connector and method of manufacturing an electrical connector

[0001] The present invention relates to an electrical connector comprising an electrical terminal and an anti-vibration member. The invention also relates to an electrical connector assembly thereof, a method of assembling the electrical connector assembly, and a method of manufacturing an electrical connector.

[0002] Electrical connectors are known in the art that include a housing member and one or more electrical terminals. The electrical terminals are received in corresponding terminal cavities of the housing member. The electrical terminals are configured to electrically contact corresponding electrical terminals of a mating complementary electrical connector when the electrical connector is mated to said complementary connector.

[0003] An electrical terminal may be fitted into its corresponding terminal cavity of the housing member, for example, by form fit or by interference fit. It is preferable to avoid a frictional arrangement of the electrical terminal to reduce the risk of degradation of the material of the housing member and the electrical terminal by frictional stress, which could impact the durability and quality of the electrical contact. Therefore, various form fit solutions for fitting an electrical terminal into a connector housing member have been devised, in particular cantilever type snap-fit ​​devices.

[0004] However, the manufacturing tolerances given for the electrical terminal and the housing member will often produce a snap fit of the electrical terminal into the housing member that still allows for relative micro-movements. In the case of high vibration environments, for example near a combustion engine, the relative micro-movements may materially degrade the electrical terminals and / or the housing member. In addition, the relative micro-movements may further increase fretting corrosion of the electrical terminal and the mating electrical terminal when the electrical connector is mated to the complementary electrical connector.

[0005] It is therefore an object of the present invention to provide an electrical contacting solution with improved vibration resistance and improved durability in high vibration environments.

[0006] This object is achieved using an electrical connector configured to be mated with a complementary electrical connector along a mating direction, the An electrical connector comprising a housing member, an electrical terminal housed in a corresponding terminal cavity of the housing member, and an anti-vibration member. According to the present invention, the electrical connector is characterized in that the housing further comprises a through groove passing from a housing member outer surface to a housing member inner surface that defines the corresponding terminal cavity, and in that the anti-vibration member is arranged in the through groove.

[0007] When the through groove passes through the housing from a housing member outer surface to a housing member inner surface that defines the corresponding terminal cavity, a gap connecting an exterior of the housing member to the terminal cavity is created. By disposing the anti-vibration member in the through groove, the anti-vibration member can provide a direct mechanical connection between the exterior of the housing member and the terminal cavity confining the electrical terminal.

[0008] Thus, the anti-vibration element may be clamped, in particular between the electrical terminal and an actuating device outside the housing element, when said actuating device is positioned along the outer surface of the housing element. This allows for additional stabilization of the electrical terminal in the terminal cavity, in particular in cases where manufacturing tolerance would still allow relative movements between an electrical terminal and a housing element.

[0009] In particular, when the electrical connector is mated along the mating direction with the complementary electrical connector, the complementary electrical connector may be the actuating device engaging, in particular compressing, the anti-vibration element with the electrical terminal. Thus, when the complementary electrical connector vibrates differently from the electrical connector, the vibrations of the complementary electrical connector may be directly and additionally transferred to the electrical terminal, which further reduces the risk of contact corrosion.

[0010] According to one aspect, the anti-vibration element may be arranged in the through groove such that the anti-vibration element projects beyond the outer surface of the housing element. Mechanical access to the anti-vibration element located in the through groove is thus facilitated.

[0011] In one aspect, the electrical connector may include a plurality of electrical terminals housed in a respective plurality of corresponding terminal cavities of the housing member. The through groove extends along an outer periphery of the housing member such that it passes through the housing member from the housing member outer surface to each of the respective housing member inner surfaces that define the plurality of corresponding terminal cavities. The anti-vibration member is arranged in the through groove such that it projection beyond the outer surface of the housing element along the outer periphery.

[0012] In this configuration, a single anti-vibration element can be interfaced at the same time with a plurality of terminal cavities containing respective electrical terminals. This means that the anti-vibration element can help to simultaneously stabilize the plurality of electrical terminals.

[0013] In one aspect, the through groove may extend along the entire circumference of the housing member, and the anti-vibration member is arranged in the through groove such that it protrudes beyond the housing member outer surface along the entire circumference of the housing member.

[0014] According to one aspect, the anti-vibration member may be formed into a shape corresponding to the outer periphery of the housing member. The anti-vibration member may thus be conveniently arranged in the through groove so as to be interfaced with each of the plurality of corresponding terminal cavities.

[0015] According to one aspect, the housing member may have a rectangular circumference in a plane orthogonal to the mating direction, and the anti-vibration member has a corresponding rectangular ring shape. With a ring-shaped anti-vibration member arranged in a circumferential through-groove, an elastic property of the anti-vibration member can be provided, which applies a stabilizing force inwardly and uniformly to a plurality of electrical terminals housed in the housing member.

[0016] According to one aspect, the anti-vibration element may be an O-ring. In this configuration, the electrical connector and, in particular, the anti-vibration element are therefore particularly cost-effective to produce.

