Electrical connector part

Abstract

The invention relates to an electrical connector part. The electrical connector part comprises an electrical contact and a housing. The electrical contact comprises a body having a sealing region. The sealing region of the electrical contact comprises a peripheral surface comprising at least one ridge or groove extending around the body. The housing comprises housing material which is overmoulded onto the electrical contact such that the housing material surrounds and contacts the electrical contact in the sealing region and is moulded onto the at least one ridge or groove.

Description

[0001] Electrical Connector Part

[0002] The present invention relates to an electrical connector part, particularly to an electrical connector part for use in a vehicle. The invention extends to a device including such an electrical connector part and to a method of manufacturing such an electrical connector part.

[0003] Electrical connectors may employ pairs of inter-engaging connector parts for interconnecting one, or more, circuits or wires through mated electrical contacts. In some connectors the connector parts are referred to as male and female connector parts and may employ a pin and socket arrangement. Electrical connectors are used in many different environments and are used to create a reliable and robust electrical connection that can be disconnected when required. An electrical connector may comprise two releasably connectable connector parts, for example a first connector part and a second connector part.

[0004] The invention provides an electrical connector part, the electrical connector part comprising an electrical contact and a housing, the electrical contact comprising a body having a sealing region, the sealing region of the electrical contact comprising a peripheral surface comprising at least one ridge or groove extending around the body, the housing comprising housing material which is overmoulded onto the electrical contact such that the housing material surrounds and contacts the electrical contact in the sealing region and is moulded onto the at least one ridge or groove.

[0005] It has been found that providing at least one ridge or groove extending around the peripheral surface of the sealing region of the body may enhance the sealing between the electrical contact and housing material. The sealing may be enhanced particularly during heating and cooling cycles. The material from which the electrical contact is fabricated and the housing material may have different coefficients of thermal expansion an this could lead to differential expansion or contraction between the parts of the electrical connection part can lead to gaps which can lead to the creation of a leak path. Enhancing the sealing between the electrical contact and housing material may increase the flexibility for use of the electrical connector part particularly when the electrical connector part may be used with a pressurised component in which the electrical connector part may act as a seal.

[0006] The electrical connector part may be part of an electrical connector, which may be any form of electrical connector. The electrical connector part may be a male or a female connector part, for example a plug or a socket connector part. The electrical connector may be a high voltage electrical connector which may be capable of handling voltages of over 100V, over 200V, over 300V, over 400V, or over 800V. The electrical connector may be a connector for carrying direct current, or for carrying alternating current.

[0007] The electrical connector part may be releasably connected to a second connector part. This releasable connection may be a friction, or interference, fit so that separation of the connector parts can be achieved by pulling the connector parts apart, for example along the first and second axes. The releasable connection may be secured in a connected configuration by a releasable or removable element or fixing, for example a clip or catch, or a screw or pin.

[0008] The electrical connector part may be any suitable shape and configuration. The connector part comprises a housing and the housing is overmoulded onto at least a part of the electrical contact.

[0009] Moulding and overmoulding processes are known and may involve an injection moulding process. In an overmoulding process, a pre-formed component, in this case the electrical contact, is arranged in a mould and a liquid material is added to the mould over and around at least part of the pre-formed component to form a moulded body of the component.

[0010] This may be referred to as an insert moulding process, with the insert being the pre-formed component. The liquid, or at least flowable, material which forms the housing material may be a molten plastic which is injected into, or otherwise added to, the mould, or may be a resin which is injected, poured, or otherwise added into the mould. This may allow the material to bond, or adhere, directly to the pre-formed component.

[0011] The electrical contact is made from a material which is electrically conductive and may be a metal. The housing material added to the mould in the overmoulding or insert moulding, process may be non-conductive such that is acts as an electrical insulator.

