Connector shroud configuration

Connector assemblies are useful on automotive vehicles for making electrical connections. A variety of connector configurations are known in the industry. Fuel economy and material cost are considerations that have tended to lead to lighter weight connectors. In some cases, the connector features are less robust. As a result, additional care is required when making connections using such connectors.

An illustrative example embodiment of a connector includes a terminal configured to establish an electrically conductive connection with another component and a shroud surrounding the terminal. The shroud includes a first sidewall and a second sidewall that is transverse to the first sidewall. The first sidewall and the second sidewall have a sidewall dimension in a direction parallel to a longitudinal axis of the terminal. The shroud includes a first transition between the first sidewall and the second sidewall in the form of a hollow cylindrical sector having a first angular measurement of more than 90 degrees. The transition has a transition dimension that is less than the sidewall dimension.

In an example embodiment having one or more features of the connector of the previous paragraph, the shroud includes a third sidewall and a second transition between the second sidewall and the third sidewall in the form of a hollow cylindrical sector having a second angular measurement of more than 90 degrees. The second sidewall is transverse to the third sidewall. The third sidewall has the sidewall dimension, and the second transition has the transition dimension.

In an example embodiment having one or more features of the connector of any of the previous paragraphs, the first and second transitions are situated at corners of the shroud and the first and second transitions protrude beyond the first, second, and third sidewalls.

In an example embodiment having one or more features of the connector of any of the previous paragraphs, the first and second transitions include a radius of curvature and the first angular measurement is equal to the second angular measurement.

In an example embodiment having one or more features of the connector of any of the previous paragraphs, the first sidewall includes a first edge, the second sidewall includes a second edge, the first and second edges are at least partially in a first plane, the transition includes a third edge, and the third edge is at least partially in a second plane that intersects the first plane at an oblique angle.

In an example embodiment having one or more features of the connector of any of the previous paragraphs, the angle is between 60° and 20°, preferably between 50° and 30°, and more preferably 40°.

An illustrative example embodiment of a connector assembly includes a first connector including a first terminal and a first shroud surrounding the first terminal and a second connector including a second terminal configured to establish an electrically conductive connection with the first terminal. The second connector includes a second shroud surrounding the second terminal. The second shroud is configured to be received adjacent and overlapping with the first shroud when the first and second connectors are connected. The second shroud includes a first sidewall and a second sidewall that is transverse to the first sidewall. The second shroud includes a first transition between the first sidewall and the second sidewall in the form of a hollow cylindrical sector having a first angular measurement of more than 90 degrees. The first transition has a transition dimension that prevents contact between the transition and the at least one first terminal.

In an example embodiment having one or more features of the connector assembly of the previous paragraph, the first sidewall and the second sidewall have a sidewall dimension in a direction parallel to a connection direction of the terminals, the transition dimension is in the connection direction, and the transition dimension is less than the sidewall dimension.

In an example embodiment having one or more features of the connector assembly of any of the previous paragraphs, the shroud includes a third sidewall and a second transition between the second sidewall and the third sidewall in the form of a hollow cylindrical sector having a second angular measurement of more than 90 degrees, the second sidewall is transverse to the third sidewall, the third sidewall has the sidewall dimension, and the second transition has the transition dimension.

In an example embodiment having one or more features of the connector assembly of any of the previous paragraphs, the first and second transitions are situated at corners of the shroud and the first and second transitions protrude beyond the first, second, and third sidewalls.

In an example embodiment having one or more features of the connector assembly of any of the previous paragraphs, the first and second transitions include a radius of curvature and wherein the first angular measurement is equal to the second angular measurement.

In an example embodiment having one or more features of the connector assembly of any of the previous paragraphs, the first sidewall includes a first edge, the second sidewall includes a second edge, the first and second edges are at least partially in a first plane, the transition includes a third edge, and the third edge is at least partially in a second plane that intersects the first plane at an oblique angle.

In an example embodiment having one or more features of the connector assembly of any of the previous paragraphs, the angle is between 60° and 20°, preferably between 50° and 30°, and more preferably 40°.

The various features and advantages of at least one disclosed example embodiment will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.

FIG. 1 is a perspective illustration of an example connector designed according to an embodiment of this invention.

FIG. 2 shows selected features of the example connector.

FIG. 3 shows selected features of the example connector from a sectional view taken along the lines 3 - 3 in FIG. 2 .

FIG. 4 diagrammatically illustrates an example connector assembly.

FIG. 1 diagrammatically shows an example embodiment of a connector 20 . A plurality of terminals 22 are configured to make an electrically conductive connection with another connector or device. The terminals 22 are surrounded by a shroud 24 .