[0017] According to one aspect, the anti-vibration element may be made of a rubber or a thermoplastic elastomer, in particular with a Shore hardness of between 50 and 30, preferably between 35 and 45. The anti-vibration elements thus configured are adapted to provide desired flexibility and elastic properties, without risking damage to the housing element or the electrical terminal,

[0018] According to one aspect, the anti-vibration element may be arranged in the through groove such that it is in contact with one or the plurality of electrical terminals. Thus, any pressure or force applied to the anti-vibration element is directly and immediately transferred to the electrical terminal as well, and the anti-vibration element and the electrical terminal may move together.

[0019] In one aspect, the anti-vibration element may be arranged in the through groove such that it is frictionally engaged with one or the plurality of electrical terminals. This allows for improved stabilization of the electrical terminals in their respective terminal cavities even when the electrical connector is in a decoupled.

[0020] In one aspect, the anti-vibration element may protrude beyond the housing member internal surfaces that define the one or plurality of corresponding terminal cavities, into the one or plurality of corresponding terminal cavities. In this configuration, a frictional engagement between the anti-vibration element and the electrical terminal may be achieved when the electrical terminal is fitted, e.g., by snap-fitting, into its corresponding terminal cavity.

[0021] According to one aspect, the through groove may pass through the housing member in a direction orthogonal to the mating direction. Therefore, when electrical terminals are housed in the housing member extending parallel to the mating direction, arranging the anti-vibration member to be interfaced with one or the plurality of electrical terminals is more convenient. That is, the distance between the housing member outer surface and the housing member inner surface defining a corresponding terminal cavity may be shorter.

[0022] In one aspect, each of the electrical terminals may be a socket contact terminal including an internally tapered portion configured to make electrical contact with a mating pin contact terminal. For each electrical terminal, the through groove extends through the housing from the housing member outer surface to a portion of the housing member inner surface defining the corresponding terminal cavity that faces the respective internally tapered portion of the electrical terminal.

[0023] Thus, when a mechanical force compresses the anti-vibration member against the electrical terminal, the compressive force is applied locally to the internally constricted portion of the electrical terminal. That is, the location of the greatest compressive force applied to the electrical terminal may be the internally constricted portion of the electrical terminal, which, when the electrical connector is mated with the complementary electrical connector, includes the electrical contacting point or points. Therefore, fretting corrosion resulting from micromovements between the electrical terminal and a corresponding electrical terminal, configured as a contact pin housed in the complementary electrical connector, may be reduced.Notably, when the anti-vibration element vibrates together with the complementary electrical connector, the vibrations of the complementary electrical connector and the corresponding electrical terminal are transferred to the electrical contact point.

[0024] The object of the invention is also achieved by means of an electrical connector assembly, comprising an electrical connector according to any one of the above-described aspects of the invention, and a complementary electrical connector comprising a casing element, wherein the complementary electrical connector The electrical connector is mated with the electrical connector such that the shell member envelops the housing member. A shell that envelops the housing may conveniently interact with a through groove extending along an outer periphery of the housing member of the electrical connector.

[0025] In one aspect of the electrical connector assembly, the complementary electrical connector may be mated with the electrical connector such that the anti-vibration element is compressed between the housing member and one or more of the electrical terminals. Thus, the anti-vibration element further stabilizes the electrical terminal in its cavity and particularly allows the one or more of the electrical terminals to vibrate with the complementary electrical connector, rather than with the housing member of the electrical connector.

[0026] In one aspect of the electrical connector assembly, the shell member may include an inner surface with a chamfered portion configured to engage the anti-vibration element, particularly for compression of the anti-vibration element between the shell member and one or more electrical terminals when the complementary electrical connector is mated with the electrical connector. The chamfered portion allows for gradual compression of the anti-vibration element when the connectors of the electrical connector assembly are mated. This may improve the smoothness of the mating motion.

[0027] The invention also comprises a method for assembling the set of electrical connectors according to one of the preceding aspects. The method comprises the steps of: matching the housing element and the envelope element such that the envelope element envelopes the housing element, and compressing the anti-vibration element between the casing element and the electrical terminal.

[0028] When the set of electrical connectors is assembled according to this method, electrical contact between the electrical terminals is made, which provides the above-described advantages of the invention.

[0029] In one aspect of the method of assembling the electrical connector assembly, an inner surface of the shell member of the complementary electrical connector includes a chamfered portion, and the compressing step includes compressing between the chamfered portion and the electrical terminal. The chamfered portion allows for gradual compression of the anti-vibration member as the connectors of the electrical connector assembly are mated. This can improve the smoothness of the mating motion.

[0030] The present invention also relates to a method of manufacturing an electrical connector, in particular the electrical connector according to one of the aspects described above. The method of manufacturing an electrical connector comprises the steps consisting of: providing a housing member including a through groove that passes through the housing member from a housing member outer surface to a housing member inner surface that defines a terminal cavity for an electrical terminal; arranging an anti-vibration member in the through groove so that the anti-vibration member protrudes beyond the outer surface of the housing member, and inserting an electrical terminal into the terminal cavity. The electrical connector manufactured by this method solves the problem of the invention and, in particular, achieves the corresponding advantages described above of various aspects of the invention.

