Electrical connector and method of assembling an electrical connector

Abstract

Electrical connector comprising a housing having an interior defined between a base and a cover, the base having a bottom wall and being open at an end opposite to the bottom wall, the cover having a top wall, and wherein one or both of the base and cover include a connection feature by which the base and cover are connected together, an electrical component received in the interior and including a wire retainer located in the interior, and a wire having an end received in the interior and connected to the wire retainer, wherein the top wall overlaps the bottom wall in a first direction, and the wire is inserted into the wire retainer in the first direction to connect the wire to the wire retainer.

Description

ELECTRICAL CONNECTOR AND METHOD OF ASSEMBLING AN ELECTRICAL CONNECTORTechnical Field

[0001] The present disclosure relates generally to an electrical connector and a method of assembling an electrical connector.Background Art

[0002] An electrical connector is a device used to join electrical circuits together. It allows for the easy and secure connection and disconnection of electrical wires or cables. However, one of the drawbacks of electrical connectors can be the complexity in assembling that would increase the manufacturing costs.Disclosure of the Invention

[0003] According to an aspect of the invention, an electrical connector is provided. The electrical connector comprises a housing having an interior defined between a base and a cover, the base having a bottom wall and being open at an end opposite to the bottom wall, the cover having a top wall, and wherein one or both of the base and cover include a connection feature by which the base and cover are connected together; an electrical component received in the interior and including a wire retainer located in the interior; and a wire having an end received in the interior and connected to the wire retainer, wherein the top wall overlaps the bottom wall in a first direction, and the wire is inserted into the wire retainer in the first direction to connect the wire to the wire retainer.

[0004] According to another aspect of the invention, a method of assembling an electricalconnector is provided. The method comprises the steps of: installing in a first direction an electrical component into a base of a housing; providing a wire over a wire retainer connected to the electrical component; and installing in the first direction a cover of the housing onto the base of the housing, wherein a movement of the cover relative to the base as the cover is installed onto the base causes the wire to be electrically connected to the wire retainer.

[0005] Other aspects and features are defined in the appended claims. Examples of the disclosure may make it possible to obtain an electrical connector - and a corresponding assembling method - that provides a proper coupling with other electrical components and is easy to manufacture.Brief Description of the Drawings

[0006] The following detailed description of preferred implementations and best mode will be set forth with regard to the accompanying drawings, in which:

[0007] FIG. 1 is a perspective view of an electrical connector with a housing cover separated from a housing base;

[0008] FIG. 2 is a perspective view of the base, showing an interior thereof;

[0009] FIG. 3 is a perspective view of the cover, showing inner surfaces thereof;

[0010] FIG. 4 is a perspective view of a circuit board including wire retainers; and

[0011] FIG. 5 is a sectional view of an assembled connector.Detailed Description of Illustrative Embodiments

[0012] Referring in more detail to the drawings, FIG. 1 illustrates an electrical connector10 that includes a housing 12 with a base 14, a cover 16 that is securable to the base 14 to define with the base 14 an interior 18 of the housing 12, and one or more electrical components 20 arranged within the interior 18 of the housing 12. The electrical connector 10 may include a coupling between one or more wires 22 and: other wires; a circuit board 24; or one or more electrical components 20, or a combination of two or more of these in the interior 18. The housing 12 may cover and protect the wire connection(s) and facilitate coupling to another electrical connector.

[0013] In at least some implementations, as shown in FIG. 2, the base 14 includes a bottom wall 26, and a pair of sidewalls 28 and a pair of end walls 30 connected to the sidewalls 28 and extending vertically from the bottom wall 26. The bottom wall 26, side walls 28 and end walls 30 include inner surfaces that define part of the interior 18, and outer surfaces that define part of an exterior 32 (FIG. 1) of the housing 12. The sidewalls 28 and end walls 30 extend from a first or lower end 34, that is coupled to the bottom wall 26, to a second or upper end 36, which may define a free end of the walls such that the upper portion or top 38 of the base 14, the face or side opposite to the bottom wall 26, is open.