[0012] The electrical connector may be fabricated from a metallic material. The metallic material may be a bare metal or may be coated, for example with another metallic material. For example, the material may be a copper material, and the copper material may be coated with silver. The housing material may be a plastic material. The housing material may comprise a reinforcing fibre, for example a glass fibre, within the plastic matrix. The reinforcing fibre may make up at least 20%, at least 30% or at least 35% of the weight of the housing material. The plastic may be a polypropylene, a polyphenylene sulfide, a polycarbonate, or a polyamide. The material may be classified as GF-40 which refers to a glass fibre reinforced material with 40% w / w glass fibres.

[0013] The electrical contact may be any suitable shape. The electrical contact may comprise a terminal end to be connected to an electrical connection of a component. The electrical contact may comprise a contact end which is to engage, and form an electrical connection with, a contact end of an electrical contact of a second connector part.

[0014] The connector portion of the electrical contact can be in any suitable form. The connector portion may be in the form of a pin to engage with a corresponding socket of a second connector portion. This can provide a convenient and reliable electrical connection, but other forms are also possible. The pin may be substantially cylindrical, and the associated socket may be a cylindrical shape to accept a cylindrical pin to provide a radial connection. These sorts of connectors are commercially available under the trademark RADSOK®.

[0015] The sealing region of the electrical contact being arranged between the terminal end and the contact end. The sealing region may be any suitable shape, for example the sealing region may be substantially cylindrical. The contact end of the body of the electrical contact may comprise a substantially cylindrical pin.

[0016] The electrical connector may comprise a plurality of electrical contacts. The plurality of electrical contacts may be identical, or they may differ from one another. Each of the plurality of electrical contacts may comprise a pin to engage with a corresponding electrical socket which is part of a second connector part. The, or each, of the electrical contacts may comprise an associated sealing region. The electrical connector part may comprise three electrical contacts, each electrical contact may comprise a body having a sealing region, the sealing region of each electrical contact may comprise a peripheral surface comprising at least one ridge or groove extending around the body onto which housing material is overmoulded.

[0017] The sealing region is a region of the electrical contact with which the housing material makes contact during the overmoulding process. The sealing region extends around the electrical contact, or associated contact elements. The sealing region comprising a peripheral surface of the electrical contact, or associated contact elements. The peripheral surface comprises at least one ridge or groove extending around the body of the electrical contact. The ridge or groove extends around the body of the electrical contact and may do so in a substantially straight line with no axial deviations, or the line could deviate axially and, for example be wavy. The ridge or groove may be any suitable cross- sectional shape, for example the cross section of the groove or ridge may comprise curved or linear portions, the cross section may be curved, for example it may be continuous curve, for example and arc of a circle, semi-circular, or the cross section may be polygonal.

[0018] The ridge or groove may extend at least 0.2mm, at least 0.3mm, or at least 0.35mm into, or out of, the peripheral surface. The axial extent of the ridge or groove itself may be at least 0.2mm, at least 0.3mm, or at least 0.35mm. The ridge or groove may extend no more than 1mm, 0.8mm, 0.7mm, or 0.5mm from the peripheral surface. The axial extent of the ridge or groove itself may be no more than 2mm, 1 ,6mm, 1 ,4mm, or 1 mm.

[0019] The peripheral surface of the sealing region may comprise more than one more ridge or groove and may comprise a combination of ridges and grooves. The ridges and grooves may be substantially parallel with one another and spaced along the electrical contact. For example, the sealing region may comprise at least three ridges or grooves onto which the housing material is moulded. The, or each, ridge or groove in the sealing region may be a groove.

[0020] The sealing region may extend no more than 1cm, no more than 0.7cm, or no more than 0.5cm.

[0021] The peripheral surface of the sealing region may be any suitable shape. The shape may be regular, or irregular, polygonal, or curved. The sealing region may be substantially cylindrical in shape as this may avoid corners which could concentrate stresses.

[0022] The housing may comprise a guide wall extending around the first electrical contact. The electrical contact may extend parallel with a first axis. The guide wall may extend parallel with the first axis and extending around the fist electrical contact.

