Conductive contact with perimeter seal

Abstract

An electrical contact (10) and a connector assembly for accommodating the contact (10). The electrical contact (10) has a first mating portion (12), a transition portion (14), and a fixed portion (16). The first mating portion (12) extends in a plane substantially parallel to the plane of the fixed portion (16). The transition portion (14) extends in a plane substantially perpendicular to the plane of the first mating portion (12). The first mating portion (12) has a mating contact engagement portion (20) and a seal receiving portion (22). A seal retention projection (30) extends from the seal receiving portion (22). A peripheral seal (50) is provided in the seal receiving portion (22) of the first mating portion (12) of the electrical contact (10). The housing (100) includes a contact receiving region (102) and a connector mating region (104). A wall 106 is disposed between the contact receiving area 102 and the connector mating area 104. The wall 106 has a contact receiving opening 108 extending therethrough.

Description

[Technical Field]

[0001] The present invention is directed to a conductive contact having a perimeter seal. In particular, the present invention relates to a seal disposed on a contact, such as a ground lug, for use with a non-overmolded housing. [Background technology]

[0002] When an electrical connector is assembled to a mating electrical connector or panel, the positioning of the male blades of the electrical connector's terminals must be controlled to ensure proper mating of the terminals of the electrical connector with the mating terminals of the mating electrical connector or panel. Proper control of the positioning of the male blades of the terminals minimizes the chance of bumping between the terminals and the mating terminals during mating. This is especially important in connectors with a large number of terminals.

[0003] To more precisely control the position of the terminals and components, electrical connector housings may be manufactured using an overmolding process, which allows for control of the position of the terminals and components. Additionally, in vibration environments, the overmolded housing does not allow unwanted movement of the terminals or components during use.

[0004] While providing an overmolded housing is beneficial in many cases, incorporating a ground lug into the overmolded housing can require the use of expensive tooling and processes to provide an adequate seal in applications and environments where a seal is required. Summary of the Invention [Problem to be solved by the invention]

[0005] The problem to be solved is to provide contacts and seals, such as ground lugs, that can be placed on a housing, especially an overmolded housing, without requiring expensive tooling and processes. [Means for solving the problem]

[0006] This problem is solved by an electrical contact having a first mating portion, a transition portion, a fixed portion, and a second mating portion. The first mating portion extends in a plane substantially parallel to the plane of the fixed portion. The transition portion extends in a plane substantially perpendicular to the plane of the first mounting portion. The first mating portion has a mating contact engaging portion and a seal receiving portion. A seal retaining projection extends from the seal receiving portion.

[0007] The electrical contact may have a perimeter seal disposed in the seal receiving portion of the first mating portion of the electrical contact. The perimeter seal may be made of a compliant material having a durometer (durometer) of 50 or greater. The perimeter seal has a first surface and an opposite second surface. A top surface, a bottom surface, and a side surface extend between the first surface and the second surface. A plurality of sealing protrusions extend from the top surface, the bottom surface, and the side surfaces. Free ends of the sealing protrusions form ridges extending around the perimeter seal. Recesses are disposed between adjacent sealing protrusions.

[0008] The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a perspective view of an exemplary ground lug and seal according to the present invention; [Figure 2] FIG. 2 is a perspective view of the ground lug of FIG. 1 with the seal removed. [Figure 3] FIG. 2 is a perspective view of the seal of FIG. 1. [Figure 4] FIG. 10 is a perspective view of a portion of a housing showing the ground lug receiving area and the seal receiving opening. [Figure 5] 5 is a cross-sectional view of a portion of the housing taken along line 5-5 of FIG. 4. [Figure 6]FIG. 10 is a perspective view of a portion of a housing with a ground lug and seal aligned with the ground lug receiving area and seal receiving opening. [Figure 7] FIG. 10 is a perspective view of a portion of a housing with a ground lug and seal fully inserted and retained in the ground lug-receiving area and seal-receiving opening. [Figure 8] 8 is a cross-sectional view of a portion of the housing taken along line 8-8 of FIG. 7, with the ground lug and seal fully inserted. DETAILED DESCRIPTION OF THE INVENTION

[0010] 1 and 2, electrical contact 10 has a first mating portion 12, a transition portion 14, a fixed portion 16, and a second mating portion 18. In the illustrated embodiment, first mating portion 12 extends in a plane substantially parallel to the plane of fixed portion 16, and transition portion 14 extends in a plane substantially parallel to the plane of second mating portion 18. However, other configurations of electrical contacts may be used without departing from the scope of the present invention. In the illustrated exemplary embodiment, electrical contact 10 is a ground lug made from a conductive material such as a copper-tin alloy, although the invention is not so limited.

