Electrical connector assembly

Abstract

To provide a connector which improves sealing effect, reduces a possibility of electrolytic corrosion, and improves durability and life of an electric connector.SOLUTION: An electrical connector assembly having a female member and a male member is provided. The female member includes: a peripheral wall formed in an annular shape to define a first interior space; and a plurality of exterior walls each formed in a semi-annular shape to define a plurality of second interior spaces located outwardly of the first interior space. In particular, the peripheral wall includes a plurality of slots corresponding to the plurality of exterior walls, and the plurality of slots communicate between the first interior space and the plurality of second interior spaces. The male member includes a plurality of partition walls sized to be received by corresponding second interior spaces and slots whereby the partition walls separate the first interior space into corresponding chambers for each electrical prong of the male member.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] Cross - Reference to Related Applications This PCT international application claims the benefit of priority of U.S. Patent Application No. 16 / 139,809, filed on September 24, 2018, under 35 U.S.C. § 119, the entire content of which is incorporated herein by reference.

[0002] The present disclosure relates to an electrical connector assembly for a vehicle. The electrical assembly may include a male connector and a female connector.

Background Art

[0003] The description in this section only provides background information related to the present disclosure and does not constitute prior art.

[0004] To operate and control a vehicle, the vehicle is equipped with various electrical and mechanical devices such as an engine, a transmission, a fuel tank, wheels, etc. Electrical cables and connectors are used to transmit power or signals between such devices. Those devices and electrical components (connectors, cables) are exposed to different environments depending on the installed location, and thus are specially designed to be suitable for use in specific locations and conditions.

[0005] For example, a fuel tank for storing vehicle fuel is equipped with a fuel pump. The fuel pump discharges fuel from the fuel tank through a fuel line to the engine of the vehicle. The delivered fuel is injected into the cylinders of the engine and burned to generate power to drive the engine. The fuel pump operates by power sent from a battery or a generator via a power cable. The power cable is connected to the fuel pump and other sensors such as a fuel level sensor that measures the fuel level inside the fuel tank. When the fuel tank is filled with fuel, the electrical cables and connectors disposed inside the fuel tank come into direct contact with the fuel.

[0006] Since the electrical cable is electrically connected to the fuel pump and each sensor via each electrical connector, in order to connect between the electrical cable, the connector, and each electrical terminal for the fuel pump and each sensor, some kind of sealing is required to suppress or prevent fuel from entering each connector for the cables of the pump and each sensor and for the electrical terminals of the pump and each sensor.

[0007] When fuel penetrates into each connector, each electrical terminal of the pump or each sensor comes into contact with the fuel, and chemical corrosion or electrolytic corrosion occurs on each electrical terminal of the pump and each sensor. In particular, highly conductive fuels such as alcohol-blended fuels or ethanol-based fuels have a dramatically increased conductivity compared to ordinary gasoline, so electrolytic corrosion of electrical terminals becomes an even more serious problem.

[0008] Generally, when two terminals with opposite polarities are exposed to fuel in the same space, electrolytic corrosion occurs. For example, when a positive terminal and a negative terminal coexist in the same space (such as a chamber) of an electrical connector, when fuel enters the chamber, a current path is formed through the fuel. As a result, electrochemical corrosion (electrolytic corrosion) occurs at both terminals, and the electrical continuity between each terminal housed in the electrical connector is ultimately impaired by this corrosion. Electrolytic corrosion deteriorates in alcohol-blended fuels or ethanol-type fuels. The inventors have found that since the generation of such electrolytic corrosion becomes easier if the distance between both terminals (i.e., the positive terminal and the negative terminal) coexisting in the same chamber of the electrical connector is shorter, it is desirable to separate these terminals to make the distance between the terminals longer.

Summary of the Invention

Means for Solving the Problems

[0009] In order to improve the sealing effect and reduce the risk of electrolytic corrosion, thereby improving the durability and lifespan of the electrical connector, the present disclosure provides a compact connector assembly having individual chambers for each terminal.