[0031] According to one aspect of the method for manufacturing the electrical connector, the electrical terminal is inserted into the terminal cavity such that the electrical terminal is in contact, in particular frictionally engaged with the anti-vibration element. Thus, any pressure or force applied to the anti-vibration element can be directly and immediately transferred also to the electrical terminal, and the anti-vibration element and the electrical terminal can move together. Frictional engagement allows for better stabilization of the electrical terminals in their respective terminal cavities, even when the electrical connector is in an uncoupled state.

[0032] In one aspect of the method of manufacturing the electrical connector, the electrical terminal is inserted into the terminal cavity such that an internally narrowed portion of the electrical terminal configured to make electrical contact with a mating electrical terminal is positioned face-to-face with the anti-vibration element and / or with a portion of the housing member internal surface defining the terminal cavity through which the through groove extends through the housing member.

[0033] Thus, when a mechanical force compresses the anti-vibration element against the electrical terminal, the compressive force is applied locally to the internally constricted portion of the electrical terminal(s), which, when the electrical connector is mated with the complementary electrical connector, includes the electrical contact point(s). Therefore, contact corrosion resulting from micro-movements between the electrical terminal and a corresponding electrical terminal, configured as a contact pin housed in the complementary electrical connector, can be reduced.

[0034] In one aspect of the method of manufacturing the electrical connector, the through groove of the housing member passes through the housing member from a housing member outer surface to a plurality of housing member inner surfaces that define the plurality of corresponding terminal cavities for a respective plurality of electrical terminals, and the method further comprises additional steps of inserting the plurality of electrical terminals into their respective corresponding terminal cavities such that each of the plurality of electrical terminals is in contact with the anti-vibration element.

[0035] This method is particularly cost-effective, both with respect to material costs and manufacturing step costs, since a single anti-vibration element can be interfaced at the same time with a plurality of terminal cavities containing respective electrical terminals.

[0036] The aspects, objects, features and advantages of the present invention described above will be better understood and appreciated by careful study of the following more detailed description of a presently preferred exemplary embodiment of the invention, taken in conjunction with the accompanying drawings, in which:

[0037] [Fig. 1] is an exploded view of an electrical connector according to a first embodiment of the invention.

[0038] [Fig.2] shows the electrical connector of [Fig.l] in an unexploded perspective view.

[0039] [Fig. 3] shows a cross-sectional view of a portion of the electrical connector of [Fig. 1] in a non-final manufacturing state.

[0040] [Fig.4] shows the view of [Fig.3] in which the electrical connector is in a final manufacturing state.

[0041] [Fig.5] shows a cross-sectional view of a portion of an electrical connector assembly including the electrical connector of [Fig.l], in a non-final assembled state.

[0042] [Fig.6] shows the view of [Fig.5], in a final assembled state.

[0043] [Fig.7] shows the electrical connector assembly of Figures 5 and 6 in a perspective view.

[0044] In the following detailed description of embodiments, like references identified in different figures and / or in different parts of the description of the figures refer to like elements. Furthermore, unless explicitly indicated otherwise, the structural features of the objects illustrated in Figures 1 to 7 are not drawn to scale.

[0045] The technical features and their associated advantages or effects described in the following description of embodiments may be combined with or adapted to any aspects or embodiments of the invention, together or independently, providing additional possible embodiments or aspects of the invention.

[0046] An electrical connector according to a first embodiment of the invention will now be described in relation to Figures 1 to 4. [Fig.l] shows the electrical connector 100 according to the invention in an exploded view. According to the present first embodiment, the electrical connector 100 is configured for electrical signaling applications in a vehicle, in particular a vehicle engine. More specifically, the electrical connector 100 is suitable for electrical signaling applications in a high vibration environment, for example near or adjacent to an internal combustion engine of a motor vehicle.

[0047] The electrical connector 100 comprises a housing member 101, an anti-vibration member 103 and a jacket 105. In the present embodiment, the housing member 101 comprises a plurality, here ten, of terminal cavities 107. The terminal cavities 107 extend through the housing member 101 along a mating direction M, parallel to a Cartesian direction x, along which the electrical connector 100 is configured to be mated with a complementary electrical connector. For example, in the present embodiment, the electrical connector 100 is configured to be mated along the mating direction M with the complementary electrical connector 501, which will be described with respect to Figures 5, 6 and 7.

[0048] The housing element 101 has a housing element outer surface 109. In a plane P orthogonal to the mating direction M, the housing element outer surface 109 defines an outer periphery of the housing element 101. Furthermore, in this embodiment, the housing element 101 has a box shape, i.e., a substantially orthotopic shape. Thus, in a plane P orthogonal to the mating direction M, the housing element 101 has a substantially rectangular circumference, in particular a circumference having the shape of a rectangle with rounded corners 111.

[0049] The jacket 105 has a tubular shape defining an interior space 113. The housing member 101 is configured to fit into the interior space 113 such that the jacket 105 envelops the housing member 101, as shown in [Fig. 2]. The jacket 105 further includes a connector position assurance (CPA) device 115 configured to ensure the position of the electrical connector relative to a complementary electrical connector when the electrical connector and the complementary electrical connector are mated. More specifically, the CPA device 115 is configured to lock the electrical connector 100 with a complementary electrical connector, such as a complementary electrical connector 501, in a properly mated position.