[0014] To receive and retain the position of one or more components located in the interior 18, the bottom wall 26 and one or more sidewalls 28 may include surfaces or structures arranged to accommodate components to be installed in the housing interior 18. In the example shown, a first end 40 of the base 14 includes a channel 42 having a base 44 and sides 46 defining part of the inner surface of the bottom wall 26. The channel 42 may extend to a recess 48 in the end wall 30 to provide an opening aligned with the channel 42 and via which one or more wires 22 may extend into the housing interior 18. The bottom wall 26 may be configured to received electrical components 20 therein, such as componentsthat are mounted on the circuit board 24. In the example shown, the bottom wall 26 defines part of a cavity 50 at a depth different than the base 44 of the channel 42 and arranged to accommodate electrical components 20 extending from a lower face 52 (FIG. 4) of the circuit board 24. The sidewalls 28, end walls 30 or other surfaces defining the housing interior 18 may include retention features, such as tabs 54 or the like via which components, like the circuit board 24, can be press-fit or snap-fit into the base 14. For example, one or more tabs 54 (FIGS. 2 and 5) may extend inwardly from the sidewalls 28 and overlying a circuit board support surface 55 outboard of the channel 42. The tabs 54 may be flexible and resilient and may flex when a portion of the circuit board 24 is pressed into the base 14 and when the circuit board 24 passes the tabs 54, the tabs 54 may return toward their unflexed positions to partially overlap the circuit board 24 and inhibit removal of the circuit board 24 from the base 14.

[0015] Of course, other arrangements and retention features may be provided with retention surfaces oriented perpendicular to the direction of assembly of components into the base 14, which, in at least some implementations is vertical, through the open top 38 of the base 14. For example, the base 14 as shown in FIG. 1 may include a post 56 (shown in dashed lines) having an axis 58 arranged vertically and a tab or barb 60 having a retention surface arranged perpendicular to the post 56. The circuit board 24 includes an opening 62 (shown in dashed lines) that is aligned with the post 56 and when the circuit board 24 is assembled into the base 14, the circuit board 24 is pressed onto the post until the retention surface passes through the opening 62 and overlaps and retains the circuit board 24 on the post 56. While the tabs 54 / 60 provide a snap-fit arrangement, a press-fit or friction fit arrangement could also be provided, if desired. Further, adhesives, welds, heat stake, or fasteners may be used,if desired, even though these involve extra material, components or assembly steps.

[0016] To facilitate connecting the cover 16 to the base 14, the base 14 may include one or more base retention structures 64 that are arranged to interact with complementary cover retention features 66 when the cover 16 is connected to the base 14. In at least some implementations, the retention features 64, 66 may provide a snap-fit or interference fit between the cover 16 and base 14 without any other component (e.g. fastener), material (e.g. adhesive) needed. Of course, adhesives, welds, heat stake, or fasteners may be used to connect the cover 16 to the base 14, if desired. Referring to FIG. 2, the base retention features 64 are defined by includes two outwardly extending flanges 64 that are each cantilevered at one end 68 to an outer surface of a respective sidewall 28 of the base 14 and which have a free end 70 spaced from the outer surface of the base 14. The free end 70 of each flange 64 may include a retention surface 72 extending outwardly from the flange and which may define an enlarged head of the flange, spaced from the side wall 28.

[0017] As shown in FIGS. 1 and 3, the cover 16 may include a top wall 74 arranged to overlap and enclose at least part, and up to all of, the open upper end 38 of the base 14. The cover 16 may include a skirt, or side and end walls 76, 78 about some or all of its periphery, which may overlap the sidewalls 28 and end walls 30 of the base 14, if desired. In the example shown, the second ends of the sidewalls 28 and end walls 30 include a reduced thickness portion 80 and the skirt or walls 76, 78 of the cover 16 are received outboard 24 thereof, and a free end of the skirt or walls 76, 78 of the cover 16 may engage a ledge or stop surface 82 (FIG. 2) that surrounds the reduced thickness portion 80 of the base side and end walls 28, 30. If desired, a seal or gasket may be provided on the stop surface 82 to provide a seal between the cover 16 and base 14. Further, the cover 16 may include a flange84 at an end wall 78 aligned with the recess 48 in the end wall 30 of the base 14, and adapted to trap the one or more wires 22 that extend into the housing interior 18 between the cover 16 and base 14, in assembly. The other end wall 78 of the cover 16 may define, with the corresponding end wall of the base 14, an opening 86 via which wires 22 may be coupled to the circuit board 24, or another electrical connector can be connected to this electrical connector 10 (e.g. with electrical contacts defined by pins and in sockets of the mating connectors).