[0011] The first mating portion 12 has a mating contact engaging portion 20 and a seal receiving portion 22. The first mating portion 12 has a circular opening 24 located near a free end 26 of the first mating portion 12. In alternative embodiments, the opening 24 may have a different configuration or may be replaced by a mating protrusion. The first mating portion 12 and the opening 24 are configured to physically and electrically engage a mating contact (not shown).

[0012] The seal receiving portion 22 extends from a fixed end 28. Portions of the fixed end 28 are integrally attached to the transition portion 14. A seal retaining projection 30 also extends from the fixed end 28. The seal retaining projection 30 extends from the first mating portion 12 in a direction substantially perpendicular to the plane of the first mating portion 12.

[0013] The transition portion 14 extends from the first mating portion 12 in a direction substantially perpendicular to the plane of the first mating portion 12. The transition portion 14 extends from the first mating portion 12 in a direction substantially opposite the seal retaining projection 30. A projection-receiving opening 32 extends through the transition portion 14.

[0014] The fixed portion 16 extends from the transition portion 14 in a direction substantially perpendicular to the plane of the transition portion 14. A retention projection or barb 34 extends from a side wall 36 of the fixed portion 16. The retention projection 34 has a ramped or lead-in surface 38 and a locking shoulder 40.

[0015] The second mating portion 18 extends from the fixed portion 16 in a direction substantially perpendicular to the plane of the fixed portion 16. A mating contact engagement portion 42 extends from a free end 44 of the second mating portion 18. In the exemplary embodiment shown, the mating contact engagement portion 42 is a compliant pin, although other types of contact engagement portions 42 may be used.

[0016] As shown in FIG. 1 , a perimeter seal 50 is provided on the electrical contact 10. The perimeter seal 50 is made of a compliant material that prevents water ingress, such as, but not limited to, liquid silicone rubber having a durometer of 50 or greater. As shown in FIGS. 2 and 3 , the perimeter seal 50 has a first surface 52 and an opposite second surface 54. A top surface 56, a bottom surface 58, and side surfaces 60 extend between the first surface 52 and the second surface 54. The top surface 56, the bottom surface 58, and the side surfaces 60 have a plurality of sealing protrusions 62 that extend around the perimeter seal 50. The free ends of the protrusions 62 form ridges 64. The ridges extend around the perimeter seal 50 and are disposed on the top surface 56, the bottom surface 58, and the side surfaces 60. Recesses 66 are provided between adjacent protrusions 62. A plurality of protrusions 68 extend outwardly from both the first surface 52 and the second surface 54. In the exemplary embodiment shown, the protrusions 68 are rounded and periodically spaced apart on the first surface 52 and the second surface 54, although other configurations and spacings of the protrusions 68 may be used.

[0017] A slot or opening 70 extends from the first surface 52 to the second surface 54. The slot 70 is spaced an equal distance from the top surface 56 and the bottom surface 58. The slot 70 is spaced an equal distance from each side surface 60.

[0018] In use, the perimeter seal 50 is first placed on the first mating portion 12 of the electrical contact 10. As this occurs, the mating contact engagement portion 20 of the first mating portion 12 is inserted into the slot 70 of the perimeter seal 50. The perimeter seal 50 is then moved to the fully inserted position shown in FIGS. 1 and 8. In the fully inserted position, the perimeter seal 50 is placed in the seal receiving portion 22 of the first mating portion 12. In this position, the protrusions 68 on the first surface 52 are engaged with the seal retaining protrusions 30 and the transition portion 14.

[0019] The slot 70 has dimensions that are smaller than the circumference of the mating contact engagement portion 20 of the first mating portion 12. However, because the perimeter seal 50 is made from a compliant material, the deformation of the top surface 56, bottom surface 58, and sides 60 allows the slot 70 to expand and conform to the shape of the seal receiving portion 22 of the first mating portion 12, such that the perimeter seal 50 exerts a force on the seal receiving portion 22 to form a seal therebetween, thereby providing a watertight connection between the perimeter seal 50 and the seal receiving portion 22 of the first mating portion 12 of the contact 10.