[0023] The invention also provides an electrical device comprising an electrical connector part attached thereto, the electrical connector part being as described above. The electrical device may generate a pressure differential across the sealing region. The electrical device may be a compressor. The invention further provides a method of manufacturing an electrical connector part, the method comprising: providing an electrical contact comprising a body having a sealing region, the sealing region of the electrical contact comprising a peripheral surface comprising at least one ridge or groove extending around the body; arranging the electrical contact in a mould; providing housing material and adding the housing material to the mould to overmould the electrical connector and form a housing of the electrical connector part, the housing material surrounding and being in contact with the electrical contact in the sealing region and being moulded onto the at least one ridge or groove.

[0024] The invention will now be described by way of example only with reference to the following figures in which:

[0025] Figure 1 shows a schematic cross-section through an electrical connector part;

[0026] Figure 2 shows a schematic cross-section through a different electrical connector part;

[0027] Figure 3 shows a view of an electrical contact;

[0028] Figure 4 shows a cross-section through a further electrical connector part;

[0029] Figure 5 shows a view of an electrical connector part having three electrical contacts;

[0030] Figure 6a and 6b show schematic views of an interface between an electrical contact and a housing;

[0031] Figure 7a and 7b show schematic views of an interface between an electrical contact with a groove and a housing;

[0032] Figure 8 shows a view of parts of an assembly comprising a compressor and an inverter;

[0033] Figure 9 shows an assembly formed from the parts of Figure 8;

[0034] Figure 10 shows a view of parts of an assembly comprising a compressor and an inverter; and

[0035] Figure 11 shows a flowchart of a method of manufacturing an electrical connector part.

[0036] Figure 1 shows schematic cross-section through an electrical connector part 1. The electrical connector part 1 comprises an electrical contact 2 and a housing 4. The electrical contact 2 comprises a body 6 having a sealing region 8. The sealing region 8 of the electrical contact 2 comprises a peripheral surface 10 comprising at least one groove 12 extending continuously around the body 6. The housing 4 comprising housing material 14 which is overmoulded onto the electrical contact 2 such that the housing material 14 surrounds and contacts the electrical contact 2 in the sealing region 8 and is moulded into the at least one groove 12.

[0037] The electrical connector part 1 comprises an electrical contact 2 extending parallel with a first axis 16 of the electrical connector part 1. The electrical connector part 1 comprises a first guide wall 18 that extends parallel with the first axis 16, is spaced from, and extends around the first electrical contact 2. The first guide wall 18 is a substantially continuous structure around the first electrical contact 2.

[0038] The electrical connector part 1 also comprises a housing 4 which is overmoulded onto the electrical contact 2 in an overmoulding or insert moulding process in which the electrical contact 2 is arranged in a mould and then housing material 14 which is to form the housing 4 is introduced into the mould. During the moulding process, the material 14 which is to form the housing 4 contacts the sealing region of the first electrical contact 2 so that the first electrical contact 2 is secured into the first connector body 4. The housing material 14 also extends into the groove 12.

[0039] The electrical contact 2 comprises a contact end 22 which, in this example, comprises a substantially cylindrical pin. The contact end 22 is exposed within the first guide wall 18. The electrical contact 2 comprises a terminal end 22 which includes a fixing hole 26 though which a fixing can be passed to secure the first connector part 1 to another component.

[0040] Figure 2 shows schematic cross-section through a different electrical connector part 101. The electrical connector part 101 is the same as the electrical connector 1 of Figure 1, with the exception that there are three grooves 112 which extend around the body 106 of the electrical contact 102 in the sealing region 108.

[0041] Figure 3 shows a view of an electrical contact 202. The electrical contact 202 comprises a contact end 222 which, in this example, comprises a substantially cylindrical pin. The contact end 222 and a terminal end 224. The terminal end 224 includes a fixing hole 226 though which a fixing can be passed to secure the first connector part 1 to another component. Figure 4 shows a cross-section through a further electrical connector part 201 which includes the electrical contact 202. Only a part of the guide wall 218 that surrounds the contact end 222 of the electrical contact 202 can be seen.