[0018] To retain the cover 16 on the base 14, the cover retention features 66 may include arms 88 that are adapted to overlie and couple to the flanges 64 of the base 14. In the example shown, each arm 88 includes an opening 90 constructed to be snap-fit over the head or retention surface 72 of the corresponding flange 64, with the opening 90 being expanded and / or the head / retention surface 72 being compressed to permit the flange to pass through the opening and thereafter be overlapped to inhibit removal of the arm from the flange. In at least some implementations, the snap-fit receipt of the flange 64 through the opening 90 occurs automatically when the cover 16 is pressed onto the base 14, such as by orienting the arms 88 so that the engage and are flexed outwardly by the flanges 64 and then resiliently return inwardly after passing the ends of the flanges 64. In this way, a separate operation to press the arms 88 inwardly over the flanges 64 is not needed, but could be utilized in some applications, as desired. This snap-fit arrangement is one example of a connection that can be made between the cover 16 and base 14, but others are possible, such as but not limited to, an interference or friction fit, adhesives, welds, heat stake, or fasteners.

[0019] Further, in the example shown in FIGS. 1 and 4, the connector 10 includes wire retainers 92 adapted to receive, retain and electrical connect to wires 22 inserted in thehousing 12. Referring to FIG. 4, the wire retainers 92 include conductors, shown as conductive metal prongs that are electrically coupled to one or more electrical components 20 on the circuit board 24 (e.g. by wires or conductive traces). The conductive prongs 92 have a post 91 that may be electrically coupled (e.g. soldered or the like) to conductive traces 93 or wires of the circuit board 24, and two fingers 94 spaced apart by an opening, such as a slot 96 in which a wire 22 is received in assembly. The width of the slot 96 (e.g. the gap between the fingers 94) may be less than the diameter of a wire 22 to be inserted therein, where the wire may include one or more outer layers of a nonconductive or insulative material surrounding a conductive wire in known manner. When a wire 22 is pressed into the slot 96 of a wire retainer 92, the fingers 94 may cut into or displace the nonconductive outer layer(s) so that the inner conductor / wire directly and electrically engages at least one of the fingers 94. The wire retainer 92 thereby functions as an insulation displacement terminal, which is sometimes also referred to as a connector blade. If no insulation is provided on that section of the wire, then the conductor may be compressed between and directly engaged with both fingers when the wire is pressed into the slot. In this way, the wires 22 are electrically connected to the wire retainers 92 by simply pressing each wire into the slot 96 of a respective one of the wire retainers. While press-fit wire retainers 92 are shown, the wires 22 may be coupled to the circuit board 24 or other internal components of the housing 12 in different ways, including but not limited to splicing, crimping, soldering, brazing, or welding.

[0020] In at least some implementations, the cover 16 and base 14 are arranged to define a desired interior and exterior configuration, and to be assembled together in a first direction 98, shown in FIG. 1, which may be perpendicular to the bottom wall 26 of the base in someimplementations. Further, components in the interior 18 of the housing 12, like the circuit board 24, may be assembled into the housing 12 in the first direction. Still further, the wire or wires 22 may overlap in the first direction the circuit board 24 or other component to which they are to be connected, and may be connected to respective wire retainers 92 in the first direction. For example, in the embodiments with wire retainers 92 that include conductive prongs, the slots 96 in the prongs 92 may be oriented in the first direction and the wires 22 may be pressed into or otherwise engaged with the conductive prongs in the first direction. Other examples may include pins or sockets arranged in the first direction (e.g. axes of the pins, and / or axes of openings in the sockets, are parallel to the first direction) and the connection of such pins and sockets, or wire ends into openings of the sockets, may occur in the first direction to connect one or more wires to the circuit board 24, and this may occur when the cover 16 is connected to the base 14 in the first direction.

[0021] The retention features 54 / 60 and connection features 64, 66 that couple components to the housing 12, and couple the cover 16 to the base 14, may be integrated into one or both of the cover 16 and base 14. That is, the features may be formed in the same piece of material as the cover 16 and base 14 so that fewer components are needed in the electrical connector and assembly of the connector can be made easier, faster and less costly. In this way, the connection features 64, 66 are carried by the cover 16 and base 14 prior to assembly of the housing 12, and are connected together when the cover 16 and base 14 are connected together.