[0050] The housing member 101 comprises a through groove 117. The through groove 117 extends along an outer periphery of the housing member 101. Specifically, the through groove 117 extends along an entire circumference of the housing member 101, in particular an entire rectangular circumference in a plane P' orthogonal to the mating direction M. As shown in [Fig.l], the through groove 117 has a width W, i.e., an extension along the mating direction M, corresponding to between 1% and 10% of the extension along the mating direction M of the housing element 101. Alternatively or additionally, the through groove 117 has a width W corresponding to between 80% and 120% of the height H, i.e. of the extension in a direction O orthogonal to the mating direction M and parallel to a Cartesian direction y, of the terminal cavities 107.

[0051] The through groove 117 passes through the housing member 101 from the outside of the housing member 101 to the inside of the housing member 101 in each of the terminal cavities 107. Specifically, the through groove 117 passes through the housing member 101 from the housing member outer surface 109 to each housing member inner surface 301 defining a respective terminal cavity 107 formed in the housing member 101. The housing member inner surfaces 301 are not visible in Figures 1 and 2, but are illustrated in Figures 3 to 6 and described in the following with reference thereto.

[0052] The electrical connector 100 of the first embodiment further comprises ten electrical terminals 300, and each electrical terminal 300 is respectively housed in a corresponding one of the ten terminal cavities 107. The electrical terminals 300 are not visible in [Fig.l] or 2, but one electrical terminal 300 is illustrated in Figs. 3 to 6 and should be described with reference thereto. In alternative embodiments, some of the terminal cavities 107 may not contain an electrical terminal. In other words, each of the plurality, here ten, of terminal cavities 107 need not house a respective electrical terminal. Instead, the electrical connector 100 may include fewer electrical terminals than terminal cavities 107, e.g., only one, two, four, five, or eight, with one to nine of the terminal cavities 107 not housing a respective electrical terminal, but rather being empty.

[0053] The anti-vibration element 103 is configured as an elastic band that can be pulled over the housing element 101. Here, the anti-vibration element 103 has a rectangular ring shape, corresponding to the extension of the outer periphery, here the rectangular circumference, of the housing element 101. The anti-vibration element 103 is configured such that in an unstretched rest state, the anti-vibration element 103 has an inner surface A that is smaller than the rectangular cross-sectional area of ​​the housing element 101, both in the plane P outside the groove 117 and in the plane P' inside the groove 117.

[0054] Preferably, the anti-vibration element 103 has a Shore hardness of between 50 and 30, preferably between 35 and 45, for example, here, 40. In a variant, the anti-vibration element 103 may also be torus-shaped or donut-shaped. In one example, a commercial O-ring may be used as the anti-vibration element 103.

[0055] The housing member 101, the anti-vibration member 103 and the jacket 105 are preferably made from materials designed for operating temperatures of at least 125°C, preferably at least 150°C. The anti-vibration member 103 may be molded in one piece, preferably from rubber or thermoplastic elastomer. The housing member 101 may be molded from polybutylene terephthalate (PBT).

[0056] The housing element 101 also comprises, for each terminal cavity 107, a corresponding snap-in opening 119 to enable snap-in locking of the electrical terminals 300 in their corresponding terminal cavities 107. This function will be described in more detail with reference to Figures 3 and 4.

[0057] [Fig. 2] shows the electrical connector 100 in a perspective view, in an assembled distribution state. The housing member 101 is fitted into the jacket 105 such that a mating gap 200 is formed between the housing member outer surface 109 and an inner jacket surface 201. The mating gap 200 has a mating gap opening 203 oriented in the mating direction M. The mating 200 is configured to receive a shell member, for example a shell member 503 as shown in FIGS. 5 and 6, of a complementary electrical connector through the mating gap opening 203 when the electrical connector 100 is mated to said complementary electrical connector.

[0058] The terminal cavities 107 are arranged in the housing element 101 in two parallel rows RI, R2 of five terminal cavities 107 each. The rows RI, R2 extend in a direction perpendicular to the mating direction M. In one variant, the housing element according to the invention may also comprise a single terminal cavity. In other variants, the housing element according to the invention may comprise a different number of terminal cavities, for example two, four, seven or 20 terminal cavities, which are arranged in one row or in two rows, such as the rows RI, R2. The number of terminal cavities is preferably at least as large as the number of electrical terminals.

[0059] As seen in [Fig. 2], the anti-vibration member 103 is arranged in the through groove 117. More specifically, the anti-vibration member 103 extends along the circumference, in the plane P' orthogonal to the mating direction M, of the housing member 101 in the through groove 117. Since the anti-vibration member 103 has an inner surface area A that is smaller than the rectangular cross-sectional area of ​​the housing member 101 in the plane P' inside the groove 117, the anti-vibration member 103 is in a stretched state when arranged in the through groove 117.