[0042] Figure 5 shows a view of an electrical connector part 301 having three electrical contacts 202. The housing 304 is overmoulded onto the electrical contacts 202 such that the housing material 214 extends into the grooves 212 (not visible in this Figure) in the sealing regions 208 of the electrical contacts 202.

[0043] Figures 6a and 6b show schematic cross sections of an interface 28 between an electrical contact 302 and a portion of housing material 314. In these Figures the electrical contact 302 does not include any ridge or groove.

[0044] In Figure 6a the housing material 314 is in contact with the electrical contact 302 at the interface 28. In Figure 6b a gap 30 between the housing material 314 and electrical contact 302 has been created at the interface 28 by differential thermal expansion of the materials. The gap 30 provides a leak path through which fluids, particularly gasses, can pass.

[0045] Figures 7a and 7b show schematic cross sections of an interface 428 between an electrical contact 402 and a portion of housing material 414. In these Figures the electrical contact 402 includes a groove 412 in the sealing region 408. The housing material 414 has been forced into the groove 414 during the overmoulding process during manufacturing to form a corresponding ridge 32. The groove 412 is substantially semi-circular in cross-section and has a radius of about 0.4mm.

[0046] In Figure 7a the housing material 414 is in contact with the electrical contact 402 at the interface 428. In Figure 7b a gap 430 between the housing material 414 and electrical contact 402 has been created at the interface 428 by differential thermal expansion of the materials. However, unlike in Figure 6b, the gap 430 does not provide a simple leak path for fluids as the ridge 32 of housing material 414 extends across the gap 430 and into the groove 412. In this example, the gap 430 is created as the housing material 414 has a greater coefficient of thermal expansion than the material of the electrical contact 402 and the ridge 32 will also expand slightly more than the groove 412 and may continue to provide a substantially fluid tight seal within the groove 412 or will at least provide a tortuous leak path between the housing material 414 and electrical contact 402. Comparing Figures 6a and 6b with Figure 7a and 7b, it can be understood that the combination of an overmoulding process with the provision of grooves (or ridges) formed in the sealing region 408 of the electrical contact 402 can enhance the sealing at the interface 428 between the housing material 414 and electrical contact 402.

[0047] Figure 8 shows a schematic view of parts of an assembly 34. The assembly 34 comprises an electrically powered compressor 36, an electric power supply 38 and an electrical connector 40. The electrical connector 40 comprises an electrical connector part 401 which is substantially as described above and a second connector part 42.

[0048] The electrical connector part 401 of this example is a terminal block connected to the electrically powered compressor 36 in a predetermined position. The electrical connector part 401 is electrically connected to the electrically powered compressor 36. The electrical connector part 401 is connected to the electrically powered compressor 36 using fixings 44 which are inserted substantially perpendicular to a first axis 46 of the electrical connector part 401. During assembly, at least part of the electrical connector part 401 is covered by a cover component 48.

[0049] The power supply 38 in this example is an inverter and comprises the second connector part 42. The second connector part 42 is connected to a mounting plate 50 to which other parts 52,54 of the power supply 38 are connected. In this example, the mounting plate 50 comprises a mounting plate feature 56. During assembly, the mounting plate feature 56 is aligned with a corresponding feature 58 on the electrically powered component 54.

[0050] Figure 9 shows a schematic view of an assembly 52 assembled from the parts of Figure 8. The electrical connector part 401 and second connector part 42 are releasably coupled together such that the power supply 38 can provide electrical power to the electrically powered compressor 36 through the electrical connector 40. In use the compressor 36 pressurises the cover component 48. The electrical connector part 401 seals at least one opening through the cover 48. As discussed above, the overmoulding process with the provision of grooves (or ridges) formed in the sealing region 408 of the electrical contact 402 of the electrical contact part 401 can enhance the sealing at the interface 428 between the housing material 414 and electrical contact 402 which can prevent leakage of pressurised gas. Figure 10 shows a view of parts of an assembly 534 comprising a compressor 536 and an inverter 538. The compressor 536 includes an electrical connector part 501 coupled thereto and the inverter includes a second electrical connector part 542.