[0010] In one form, the present disclosure provides an electrical female connector having an upper open end for an electrical male connector formed with a plurality of partition walls. The electrical female connector includes a lower plate, a peripheral outer wall, and a plurality of protruding side walls. The peripheral outer wall extends in a first direction (Z direction) so as to intersect the lower plate and is configured to define an internal cavity of the electrical female connector together with the lower plate. The peripheral outer wall has a plurality of slots formed along the first direction, and the plurality of slots are configured to divide the peripheral outer wall into a plurality of partial walls. Each of the plurality of protruding side walls protrudes outward from the peripheral outer wall and is configured to continuously connect at least two of the divided partial walls to each other, and the peripheral outer wall and the plurality of protruding side walls form a continuous outer wall of the electrical female connector.

[0011] In particular, each of the plurality of protruding side walls forms a chamber for receiving a corresponding portion of the partition wall of the electrical male connector, and each slot and each chamber have a cross-sectional shape that conforms to the cross-sectional profile of the corresponding portion of the partition wall of the electrical male connector. With this arrangement, when the partition walls of the electrical male connector are inserted along each slot into the corresponding chambers of the electrical female connector, respectively, the internal cavity of the electrical female connector is divided into a plurality of insulating chambers for each electrical post.

[0012] In another form, the chamber is open to the internal cavity via the corresponding slot, and each slot and each chamber together have a cross-sectional shape that conforms to the cross-sectional shape of the corresponding partition wall of the electrical male connector.

[0013] The electrical female connector may further include a plurality of inward protrusions, each of which protrudes inward from the corresponding protruding side wall and divides the corresponding slot among the plurality of slots into a first sub-slot and a second sub-slot respectively. And at least two inward protrusions of the electrical female connector face each other to form a gap "G" for receiving the corresponding portion of each partition wall of the electrical male connector. In one form, the lengths of the inward protrusions of the opposing partition walls are set to be different from each other.

[0014] In another aspect of the present disclosure, a plurality of protruding side walls and the first and second sub-slots are formed in pairs. Each pair has an inward protrusion and the first and second sub-slots, and the inward protrusion and the first and second sub-slots face the inward protrusion and the first and second sub-slots of the other of the pair. Thereby, each pair forms an opening shape that conforms to the H-shaped cross-section of the corresponding partition wall of the electrical male connector, and a plurality of insulating chambers are formed.

[0015] In another form of the present disclosure, an electrical connector assembly is provided, which includes a female member connected to a male member. The female member may include a peripheral wall formed in an annular shape and defining a first internal space, and a plurality of outer walls located outside the peripheral wall. Each of the plurality of outer walls is formed in a semi-annular shape and defines a plurality of second internal spaces located outside the first internal space. In particular, the peripheral wall may have a plurality of slots corresponding to the plurality of outer walls, and the plurality of slots communicate the first internal space with the plurality of second internal spaces.

[0016] The male member may include a plurality of partition walls sized to be received by the corresponding second internal space and slot. Thereby, the partition walls separate the first internal space into corresponding chambers for each electrical prong of the male member.

[0017] In yet another form, a plurality of electrical posts may be arranged on the lower plate of the female member. Each electrical post is received in a corresponding chamber and is configured to connect to the corresponding electrical prong of the male member.

[0018] Furthermore, from the description provided herein, the applicable areas will become apparent. It should be understood that this description and the specific examples are for illustrative purposes only and are not intended to limit the scope of the present disclosure.

[0019] Next, for a better understanding of the present disclosure, various forms given as examples will be described with reference to the accompanying drawings.

Brief Description of the Drawings

[0020]

Figure 1

Figure 2

Figure 3A

Figure 3B

Figure 3C

Figure 3D

Figure 4A

Figure 4B

Figure 4C

Figure 4D

Figure 5

Figure 6

Modes for Carrying Out the Invention

[0021] The drawings described in this specification are for illustrative purposes only and are in no way intended to limit the scope of the present disclosure.

[0022] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its applications, or uses. Throughout the drawings, it should be understood that corresponding reference numerals indicate like or corresponding parts and features.