The shroud 24 includes a first sidewall 26 that is transverse to a second sidewall 28 . A third sidewall 30 is transverse to the second sidewall 28 and parallel to the first sidewall 26 . The shroud 24 includes transitions between the sidewalls. A first transition 32 is situated between the first sidewall 26 and the second sidewall 28 . A second transition 34 is situated between the second sidewall 28 and the third sidewall 30 . The shroud 24 is generally rectangular in the illustrated example embodiment and the transitions 32 and 34 have a radius of curvature having an angular measurement of more than 90 degrees so that the corners of the shroud 24 are rounded in the form of a hollow cylindrical sector.

Referring to FIGS. 1 and 2 , the sidewalls 26 , 28 and 30 have a sidewall dimension SD in a direction parallel to a longitudinal axis 35 of the terminals 22 . The axis 35 extends in an insertion or connection direction along which relative movement between the connector 20 and an associated component facilitates making the desired connection. The transitions 32 and 34 have a transition dimension TD that is smaller than the sidewall dimension SD. The transition dimension TD is also defined in a direction parallel to the axis 35 . From the perspective of FIG. 2 , the sidewall dimension SD can be considered a height of each sidewall and the transition dimension TD can be considered a height of the transition. With smaller transition sections, the corners of the shroud 24 do not extend as far in the connection direction as the sidewalls 26 , 28 and 30 . The smaller transitions provide at least two features that are useful.

The inventors have discovered that the shape of the transitions 32 and 34 causes a material flow into a correspondingly shaped mold during an injection molding process that produces a shroud 24 that is less susceptible to warping of the sidewalls 26 , 28 , 30 compared to an alternative arrangement in which the transitions between the sidewalls are just as long or as large as the sidewalls in the connection direction. This is a particular benefit when the mold gate is located opposite the transitions 32 , 34 in the mold. In an example embodiment, the shroud 24 is made of a glass filled nylon material. Reducing the likelihood of sidewall warping provides a better quality connector and reduces the likelihood of difficult connection with the connector 20 .

In the illustrated example embodiment, the sidewall 26 includes an edge 36 at an open end of the shroud 24 . The sidewall 28 includes an edge 38 and the sidewall 30 includes an edge 40 . The transition 32 includes an edge 42 and a transition 34 includes an edge 44 . The edges 36 , 38 and 40 on the respective sidewalls are all situated in a reference plane 50 as schematically shown in FIG. 2 . Given the smaller transition dimension TD compared to the sidewall dimension SD, the edges 42 and 44 are outside of the reference plane 50 (and below it in FIG. 2 ).

The edges 42 and 44 include a surface that is situated within a reference plane 52 as shown in FIG. 3 that is at an oblique angle A relative to the reference plane 50 . In the illustrated example embodiment, the angle A is between 20° and 60°. In some embodiments, the angle A is between 30° and 50°. According to one particular embodiment, the angle A is 40°.

The smaller transition dimension TD and the angled orientation of the surfaces 42 and 44 reduce or eliminate a likelihood that the shroud 24 will undesirably contact a terminal on a connector or device to which the connector 20 is being coupled. FIG. 4 illustrates an example scenario in which a connector 60 is designed to be coupled with the connector 20 . The connector 60 includes terminals 62 correspondingly shaped to mate with the terminals 22 of the connector 20 . A shroud 64 surrounds the terminals 62 . FIG. 4 shows the connectors 20 and 60 misaligned. When they are properly oriented for making a connection, the shrouds 64 and 24 are parallel to each other.

Even though a portion of the shroud 24 is able to penetrate into the space within the shroud 64 in the orientation shown in FIG. 4 , the size of the transitions 32 and 34 prevent undesirable contact between the shroud 24 and the terminals 62 . The transitions 32 and 34 are the portions of the shroud 24 that are most likely to penetrate the deepest into the shroud 64 when the connectors 20 and 60 are misaligned in a condition like that shown in FIG. 4 . Having a smaller transition dimension TD avoids undesired contact between the shroud 24 and the terminals 62 . This protects the integrity of the terminals 62 .

The illustrated example connector 20 includes transitions 32 and 34 that are configured to avoid undesired contact with terminals on another connector or device. The relationship between the transitions 32 and 34 and the adjacent sidewalls 26 , 28 and 30 , also enhances the integrity and reliability of the shroud 24 by reducing or eliminating the likelihood of those sidewalls warping.

The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this invention. The scope of legal protection given to this invention can only be determined by studying the following claims.