[0051] The inverter 538 includes a plurality of fixing features 556 and the compressor 536 comprises a plurality of fixing features 558 which can help to align and couple the compressor 536 to the inverter 538.

[0052] The assembly 534 may be an assembly of an inverter and e-compressor for use in the fuel supply system of a fuel cell powered vehicle.

[0053] Figure 11 shows a flowchart of a method 60 of manufacturing an electrical connector part. The method comprises in 62 providing an electrical contact comprising a body having a sealing region, the sealing region of the electrical contact comprising a peripheral surface comprising at least one ridge or groove extending around the body.

[0054] In 64 the electrical contact is arranged in a mould and in 66 a housing material is provided, and the housing material is added to the mould to overmould the electrical connector and form a housing of the electrical connector part. The housing material surrounds and is in contact with the electrical contact in the sealing region and is moulded onto the at least one ridge or groove.

Claims

Claims1. An electrical connector part, the electrical connector part comprising an electrical contact and a housing, the electrical contact comprising a body having a sealing region, the sealing region of the electrical contact comprising a peripheral surface comprising at least one ridge or groove extending around the body, the housing comprising housing material which is overmoulded onto the electrical contact such that the housing material surrounds and contacts the electrical contact in the sealing region and is moulded onto the at least one ridge or groove.

2. An electrical connector part as claimed in claim 1, in which the sealing region comprises at least three ridges or grooves onto which the housing material is moulded.

3. An electrical connector part as claimed in claim 1 or claim 2, in which the peripheral surface of the sealing region is substantially cylindrical in shape.

4. An electrical connector part as claimed in any preceding claim, in which the, or each, ridge or groove in the sealing region is a groove.

5. An electrical connector part as claimed in claim 4, in which the, or each, groove has a cross-section shaped like an arc of a circle.

6. An electrical connector part as claimed in claim 4, in which the, or each, groove has a cross-section which is substantially semi-circular.

7. An electrical connector part as claimed in any preceding claim, in which the body of the electrical contact comprises a terminal end and a contact end, the sealing region of the electrical contact being arranged between the terminal end and the contact end.

8. An electrical connector part as claimed in claim 7, in which the contact end of the body of the electrical contact comprises a substantially cylindrical pin.

9. An electrical connector part as claimed in any preceding claim, in which the electrical connector part comprises three electrical contacts, each electrical contact comprising a body having a sealing region, the sealing region of each electrical contact comprising a peripheralsurface comprising at least one ridge or groove extending around the body onto which housing material is overmoulded.

10. An electrical connector part as claimed in any preceding claim, in which the electrical connector is fabricated from a metallic material and the housing material is a plastic material.

11. An electrical connector part as claimed in any preceding claim, in which the housing comprises a guide wall extending around the first electrical contact.

12. An electrical connector part as claimed in claim 11, in which the electrical contact extends parallel with a first axis and the guide wall extends parallel with the first axis and extending around the fist electrical contact.

13. An electrical device comprising an electrical connector part attached thereto, the electrical connector part being as claimed in any of claims 1 to 12.

14. An electrical device as claimed in claim 13, in which the electrical device generates a pressure differential across the sealing region.

15. An electrical device as claimed in claim 13 or claim 14, in which the electrical device is a compressor.

16. A method of manufacturing an electrical connector part, the method comprising: providing an electrical contact comprising a body having a sealing region, the sealing region of the electrical contact comprising a peripheral surface comprising at least one ridge or groove extending around the body; arranging the electrical contact in a mould; providing housing material and adding the housing material to the mould to overmould the electrical connector and form a housing of the electrical connector part, the housing material surrounding and being in contact with the electrical contact in the sealing region and being moulded onto the at least one ridge or groove.

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