[0020] 4 and 5, a portion of a housing 100 is shown. The housing 100 has a contact-receiving area 102 and a connector-mating area 104. As will be described more fully below, the contact-receiving area 102 is configured to receive the contacts 10. The housing 100 is made from a dielectric material. In the exemplary embodiment shown, the housing 100 is manufactured using an overmolding process; however, the housing 100 may be manufactured using other processes.

[0021] A wall or bulkhead 106 is provided between the contact-receiving area 102 and the connector mating area 104. The wall 106 has a contact-receiving opening 108 extending therethrough. The opening 108 has a top wall 110, a bottom wall 112, and a side wall 114. A distance L1 (FIG. 4) between the top wall 110 and the bottom wall 112 is less than a distance L2 (FIG. 3) between the ridges 64 extending from the top surface 56 and the bottom surface 58 of the perimeter seal 50. A distance L3 (FIG. 4) between the side walls 114 is less than a distance L4 (FIG. 3) between the ridges 64 extending from the opposing side surfaces 60 of the perimeter seal 50.

[0022] A locating protrusion 116 extends from the wall 106 into the contact-receiving area 102. In the exemplary embodiment, the locating protrusion 116 has a generally cylindrical configuration, although other configurations may be used. The locating protrusion 116 is disposed between the opening 108 and a fixed portion 118 of the contact-receiving area 102.

[0023] The securing portion 118 has a bottom wall 120 and a side wall 122. The bottom wall 120 and the side wall 122 extend from the wall 106. In the exemplary embodiment shown, the bottom wall 120 and the side wall 122 extend substantially perpendicularly from the wall 106. A protrusion 124 extends from the side wall 122. The protrusion 124 is spaced apart from the bottom wall 120, thereby forming a securing recess 126 between the protrusion 124 and the bottom wall 120.

[0024] The connector mating region 104 has a flange 130 having a contact locating surface 132. An opening 134 extends through the flange 130 to the contact locating surface 132.

[0025] Once the perimeter seal 50 is properly seated on the contact 10, as described above, the assembled contact 10 is moved into the contact receiving area 102, as shown in Figure 6. In this position, the contact 10 is aligned with the opening 108. The contact 10 is then inserted or moved in the direction of arrow 150, as shown in Figure 6.

[0026] As the contact 10 is moved in the direction of arrow 150, the free end 26 of the first mating portion 12 is moved into the opening 108. As insertion continues, the fixed portion 16 of the contact 10 is received in the fixed portion 118 of the housing 100. As this occurs, the protrusion 124 guides the side wall 36 of the fixed portion 16 into the fixed recess 126 to facilitate proper positioning of the contact 10. The protrusion 124 cooperates with the side wall 36 to prevent movement of the fixed portion 16 and the contact 10 in a direction perpendicular to the insertion of the contact 10.

[0027] As insertion continues, the barbs 34 protruding from the side walls 36 of the fixed portion 16 move or slide into the locking recesses 126. As this occurs, the lead-in surfaces 38 of the barbs 34 dig into or displace material on the side walls 122 of the fixed portion 118. Once fully inserted, the locking shoulders 40 engage the side walls 122 to prevent the contact 10 from undesirably disengaging from the fully inserted position.

[0028] As the contact is moved in the direction of arrow 150, the lug-receiving opening 32 of the transition portion 14 is moved into engagement with a locating lug 116 extending from the wall 106 of the housing 100. Once the locating lug 116 is received in the lug-receiving opening 32, the locating lug 116 guides the contact 10 as it is inserted, thereby facilitating proper final positioning of the contact 10 relative to the housing 100.

[0029] As the contact 10 is moved in the direction of arrow 150, the perimeter seal 50 is moved into the opening 108. The projections 68 on the first surface 52 engage the transition portion 14 and the seal retaining projections 30, causing the perimeter seal 50 to move with the contact 10 as the contact 10 is moved in the direction of arrow 150.