[0060] As will be described in more detail with reference to [Fig.3], the anti vibration 103 is arranged in the through groove 117 such that it protrudes beyond the outer surface of the housing member 109. Specifically, [Fig. 2] shows that the anti-vibration member 103 is arranged in the through groove 117 such that it protrudes beyond the outer surface of the housing member 109 into the mating space 200 along at least a portion of the rectangular circumference of the housing member 101.

[0061] Figures 3 and 4 show a same cross-sectional view of a portion of the electrical connector 100, along the cross-sectional view section line V indicated in [Fig.l]. While in [Fig.4], the electrical connector 100 is in a final manufacturing state, in [Fig.3], the electrical connector 100 is in a non-final manufacturing state. In particular, in the view of [Fig.3], the electrical terminal 300 is not yet completely inserted and locked into the housing member 101.

[0062] As already mentioned, the electrical connector 100 comprises ten electrical terminals 300, one for each terminal cavity 107. The ten electrical terminals 300 are structurally identical and arranged identically in their corresponding terminal cavity 107 such that they are mated with mating electrical terminals of the complementary electrical connector when the electrical connector 100 is mated along the mating direction M with said complementary electrical connector.

[0063] Because in this embodiment, the electrical terminals 300 and the terminal cavities 107 are each identical and their characteristics and effects are mutually corresponding, the present disclosure will be limited to describing the characteristics and effects of a terminal cavity 107 and an electrical terminal 300.

[0064] [Fig. 3] shows an electrical terminal 300 partially inserted in the mating direction M into a corresponding terminal cavity 107. The cavity 107 is defined by a housing member inner surface 301, and extends into the housing member 101 along the mating direction M. In this embodiment, the electrical terminal 300 is stamped from an electrically conductive metal foil. The electrical terminal 300 includes a crimping portion 303 configured to be crimped onto an electrical conductor, and a contacting portion 305 configured to electrically contact a corresponding electrical terminal. The crimping portion 303 is joined to the contacting portion 305 longitudinally in the mating direction M.

[0065] In this embodiment, the electrical terminal 300 is a socket contact terminal, or female contact, and is therefore configured to receive a pin contact terminal, or male contact, when the electrical connector 100 is mated with a mating complementary electrical connector. Preferably, the electrical terminal 300 is a copper contact with a coating of tin, silver, or gold.

[0066] The electrical contact 300 comprises a spring lance 307 projecting outwardly, transversely to the mating direction M, and configured as a cantilevered snap-in device. In the partially inserted view of [Fig. 3], the electrical terminal 300 is in an intermediate insertion state in which the spring lance 307 has not reached the snap-in opening 119. Thus, the spring lance is still bent downward, i.e., inward toward the electrical terminal body 300, by the housing member inner surface 301, and the electrical terminal 300 is not locked to the housing member 101.

[0067] The electrical terminal includes an internally narrowed portion 309. The internally narrowed portion 309 is configured to make electrical contact with a mating pin contact terminal when the electrical connector 100 is mated with a complementary electrical connector.

[0068] The through groove 117 extends through the housing member 101 in a direction O orthogonal to the mating direction, from the exterior of the electrical connector 100 toward the terminal cavity 107. Specifically, the through groove 117 passes through the housing member 101 from the housing member outer surface 109 to the housing member inner surface 301 defining the terminal cavity 107.

[0069] The anti-vibration member 103 is arranged in the through groove 117 such that it protrudes beyond the housing member outer surface 109. Specifically, the anti-vibration member 103 is arranged in the through groove 117 such that it protrudes beyond the front portion 311 of the housing member outer surface 109, the front portion 311 being adjacent to the through groove 117 on the side facing in the mating direction M. The front portion 311 extends in the mating direction M from the through groove 117 to the distal end 313 of the housing member 101. The anti-vibration member 103 protrudes beyond the front portion 311 of a distance DI.

[0070] [Fig. 4] shows a view corresponding to the view of [Fig. 3] in which the electrical connector 100 is in a final manufacturing state. In particular, the electrical terminal 300 is completely inserted into the terminal cavity 107, such that the electrical terminal 300 is correctly housed in the terminal cavity 107 and locked, in particular snapped, onto the housing element 101.

[0071] In other words, the electrical terminal 300 has been further inserted into the terminal cavity 107 in the mating direction M, such that the elastic lance 307 has moved into a position in which it can extend into the snap opening 119. [Fig. 4] shows that the elastic lance 307 is extended back outward into its rest position, such that the electrical terminal 300 is locked between a narrowed terminal cavity opening 400 and a snap stop surface 401 of the snap opening 119 in the housing member 101.

[0072] In the final manufacturing state shown in [Fig. 4], the electrical terminal 300 is frictionally engaged with the anti-vibration member 103 arranged in the through groove 117 which passes through the housing member 101 into the terminal cavity 107. As can be seen, the through groove 117 passes through the housing member 101 to a portion of the housing member inner surface 301 which faces the internally narrowed portion 309 of the electrical terminal 300 when said electrical terminal 300 is inserted completely into the terminal cavity 107.