[0023] FIG. 1 shows an electrical connector assembly 10 as one form of the present disclosure. The electrical connector assembly 10 includes an electrical female connector 100 and an electrical male connector 200. By fitting the electrical male connector 200 into the electrical female connector 100 in a watertight manner, the intrusion of a liquid such as fuel into the interior of the electrical connector assembly is suppressed, reducing the risk of electrolytic corrosion between the electrical terminals housed inside the electrical connector assembly. In one form, the electrical connector assembly 10 is disposed inside a fuel tank of a vehicle, and thus is exposed to the fuel stored in the fuel tank.

[0024] The structures of the electrical female connector 100 and the male connector 200 in one form of the present disclosure will be described in detail with reference to FIGS. 2 to 5. FIG. 2 is a perspective view of the electrical female connector 100. FIG. 3A is a top view of the electrical female connector 100. FIG. 3B is a front view of the electrical female connector 100. FIG. 3C is a side view of the electrical female connector 100. FIG. 3D is a cross-sectional view of the electrical female connector in one form of the present disclosure taken along line B-B of FIG. 3A.

[0025] Referring to FIGS. 2 and 3A to 3D, the electrical female connector 100 has an upper open end into which the electrical male connector 200 is inserted. Further, the electrical female connector 100 includes a lower plate 120 and a peripheral outer wall 130 that extends in a first direction (Z direction) so as to intersect the lower plate and defines an internal cavity 110 of the electrical female connector together with the lower plate. In particular, the peripheral outer wall 130 has a plurality of slots 180 (182, 184), and the slots 180 are formed along the first direction and divide the peripheral outer wall 130 into a plurality of partial walls 134. The divided partial walls 134 are continuously connected to each other by respective protruding side walls 140. Each of the protruding side walls 140 protrudes outward from the peripheral outer wall 130 and continuously connects at least two of the divided partial walls 134 to each other. Thereby, the peripheral outer wall 130 and the plurality of protruding side walls 140 form a continuous outer wall of the electrical female connector 100. As shown in FIGS. 2 and 3A, the leftmost partial wall and the rightmost partial wall 134 have different shapes compared to the other partial walls disposed between the rightmost partial wall and the leftmost partial wall. In one form, the leftmost partial wall and the rightmost partial wall 134 are semi-circular ring-shaped, and the other partial walls located in the middle are flat-shaped.

[0026] FIGS. 4A to 4D and FIG. 5 show the detailed structure of the electrical male connector 200. FIG. 4A is a front view of the electrical male connector 200 in one form of the present disclosure, FIG. 4B is a bottom view of the electrical male connector, FIG. 4C is a side view of the electrical male connector, and FIG. 4D is a cross-sectional view of the electrical male connector taken along line A-A of FIG. 4A. FIG. 5 is a perspective view of the electrical male connector in one form of the present disclosure.

[0027] Referring to FIGS. 2, 3A, 4A to 4C, each of the plurality of protruding side walls forms a chamber 150 (152, 154) that receives a corresponding portion of the partition wall 210 of the electrical male connector 200. Also, each slot 180 and each chamber 150 of the electrical female connector 100 have a cross-sectional shape that conforms to the cross-sectional shape of the corresponding portion of the partition wall 210 of the electrical male connector 200. With this configuration, when the partition wall 210 of the electrical male connector is inserted into the corresponding chamber of the electrical female connector along each slot, the internal cavity 110 of the electrical female connector is divided into a plurality of insulating chambers 111, 112, 113, 114 for each electrical post 160 and for each corresponding electrical prong 220 of the electrical male connector. This electrical prong is connected to the electrical post within one of the insulating chambers.

[0028] As shown in FIGS. 2 and 3D, a plurality of electrical posts 160 are arranged on the lower plate 120 of the female connector 100. Each electrical post 160 is received within a corresponding chamber 111, 112, 113, 114 and is connected to a corresponding electrical prong 220 of the electrical male connector 200.

[0029] In one form, the chambers 150 (152, 154) of the electrical female connector 100 are open to the internal cavity 110 via corresponding slots 180 (182, 184). Also, when each partition wall 210 of the electrical male connector is inserted into each chamber 150 (152, 154) and each slot 180 (182, 184) of the electrical female connector, the lower end portions of each partition wall 210 of the electrical male connector 200 are respectively fitted into grooves 122 formed on the upper surface of the lower plate 120. Thereby, the internal cavity 110 of the electrical female connector 100 is divided into a plurality of insulating chambers 111, 112, 113, 114, and within the insulating chambers, the respective electrical posts 160 and electrical prongs 220 are mechanically and electrically connected to each other.