[0030] As perimeter seal 50 enters opening 108, ridges 64 of projections 60 of perimeter seal 50 are deformed or compressed by walls 110, 112, and 114 of housing 110. The compression of ridges 64 causes ridges 64 to exert a force against walls 110, 112, and 114, thereby forming a seal between perimeter seal 50 and opening 108 of housing 110, as shown in FIG.

[0031] Insertion of contact 10 continues until transition wall 14 of contact 10 is brought into engagement with wall 106 of housing 100. Once transition wall 14 contacts wall 106, contact 10 is fully inserted into housing 100, as shown in Figures 7 and 8.

[0032] 7 and 8 , when the contact 10 is fully inserted into the housing 100, the mating contact engaging portion 20 of the contact 10 is positioned adjacent to or in engagement with the contact locating surface 132 of the flange 130 of the housing 100. In this position, the opening 24 of the mating contact engaging portion 20 is aligned with the opening 134 of the flange 130. The seal receiving portion 22 and the peripheral seal 50 of the first mating portion 12 are positioned in the opening 108. As previously described, the peripheral seal 50 exerts a force on the opening 108 of the housing 110 to form a seal therebetween. In addition, the peripheral seal 50 exerts a force on the seal receiving portion 22 to form a seal therebetween. As a result, a watertight seal is provided to prevent moisture or other contaminants from entering the contact receiving area 102 and other interior portions of the housing 100 from outside the housing 100 .

[0033] In the fully inserted position, the projection-receiving opening 32 of the transition portion 14 engages the locating projection 116 extending from the wall 106 of the housing 100, thereby preventing movement of the contact 10 in a direction transverse to the longitudinal axis of the locating projection 116. Additionally, the locking shoulder 40 of the barb 34 engages the side wall 122 of the fixed portion 118 of the housing 100, thereby preventing the contact 10 from undesirably removing from the fully inserted position.

[0034] The use of contacts, contact assemblies, and housings allows contacts, such as, but not limited to, ground lugs, to be placed and sealed into the housing without the need for expensive tooling and processes, which can be particularly beneficial when the housing is overmolded.

Claims

1. A first mating portion (12), a transition portion (14), a fixed portion (16) and a second mating portion (18). An electrical contact (10) comprising: the first mating portion (12) extends in a plane substantially parallel to the plane of the fixed portion (16), and the transition portion (14) extends in a plane substantially perpendicular to the plane of the first mating portion (12); The first mating portion (12) has a mating contact engaging portion (20) and a seal receiving portion (22), and a seal retaining projection (30) extends from the seal receiving portion (22); a projection-receiving opening (32) extending through said transition portion (14); Electrical contact (10).

2. The electrical contact (10) of claim 1, wherein the electrical contact (10) is a ground lug made from an electrically conductive material.

3. 2. The electrical contact (10) of claim 1, wherein the first mating portion (12) has an opening (24) disposed near a free end (26) of the first mating portion (12).

4. 2. The electrical contact (10) of claim 1, wherein the seal retention projection (30) extends from the first mating portion (12) in a direction substantially perpendicular to the plane of the first mating portion (12).

5. The electrical contact (10) of claim 1, wherein the fixed portion (16) has a retention projection (34) extending from a sidewall (36) of the fixed portion (16).

6. The electrical contact (10) of claim 5, wherein the retention projection (34) has a lead-in surface (38) and a locking shoulder (40).

7. 2. The electrical contact (10) of claim 1, wherein the second mating portion (18) extends from the fixed portion (16) in a direction substantially perpendicular to a plane of the fixed portion (16).

8. 8. The electrical contact (10) of claim 7, wherein a mating contact engagement portion (42) extends from a free end (44) of the second mating portion (18), the mating contact engagement portion (42) being a compliant pin.

9. The electrical contact (10) of claim 1, wherein a perimeter seal (50) is provided in the seal receiving portion (22) of the first mating portion (12) of the electrical contact (10).

10. 10. The electrical contact (10) of claim 9, wherein the perimeter seal (50) is made from a compliant material having a durometer of 50 or greater.

11. The perimeter seal (50) has a first surface (52) and an oppositely facing second surface (54); a top surface (56), a bottom surface (58), and a side surface (60) extending between said first surface (52) and said second surface (54); A plurality of sealing projections (62) extend from the top surface (56), the bottom surface (58), and the side surfaces (60), the free ends of the sealing projections (62) forming ridges (64), and recesses (66) being provided between adjacent sealing projections (62). The electrical contact (10) of claim 9.