[0073] In this final manufacturing state of [Fig. 4], the electrical terminal 300 is frictionally engaged with the anti-vibration member 103 arranged in the through groove 117 so that the electrical terminal 300 is further stabilized in the terminal cavity 107. In particular, the electrical terminal 300 is specifically frictionally engaged with the internally narrowed portion 309 of the electrical terminal 300. This allows the electrical terminal 300 to be advantageously stabilized at the electrical contact point in the case of mating with a mating pin contact terminal.

[0074] The anti-vibration element 1033 is arranged in the through groove 117 along the entire circumference of the housing element 101. Thus, the anti-vibration element 103 is in the same contact, in particular a frictional engagement, with each of the ten electrical terminals 300 arranged in their respective terminal cavities 107, both in a row RI and a row R2.

[0075] In the first embodiment of the invention described herein, the anti-vibration and 103 only marginally protrudes into the terminal cavity 107, not visible in [Fig. 3] and [Fig. 4]. This allows for a slight frictional engagement between the anti-vibration element 103 and the electrical terminal 300. However, in variants, the anti-vibration element may be arranged in the through groove such that it protrudes, i.e. exceeds the inner surface of the housing element, into the terminal cavity by a distance, for example the distance D1.

[0076] A method of manufacturing an electrical connector according to a second embodiment of the invention will now be described with reference to Figures 1 to 4. The method according to the second embodiment described in the following is a method of manufacturing the electrical connector 100 already described in the above.

[0077] The method begins with a step A of providing the housing member 101. As already described with reference to Figures 1 to 4, the housing member 101 includes the through groove 117 which passes through the housing member 101 from a housing member outer surface 109 to at least one of the housing member inner surfaces 301 which define the terminal cavities 107.

[0078] In a step B, the anti-vibration element 103 is arranged in the through groove 117 such that the anti-vibration element 103 protrudes beyond the surface outer surface of housing element 109, in particular the front portion 311, as described with reference to Figures 3 and 4. For this purpose, the anti-vibration element 103 is elastically stretched, for example manually, to be slid over the outer surface of housing element 109 into the through groove 117. As already mentioned, the anti-vibration element 103 is dimensioned such that it contracts inward when it reaches the through groove 117. Thus, the anti-vibration element 103 is firmly seated in the through groove 117 and can provide an inward force to stabilize the electrical terminals 300.

[0079] In a step C, an electrical terminal 300 is inserted along the mating direction M into the corresponding terminal cavity 107, so that the electrical terminal 300 is in contact with the anti-vibration member 103. As specifically described above, the electrical terminal 300 is inserted in the mating direction M into the terminal cavity 107 until said electrical terminal 300 is snapped onto the housing member 101 and the internally narrowed portion 309 of the electrical terminal 300 is frictionally engaged and face-to-face with the anti-vibration member 103.

[0080] A set of electrical connectors according to a third embodiment of the invention will now be described with reference to Figures 5, 6 and 7. The set of electrical connectors 500 of the third embodiment comprises the electrical connector 100 of the first embodiment of the invention, and a complementary electrical connector 501. The complementary electrical connector 501 is configured to be paired with the electrical connector 100 to achieve electrical contacting of the ten electrical terminals 300 with ten mating electrical terminals 503 of the complementary electrical connector 501.

[0081] Figures 5 and 6 show a cross-sectional view of a portion of the electrical connector assembly 500 along the cross-sectional view line V shown in [Fig. 1]. Specifically, Figures 5 and 6 show the same cross-sectional view of a portion of the electrical connector 100 as seen in Figures 3 and 4, in which the electrical connector 100 is in different mating states of mating with the complementary electrical connector 501. While in [Fig. 6], the electrical connector assembly 500 is in a final assembly state, i.e., the connectors 100, 501 are completely mated, in [Fig. 5], the electrical connector assembly 500 is not yet completely assembled. In [Fig. 5], the electrical connector assembly 500 is in an intermediate mating state.

[0082] [Fig. 5] shows a shell element 503 of the complementary electrical connector 501. The shell element 503 is configured as a wrap-around shell, as seen in [Fig. 7]. The shell element 503 extends along of a direction parallel to the mating direction M and includes an inner surface 505 configured to be mated with the outer surface of housing member 109. The inner surface 505 of the shell member 503 includes a stop step 507 and a chamfered portion 509. The stop step 507 is closer to the distal end 511 of the shell member 501 than the chamfered portion 509. The chamfered portion 509 is configured such that it narrows the shell space 513 of the shell member 503 in the mating direction M, i.e., away from the distal end 511.

[0083] The complementary electrical connector 501 further comprises at least one, here ten, mating electrical terminals 515. The mating electrical terminals 515 are pin contact terminals configured to be received in corresponding socket contact terminals, such as the electrical terminals 300. Since in the present embodiment, the mating electrical terminals 515 are identical and correspondingly arranged to pair corresponding electrical terminals 300, only one mating electrical terminal 515 and its pairing will be described in the following.

[0084] In the intermediate mating state shown in [Fig. 5], the electrical connector 100 has been plugged into the complementary electrical connector 501 in the mating direction M so that the housing member 101 has been partially inserted into the complementary electrical connector 500. That is, the shell member 503 has partially slid into the mating gap 200.