[0030] For example, in the insulating chamber 111, the negative electrical post 160 is connected to the negative electrical prong 220, while in another insulating chamber 112, the positive electrical post 160 is connected to the positive electrical prong. The insulating chambers 111 and 112 are separated by the inserted partition wall 210 of the electrical male connector 200 and also by the partition walls (i.e., inward protrusions) 190, 192 of the electrical female connector 100. This will be described in detail below.

[0031] In one form, the electrical female connector 100 includes a plurality of inward protrusions 190, 192, each of which protrudes inwardly from the respective protruding side wall 140 and divides the corresponding slot 180 of the plurality of slots into a first sub-slot 182 and a second sub-slot 184 as shown in FIGS. 2 and 3A. In another form, at least two inward protrusions 190, 192 of the electrical female connector 100 face each other and form a gap "G" for receiving the corresponding portion 211 of each partition wall 210 of the electrical male connector 200. In another form, if desired, two facing inward protrusions 190, 192 of the electrical female connector 100 are integrated into one wall with no gap, forming a single partition wall.

[0032] In another form, the lengths of the inward protrusions 190, 192 are set to be different from each other. For example, as shown in FIGS. 2 and 3A, the length "L1" of the inward protrusion 190 in the X direction is longer than the length "L2" of the other inward protrusion 192, and thus the gap "G" is formed. As another method, the long inward protrusion 190 and the short inward protrusion 192 can be arranged in the Y direction along the outer wall of the electrical female connector 100. This arrangement provides an additional barrier to prevent fuel from circulating inside the electrical connector assembly or the female connector when fuel penetrates inside the electrical female connector.

[0033] FIG. 3D is a cross-sectional view of the electrical female connector along the B-B line of FIG. 3A, showing that the depth for receiving the electrical prong 220 of the electrical male connector 200 is different from the depth for receiving the partition wall 210. Specifically, the depth “D1” of the insulating chambers 111, 112, 113, 114 of the female connector 100 for receiving the electrical prong 220 is smaller than the depth of each part of the female connector 100 for receiving the partition wall 210 of the male connector 200, whereby the partition wall 210 of the male connector is firmly and reliably fitted by the lower plate 120. Further, this difference in depth creates another barrier that blocks the flow of fuel entering the female connector between the insulating chambers 111, 112, 113, 114, thereby significantly reducing the risk of electrolytic corrosion that occurs when opposite polarities are exposed to the same fuel in the same space.

[0034] Referring to FIGS. 4A to 4D and FIG. 5, the portion 211 of the partition wall 210 of the electrical male connector 200 has the form of a web connecting two adjacent partition walls 210 parallel to each other, jointly forming an “H-shaped” cross-section. In this way, the electrical female connector 100 has an opening shape that conforms to the H-shaped cross-section of the partition wall 210 of the electrical male connector 200, whereby they are firmly engaged with each other.

[0035] As described above, the long inward protrusion 190 and the short inward protrusion 192 can be arranged along the outer wall of the electrical female connector 100 as another method, so the position of the gap “G” formed between the two inward protrusions 190, 192 of the electrical female connector 100 varies appropriately. The position of each portion 211 of the partition wall 210 is arranged according to the position of the corresponding gap “G” of the female connector and is properly engaged.

[0036] Referring to FIGS. 2 and 3A, a plurality of protruding side walls 140 are formed to be paired with the first sub-slot 182 and the second sub-slot 184. For example, the first pair has an inward protrusion 190, the first sub-slot 182, and the second sub-slot 184, and the second pair facing the first pair has the other inward protrusion 192, the first sub-slot 182, and the second sub-slot 184. Thus, the first pair and the second pair facing each other form an opening shape that conforms to the H-shaped cross-section of the corresponding partition wall 210 of the electrical male connector 200, and a plurality of insulating chambers 111, 112, 113, 114 are formed. A plurality of partition walls 210 of the electrical male connector 200 arranged along the Y direction are set to be the same number as the chambers 150 (152, 154), whereby the internal cavity 110 of the electrical female connector is divided into desired independent / insulating chambers 111, 112, 113, 114.