12. The electrical contact (10) of claim 11, wherein a second projection (68) extends outwardly from both the first surface (52) and the second surface (54).

13. A first mating portion (12), a transition portion (14), a fixed portion (16) and a second mating portion (18). An electrical contact (10) comprising: the first mating portion (12) extends in a plane substantially parallel to the plane of the fixed portion (16), and the transition portion (14) extends in a plane substantially perpendicular to the plane of the first mating portion (12); The first mating portion (12) has a mating contact engaging portion (20) and a seal receiving portion (22), and a seal retaining projection (30) extends from the seal receiving portion (22); The fixed portion (16) has a retention projection (34) extending from a side wall (36) of the fixed portion (16). Electrical contact (10).

14. An electrical contact (10) as described in claim 13, wherein the retaining protrusion (34) has a retraction surface (38) and a locking shoulder portion (40).

15. A first mating portion (12), a transition portion (14), a fixed portion (16) and a second mating portion (18). An electrical contact (10) comprising: the first mating portion (12) extends in a plane substantially parallel to the plane of the fixed portion (16), and the transition portion (14) extends in a plane substantially perpendicular to the plane of the first mating portion (12); The first mating portion (12) has a mating contact engaging portion (20) and a seal receiving portion (22), and a seal retaining projection (30) extends from the seal receiving portion (22); the second mating portion (18) extends from the fixed portion (16) in a direction substantially perpendicular to the plane of the fixed portion (16); a mating contact engaging portion (42) extending from a free end (44) of the second mating portion (18), the mating contact engaging portion (42) being a compliant pin; Electrical contact (10).

16. A first mating portion (12), a transition portion (14), a fixed portion (16) and a second mating portion (18). An electrical contact (10) comprising: the first mating portion (12) extends in a plane substantially parallel to the plane of the fixed portion (16), and the transition portion (14) extends in a plane substantially perpendicular to the plane of the first mating portion (12); The first mating portion (12) has a mating contact engaging portion (20) and a seal receiving portion (22), and a seal retaining projection (30) extends from the seal receiving portion (22); a peripheral seal (50) is provided in the seal receiving portion (22) of the first mating portion (12) of the electrical contact (10); The perimeter seal (50) has a first surface (52) and an oppositely facing second surface (54); a top surface (56), a bottom surface (58), and a side surface (60) extending between said first surface (52) and said second surface (54); A plurality of sealing projections (62) extend from the top surface (56), the bottom surface (58), and the side surfaces (60), the free ends of the sealing projections (62) forming ridges (64), and recesses (66) being provided between adjacent sealing projections (62). Electrical contact (10).

17. a contact receiving area (102) and a connector mating area (104); a wall (106) disposed between the contact receiving area (102) and the connector mating area (104), the wall (106) having a contact receiving opening (108) extending therethrough, and a positioning projection (116) extending from the wall (106) into the contact receiving area (102); A fixing portion (118) having a fixing recess (126) a housing (100) comprising: A first mating portion (12), a transition portion (14) and a fixed portion (16) A contact (10) comprising: The first mating portion (12) has a mating contact engaging portion (20) and a seal receiving portion (22), and a seal retaining projection (30) extends from the seal receiving portion (22); a peripheral seal (50) is provided in the seal receiving portion (22) of the first mating portion (12) of the contact (10); Contact (10) and A connector assembly comprising: the first mating portion (12) extends in a plane substantially parallel to a plane of the fixed portion (16), the fixed portion (16) extending from the transition portion (14) in a direction opposite to an insertion direction (150) of the first mating portion (12) into the contact-receiving opening (108); a projection-receiving opening (32) extending through said transition portion (14) to engage said positioning projection (116); A connector assembly, wherein the side wall (36) of the fixed portion (16) engages with the fixed recess (126).

18. 18. The connector assembly of claim 17, wherein the seal receiving portion (22) and the peripheral seal (50) of the first mating portion (12) are disposed in the contact receiving opening (108), and the peripheral seal (50) exerts a force on the seal receiving portion (22) and the contact receiving opening (108) of the first mating portion (12) to provide a watertight seal to prevent moisture or other contaminants from entering the contact receiving area (102) of the housing (100).

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