[0022] In implementations where the components are assembled in one direction, assembly of the electrical connector 10 can readily be automated and performed by machines with little to no human involvement, if desired. With regard to assembly of the example electricalconnector 10 shown in the drawings: a) the base 14 may be provided, b) the circuit board 24 may be fitted into the base 14 in the first direction with posts 91 of the wire retainers received in the channel 42, c) the wires / cable 22 may be overlaid on the wire retainers 92, and d) the cover 16 may be pressed onto the base 14 to simultaneously connect the cover 16 to the base 14, and to insert the wires 22 into the openings / slots 96 of respective wire retainers 92 and thereby electrically couple the wires to the circuit board 24. Multiple wires 22 may be simultaneously coupled to the circuit board 24 (or other component(s) in the housing 12). In at least some implementations, the wires 22 may be connected together, such as in a ribbon cable 100 (shown in FIG. 4) in which the outer, nonconductive layer of adjacent wires are connected together to define a ribbon comprising multiple wires 22, to facilitate alignment of individual wires 22 with individual wire retainers 92 in the housing 12. In at least some implementations, the cover 16 includes one or more wire engagement surfaces 102 that engage(s) and displace(s) the wires into position in or on the wire retainers 92. In the example shown, the cover includes slots 104 that are aligned with the prongs 92 so that when the cover 16 is connected to the base 14, the prongs 92 are partly received in the slots 104 and the surfaces 104 of the cover 16 outboard of the slots 104 engages the wires 22 and pushes the wires 22 in to the slots 96 of the prongs 92. This may further facilitate assembly of the connector 10 and ensure proper connection of the wires 22.

[0023] The electrical connectors 10 described herein may have terminations and terminating elements (e.g. wire connections) located with the interior 18 of the housing 12. Further, the housing 12 may be defined by two components (e.g. base 14 and cover 16) with integrated connection features 64, 66 to facilitate assembling the housing 12. The components may be constructed to permit assembly in one direction, such as a "top-down"assembly process that may be automated and efficient. The bottom wall 26 of the base 14 may conveniently have a flat or generally planar outer surface opposite the open upper end 38 of the base 14, and the flat surface may provide a stable surface for the assembly process, e.g. as the cover 16 is pressed down onto the base 14 in the first direction, during assembly.

[0024] While the forms of the invention herein disclosed constitute presently preferred embodiments, many others are possible. For example, while the housing 12 is shown as having a base 14 with a generally planar bottom wall 26 and a cover 16 with a generally planar top wall 74, other shapes and sizes of housings and connectors may be used. It is not intended herein to mention all the possible equivalent forms or ramifications of the invention. It is understood that the terms used herein are merely descriptive, rather than limiting, and that various changes may be made without departing from the spirit or scope of the invention.

[0025] All terms used in the claims are intended to be given their broadest reasonable construction and their ordinary meanings as understood by those skilled in the art unless an explicit indication to the contrary is made herein. In particular, use of the singular articles such as "a," "the," "said," etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary.

Claims

CLAIMS1. An electrical connector, comprising: a housing having an interior defined between a base and a cover, the base having a bottom wall and being open at an end opposite to the bottom wall, the cover having a top wall, and wherein one or both of the base and cover include a connection feature by which the base and cover are connected together; an electrical component received in the interior and including a wire retainer located in the interior; and a wire having an end received in the interior and connected to the wire retainer, wherein the top wall overlaps the bottom wall in a first direction, and the wire is inserted into the wire retainer in the first direction to connect the wire to the wire retainer.

2. The connector of claim 1 wherein the connection feature is integrated into the base or cover.

3. The connector of claim 1 wherein both the base and the cover include integrated connection features arranged to snap-fit together to retain the connection between the base and the cover.

4. The connector of claim 1 wherein the wire retainer includes an opening oriented in the first direction and wherein the wire is received in the opening.

5. A method of assembling an electrical connector, comprising the steps of: installing in a first direction an electrical component into a base of a housing;providing a wire over a wire retainer connected to the electrical component; and installing in the first direction a cover of the housing onto the base of the housing, wherein a movement of the cover relative to the base as the cover is installed onto the base causes the wire to be electrically connected to the wire retainer.

6. The method of claim 5 wherein the wire retainer includes an opening oriented in the first direction and the wire is pressed into the opening in the first direction.

7. The method of claim 6 wherein the wire includes a nonconductive outer layer and a conductive wire within the outer layer, and wherein part of the nonconductive outer layer is displaced during a movement of the wire relative to the wire retainer so that the conductive wire engages the wire retainer as the wire is pressed into the opening.

8. The method of claim 5 which also includes connecting together connection features of the cover and base.

9. The method of claim 8 wherein the connection features are automatically connected together when the cover is assembled in the first direction to the base.

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