[0037] As shown in FIGS. 4A to 4D and FIG. 5, the electrical male connector 200 includes a terminal portion 280 stored in the electrical female connector 100 and a main body portion 270 in which electrical cables 260, 261 are embedded. The main body portion 270 and the electrical cables 260, 261 may be integrally formed by molding. The cables 260, 261 may be respectively bundled by an intermediate flange 267 made of polyoxymethylene (POM) or the like. An upper plate 263 is disposed between the main body portion 270 and the terminal portion 280, and this upper plate has a shape that conforms to the upper opening of the electrical female connector 100. Thus, when the terminal portion 280 of the electrical male connector 200 is stored in the female connector, the upper opening is completely covered. The partition wall 210 and the electrical prong 220 of the male connector 200 protrude from the upper plate in a direction opposite to the electrical cables 260, 261 (i.e., downward toward the female connector) and fit into the corresponding slots of the female connector 100 and into the electrical post 160 of the female connector 100. When the terminal portion 280 of the electrical male connector 200 is inserted into the female connector 100, the upper surface 144 of the outer wall of the female connector abuts against the lower surface of the upper plate 263 to jointly seal.

[0038] The male electrical connector 200 further has an external locking means 240 that can be locked to the protruding portion 146 of the female electrical connector 100, which improves the fastening between the male electrical connector and the female electrical connector. As shown in FIGS. 4A, 4C, and 4D, the external locking means of the male electrical connector is a clamp 240 extending from one of the side peripheral edges of the upper plate 263, which extends downward parallel to the outer wall of the protruding side wall 140. This clamp has a notch at its central portion to assist in fastening and enable connection between the female connector and the male connector. In contrast, the protruding portion 146 of the female electrical connector is in the form of a protrusion formed on the outer surface of the protruding side wall 140, has a shape and dimensions that fit into the notch of the clamp 240, and engages immovably with the notch of the clamp 240.

[0039] As described above in connection with FIGS. 3A and 4A - 4B, the female electrical connector 100 provides an opening shape that fits the H-shaped cross-section of the partition wall 210 of the male electrical connector 200. With this structure, within the insulating chamber 113, the negative electrical post 160 can be connected to the negative electrical prong 220, and within another insulating chamber 112, the positive electrical post 160 can be connected to the positive electrical prong. The insulating chamber 112 and the insulating chamber 113 are separated by the inserted partition wall 210 of the male electrical connector 200 and further separated by the partition walls (i.e., inward protrusions) 190, 192 of the female electrical connector 100. As described below, in this connection structure between the male electrical connector and the female electrical connector, by providing a better fit and a long creepage distance between the positive electrical prong / post and the negative electrical prong / post, the sealing performance is improved, and the occurrence of electrolytic corrosion is delayed or suppressed.

[0040] FIG. 6 is an enlarged view of a portion “C” of the electrical female connector 100 when the electrical female connector 100 is assembled with the electrical male connector 200, showing the possible flow generated by fuel that has entered the insulation chamber 112 or 113. Since the “H” shape of the partition wall 210 of the male connector 200 fits into the “H”-shaped opening of the female connector 100, if fuel enters the insulation chamber 112 through the gaps between the partition wall 210, the protruding side wall 140, and the inward projections 190, 192, the fuel may flow around the “H”-shaped partition wall 210, and only the fuel may reach the next insulation chamber 113. In FIG. 6, the possible flow of fuel is indicated by the arrows “F1” and “F2”. This illustration shows that due to a specific fitting structure between the electrical female and male connectors, the creepage distance is increased while the connectors have compact dimensions between the positive electrical prong / post and the negative electrical prong / post. As a result, the electrical connector assembly of the present disclosure not only improves the sealing function but also significantly limits the possibility of failure of the connector assembly caused by electrolytic corrosion of the positive and negative electrical prongs 220.