[0085] Thus, the shell member 503 has slid over the outer surface of the housing member 109 of the housing member 101 of the electrical connector 100. However, the stop step 507 has not yet abutted, and the chamfered portion 503 has not yet reached the anti-vibration member 103. The pin terminal 515 has partially entered the electrical terminal 300 through the narrowed terminal cavity opening 400.

[0086] In [Fig.6], the set of electrical connectors 500 is in a state final assembly. That is, the electrical connector 100 and the complementary electrical connector 501 are fully mated. In particular, when the electrical connector 100 moved further in the mating direction M so that the housing member 101 moved further into the shell space 513, the shell member 503 slid further above the housing member outer surface 109. The shell member 503 slid above the housing member outer surface 109 until the stop step 507 abutted against a stop 600 projecting outwardly from the housing member 101.

[0087] At the same time, the chamfered portion 509 reached and slid over the anti-vibration member 103. When the chamfered portion 509 narrows the envelope gap 515 in the mating direction M, the chamfered portion 509 engaged with the anti-vibration member 103 protruding outwardly beyond the outer surface of the housing member 109 of the housing member 101. When the casing space 515 defined by the casing member 503 is narrowed by the chamfered portion 509, an additional mating movement pushing the connectors 100, 501 together pushed the anti-vibration member 103 deeper into the through groove 117.

[0088] In particular, the shell element 503, in the mated electrical connector assembly, exerts a compressive force F orthogonal to the mating direction M on the anti-vibration element 103, pushing the anti-vibration element 103 into the through groove 117 and against the electrical contact 300. In other words, the anti-vibration element 103 is compressed and sandwiched between the shell element 503 and the electrical contact 300. The chamfered portion 509 allows a gradual increase in the compressive force F up to its maximum value when the anti-vibration element 103 is moved in the mating direction M above the chamfered portion 509.

[0089] [Fig. 6] shows that in the fully mated state, the pin terminal 515 has moved further into the electrical terminal 300 making electrical contact at the internally narrowed portion 309. When the anti-vibration member 103 is compressed between the shell member 503 and the electrical contact 300, a direct mechanical connection is established therebetween. This further stabilizes the electrical terminal 300 in its terminal cavity 107, reducing the potential for micro-movements of the electrical terminal 300 relative to the housing member 101 that may, due to manufacturing tolerances, remain even after the electrical terminal 300 is snapped into the terminal 107.

[0090] Furthermore, when a direct mechanical connection is established between the electrical terminal 300 and the housing member 503, the vibrations of the complementary electrical connector 501, which may be different from the vibrations of the housing member 101 of the electrical connector 100, can be transferred to the electrical terminal 300. That is, the electrical terminal 300 can advantageously vibrate with the complementary electrical connector 501 and its mating electrical terminal 515. When the electrical terminals 300 and 515 vibrate together, fretting corrosion is reduced.

[0091] [Fig. 7] shows the electrical connector assembly of Figures 5 and 6 in a perspective view. As can be seen, the electrical connector 100 is plugged onto the complementary electrical connector 501 such that the shell member 503 is received in the mating space 200. Thus, the shell member 503 envelops the circumference of the housing member 101 along its outer housing member surface 109.

[0092] Therefore, the envelope element 503 can exert the compressive force F along the entire circumference of the housing member 101, in particular along the circumference of the anti-vibration member 103. In this way, the casing member 503 also compresses one of the anti-vibration members 103 against every other of the ten electrical terminals 300 in their corresponding terminal cavities 107.

[0093] Considering the set of electrical connectors 500 described above, a method of assembling a set of electrical connectors according to a fourth further embodiment of the invention will now be described. The method according to the fourth embodiment described in the following is a method of assembling the set of electrical connectors 500, the characteristics of which have already been described in the above.

[0094] The method of assembling an electrical connector assembly according to the fourth embodiment begins with a step D of matching the housing element 101 and the shell element 503 such that the shell element 503 envelops the housing element 101. In particular, the electrical connector 100 is plugged onto the complementary electrical connector 501 such that the shell element 503 is inserted into the matching space 200, and the housing element 101 is inserted into the shell space 515. Thus, the inner surface 505 is slid over the circumference of the housing element outer surface 109 of the housing element 101.

[0095] The method according to the fourth embodiment further comprises a step E of compressing the anti-vibration member 103 between the casing member 503 and the electrical terminal 300. A chamfered portion 509 narrows the casing space 515, and thus the inner surface 505 of the casing member 503 engages with the anti-vibration member 103. More specifically, the casing member 503 exerts a compressive force F in a direction orthogonal to the mating direction M on the anti-vibration member 103 against the electrical terminal 300. That is, the anti-vibration member 103 is sandwiched between the casing member 503 and the electrical terminal 300.

[0096] The above-described embodiments of the invention each provide an electrical contact solution with improved vibration resistance and improved durability in high vibration environments.