[0041] The exemplary forms of the present disclosure have been described for illustrative purposes, and it will be understood by those skilled in the art that various changes, additions, and substitutions are possible without departing from the scope and spirit of the present disclosure.

Claims

1. An electrical female connector, having an upper open end for an electrical male connector formed with a plurality of partition walls, comprising a plurality of electrical posts arranged along a post axis, a lower plate, a peripheral outer wall, extending in a first direction so as to intersect from the lower plate, configured to define an internal cavity of the electrical female connector together with the lower plate, a peripheral outer wall having a plurality of slots formed along the first direction and configured to divide the peripheral outer wall into a plurality of partial walls, a plurality of protruding side walls, each of the plurality of protruding side walls protruding outward from the peripheral outer wall, each configured to continuously connect at least two of the divided partial walls to each other, whereby the peripheral outer wall and the plurality of protruding side walls form a continuous outer wall of the electrical female connector, a plurality of inwardly protruding projections, each of the plurality of inwardly protruding projections protruding inward from the corresponding protruding side wall, a plurality of inwardly protruding projections each configured to divide a corresponding one of the plurality of slots into a first sub-slot and a second sub-slot, and at least two of the inwardly protruding projections face each other, configured to form a gap (G) configured to receive a corresponding portion of each partition wall of the electrical male connector, the lengths of the at least two facing inwardly protruding projections are set to be different from each other, so that the gap (G) is not aligned with the corresponding electrical post in the post axis direction within the internal cavity, and the gap (G) is arranged at a lateral interval from the post axis, The protruding side wall and the inward protrusion are arranged between a plurality of electrical posts. Each of the plurality of protruding side walls is configured to form a chamber configured to receive a corresponding portion of the partition wall of the electrical male connector. Each of the slots and each of the chambers has a cross-sectional shape that conforms to the cross-sectional shape of the corresponding portion of the partition wall of the electrical male connector. When the partition wall of the electrical male connector is inserted into the chamber of the electrical female connector along each of the slots, the internal cavity of the electrical female connector is divided into a plurality of insulating chambers for each electrical post. An electrical female connector characterized by the above.

2. The electrical female connector according to claim 1, The plurality of inward protrusions protrude inward in the X direction from the corresponding protruding side walls. As the gap (G), a first gap and a second gap are provided. An electrical female connector characterized in that the position of the first gap in the X direction is different from the position of the second gap in the X direction.

3. The electrical female connector according to claim 1, The chamber is open to the internal cavity through the corresponding slot. An electrical female connector characterized by the above.

4. The electrical female connector according to claim 1, Each of the slots and each of the chambers has a cross-sectional shape that conforms to the cross-sectional shape of the corresponding partition wall of the electrical male connector. An electrical female connector characterized by the above.

5. The electrical female connector according to claim 1, At least two of the plurality of inward protrusions are arranged to face each other. As a result, the at least two inward protrusions, the first sub-slot and the second sub-slot surrounding the at least two inward protrusions form an opening shape that conforms to the H-shaped cross-section of the corresponding partition wall of the electrical male connector, and the plurality of insulating chambers are formed. An electrical female connector characterized by this.

6. The electrical female connector according to claim 1, A plurality of outer walls located outside the peripheral outer wall, Each of the plurality of outer walls is formed in a semi-annular shape and is a plurality of outer walls that define a plurality of second internal spaces located outside the first internal space defined by the peripheral outer wall, and further includes, The peripheral outer wall has a plurality of slots corresponding to the plurality of outer walls, The plurality of slots communicate the first internal space with the plurality of second internal spaces, and further includes the second internal space and the slots sized and positioned to receive the partition wall of the electrical male connector. As a result, the partition wall separates the first internal space into a plurality of chambers for receiving the electrical prongs of the electrical male connector. A plurality of grooves are formed on the upper surface of the lower plate, Each lower end portion of the plurality of partition walls is respectively fitted into the plurality of grooves. An electrical female connector characterized by this.

7. The electrical female connector according to claim 6, Some of the plurality of electrical posts are respectively, accommodated in some of the plurality of chambers, and are configured to be connected to the electrical prongs of the electrical male connector. An electrical female connector characterized by this.

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