[0097] DIGITAL REFERENCES 100 electrical connector 101 housing element 103 anti-vibration element 105 coat 107 terminal cavity 109 outer surface of housing element 111 rounded corners of the housing element 113 interior space of the mantle 115 CPA device 117 through groove 119 snap opening 200 matching space 201 inner mantle surface 203 pairing space opening 300 electric terminals 301 inner surface of housing element 303 crimping part 305 contact part 307 elastic lance 309 internally narrowed part 311 front part of the outer surface of the housing element 313 distal end of outer surface of housing element 400 narrowed terminal cavity opening 401 snap-on stop surface 500 Set of Electrical Connectors 501 additional electrical connector 503 envelope element 505 inner surface of the envelope element 507 stop step formed on the inner surface of the envelope element 509 chamfered portion formed on the inner surface of the envelope member 511 distal end of the envelope element 513 envelope space 515 electrical pairing terminal 600 stop A inner surface area of ​​the anti-vibration element DI external projection distance of the anti-vibration element F compressive force H height of a terminal cavity M pairing direction O direction orthogonal to the matching direction P, P' plane orthogonal to the matching direction RI, R2 rows of terminal cavities V cross-section line

Claims

Claims

1. An electrical connector configured to be mated with a complementary electrical connector (501) along a mating direction (M), the electrical connector (100) comprising a housing member (101), an electrical terminal (300) housed in a corresponding terminal cavity (107) of the housing member (101), and an anti-vibration member (103), characterized in that the housing member (101) further comprises a through groove (117) passing through the housing member (101) from a housing member outer surface (109, 311) to a housing member inner surface (301) that defines the corresponding terminal cavity (107), and the anti-vibration member (103) is arranged in the through groove (117).

2. An electrical connector according to claim 1, wherein the anti-vibration member (103) is arranged in the through groove (117) such that the anti-vibration member (113) protrudes beyond the outer surface of the housing member (311, 109).

3. An electrical connector according to claim 1 or 2, comprising a plurality of electrical terminals (300) housed in a respective plurality of corresponding terminal cavities (107) of the housing member (101), wherein the through groove (117) extends along an outer periphery, in particular along the entire circumference, of the housing member (101) such that it passes through the housing member (101) from the housing member outer surface (109) to each of the respective housing member inner surfaces (301) that define the plurality of corresponding terminal cavities (107), and wherein the anti-vibration member (103) is arranged in the through groove (117) such that it projects beyond the housing member outer surface (109, 311) along the outer periphery, in particular the entire circumference. circumference of the housing element (101).

4. An electrical connector according to any preceding claim, wherein the anti-vibration member (103) is formed in a shape corresponding to the outer periphery of the housing member (101), in particular wherein the housing member (101) has a rectangular circumference in a plane (P, P') orthogonal to the direction matching (M), and the anti-vibration element (103) has a corresponding rectangular ring shape.

5. An electrical connector according to any preceding claim, wherein the anti-vibration element (103) is arranged in the through groove (117) such that it is in contact, in particular frictionally engaged, with the one or the plurality of electrical terminals (300), in particular wherein the anti-vibration element (103) projects beyond the housing element internal surfaces (301) which define the one or the plurality of corresponding terminal cavities (107), into said one or said plurality of corresponding terminal cavities (107).

6. An electrical connector according to any preceding claim, wherein each of the electrical terminals (300) is a socket contact terminal (300) comprising an internally narrowed portion (309) configured to make electrical contact with a corresponding pin contact terminal (515), wherein, for each electrical terminal (300), the through groove (117) passes through the housing member (101) from the housing member outer surface (109) to a portion of the housing member inner surface (301) defining the corresponding terminal cavity (107) which faces the respective internally narrowed portion (309) of the electrical terminal (300).

7. An electrical connector assembly, comprising the electrical connector (100) according to any preceding claim, and a complementary electrical connector (501), the complementary electrical connector (501) comprising a shell member (503), wherein the complementary electrical connector (501) is mated with the electrical connector (100) such that the shell member (503) envelops the housing member (101) and the anti-vibration member (103) is compressed between the shell member (503) and one or the plurality of electrical terminals (300).

8. An electrical connector assembly according to claim 9, wherein the shell member (503) comprises an inner surface (505) with a chamfered portion (509) configured to engage the anti-vibration member (103).

9. A method of assembling the electrical connector assembly of claim 7 or 8, comprising the steps of matching the housing member (101) and the shell member (503) such that such that the envelope member (503) envelopes the housing member (101), and compressing (F) the anti-vibration element (103) between the casing element (503), in particular a chamfered portion (509) of an inner surface (505) of the casing element (503), and the electrical terminal (300).

10. A method of manufacturing an electrical connector, in particular an electrical connector (100) according to any one of claims 1 to 8, comprising the steps of providing a housing member (101) comprising a through groove (117) which passes through the housing member (101) from a housing member outer surface (109) to a housing member inner surface (301) which defines a terminal cavity (107) for an electrical terminal (300), arranging an anti-vibration member (103) in the through groove (117) such that the anti-vibration member (103) protrudes beyond the housing member outer surface (109, 301), and inserting an electrical terminal (300) into the terminal cavity (107), preferably such that the electrical terminal (300), in particular an internally narrowed portion (309) of the electrical terminal (300) configured to make electrical contact with a mating electrical terminal (515),is in contact, in particular in frictional engagement with the anti-vibration element (103).,

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