U.S. patent number RE41,182 [Application Number 11/975,342] was granted by the patent office on 2010-03-30 for sealed pass-through electrical connector.
This patent grant is currently assigned to Walbro Engine Management, L.L.C.. Invention is credited to Kenneth J. Cotton, Jeffrey D. Hanby, Kevin L. Israelson, Roger N. Smith, David L. Thomas.
United States Patent |
RE41,182 |
Cotton , et al. |
March 30, 2010 |
Sealed pass-through electrical connector
Abstract
A pass-through electrical connector assembly with a body having
at least one through-hole formed therein. A pin is forced into the
through-hole and held by the body. The pin has a shank with opposed
ends, each with a blind hole to receive a wire and a solid center
portion that seals the wires and the pin. The pin has a tip with a
barb at one end and a head with a shoulder at the other end which
captures the pin in the body after the pin is forced into the
through-hole when the shoulder engages the body. The shank has a
circumferential surface that is press-fit within the through-hole
to form a seal between the pin and the body. The body can then be
sealed to a mating flange of a fluid-holding tank.
Inventors: |
Cotton; Kenneth J. (Caro,
MI), Hanby; Jeffrey D. (Cass City, MI), Israelson; Kevin
L. (Cass City, MI), Smith; Roger N. (Ubly, MI),
Thomas; David L. (Cass City, MI) |
Assignee: |
Walbro Engine Management,
L.L.C. (Tucson, AZ)
|
Family
ID: |
37719586 |
Appl.
No.: |
11/975,342 |
Filed: |
October 18, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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10826894 |
Apr 16, 2004 |
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Reissue of: |
11265403 |
Nov 1, 2005 |
07175481 |
Feb 13, 2007 |
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Current U.S.
Class: |
439/733.1 |
Current CPC
Class: |
B60K
15/03 (20130101); H01R 13/5208 (20130101); H01R
13/5202 (20130101); H01R 2201/26 (20130101); B60K
2015/03453 (20130101); F02M 2037/082 (20130101) |
Current International
Class: |
H01R
13/40 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Duverne; Jean F
Attorney, Agent or Firm: Reising Ethington P.C.
Parent Case Text
REFERENCE TO RELATED APPLICATION
This application claims the benefit of .Iadd.and is a
continuation-in-part of .Iaddend.U.S. patent application Ser. No.
10/826,894, filed on Apr. 16, 2004.Iadd., now abandoned.Iaddend..
Claims
The invention claimed is:
1. A pass-through electrical connector assembly comprising: a body
of an electrically insulative and somewhat yieldable plastic or
rubber material; at least one through-hole formed in said body with
a shoulder adjacent to the through-hole; and an electrically
conductive pin forced into said through-hole and retained in said
body, said pin having: first and second ends each having a recess
therein constructed to receive and have permanently attached
thereto a separate electrically conductive wire; an intermediate
solid portion between said recesses constructed to separate said
wires and provide a fluid-tight seal between said wires and said
pin; a tip adjacent said first end of said pin, said tip having at
least one barb constructed to engage said body and overlie a
portion of said shoulder adjacent to the through-hole when said pin
is forced into said through-hole; a head formed adjacent said
second end of said pin, said head having a shoulder constructed to
engage said body when said pin is forced into said through-hole;
and a circumferentially continuous exterior surface between said
ends press-fit into said through-hole of said body with an
interference fit with said body and forming a fluid-tight seal
between said pin and said body.
2. A pass-through electrical connector assembly as defined in claim
1 wherein said body is a housing constructed of plastic.
3. A pass-through electrical connector assembly as defined in claim
1 wherein said body is a housing constructed of synthetic
rubber.
4. A pass-through electrical connector assembly as defined in claim
1 wherein said body is made of a low hydrocarbon permeation
material.
5. A pass-through electrical connector assembly as defined in claim
1 which also comprises a flange having a hole complementary to said
body and said body is received in said hole in said flange and
sealed to said flange.
6. A pass-through electrical connector assembly as defined in claim
5 wherein said body comprises a snap latch constructed to retain
said body in said flange.
7. A pass-through electrical connector assembly as defined in claim
5 wherein said body comprises a retainer sealing said body to said
flange.
8. A pass-through electrical connector assembly as defined in claim
1 which also comprises at least one elastomeric seal between said
pin and said body.
9. A pass-through electrical connector assembly as defined in claim
1 wherein said pin has a separate blind hole with a
circumferentially continuous sidewall opening into each of said
ends of said pin and constructed to receive a separate wire in each
blind hole permanently attached therein.
10. A pass-through electrical connector assembly as defined in
claim 1 wherein said pin has a blind hole with a circumferentially
continuous sidewall opening into one of said first and second ends
and constructed to receive a wire in the blind hole permanently
attached therein and the other of said ends is solid.
11. A pass-through electrical connector assembly as defined in
claim 1 wherein said circumferential surface is cylindrical.
12. A pass-through electrical connector assembly as defined in
claim 1 wherein said circumferential surface is tapered.
13. A pass-through electrical connector assembly as defined in
claim 1 wherein the maximum diameter of said barb is larger than
the maximum diameter of said circumferentially continuous surface
of said pin.
14. A pass-through electrical connector assembly as defined in
claim 1 wherein said shoulder of said head is diametrically larger
than said circumferentially continuous surface of said pin.
15. A pass-through electrical connector assembly as defined in
claim 1 wherein said circumferentially continuous surface of said
pin is diametrically larger than said through-hole prior to said
pin being forced into said through-hole.
16. A pass-through electrical connector assembly as defined in
claim 1 wherein the circumferentially continuous exterior surface
is defined by a radially outwardly extending rib.
17. A pass-through electrical connector assembly as defined in
claim 16 wherein said first and second ends of said pin are
solid.
18. A pass-through electrical connector assembly as defined in
claim 17 wherein at least one end of said pin is adapted to receive
thereon an engaging terminal for a wire.
19. A pass-through electrical connector assembly as defined in
claim 17 wherein said first and second ends of said pin are each
adapted to receive thereon an engaging terminal for a wire.
20. A pass-through electrical connector assembly as defined in
claim 16 wherein the rib has a leading edge disposed at an acute
included angle relative to an adjacent surface of the pin and a
trailing edge disposed at an acute included angle relative to an
adjacent surface of the pin with the angle of the leading edge
being shallower than the angle of the trailing edge.
21. A pass-through electrical connector assembly as defined in
claim 16 wherein the rib is disposed between the barb and the
shoulder.
22. A pass-through electrical connector assembly as defined in
claim 1 wherein the circumferentially continuous exterior surface
is defined by more than one radially outwardly extending rib.
23. A pass-through electrical connector assembly as defined in
claim 22 wherein each rib is spaced from each other rib.
24. A pass-through electrical connector assembly as defined in
claim 23 wherein each rib is adapted to form a circumferentially
continuous seal with a body in which the pin is received.
25. A pass-through electrical connector assembly as defined in
claim 22 wherein a first rib and a second rib are provided with a
first rib leading the second rib relative to the direction of
insertion of the pin into a body and being of smaller maximum outer
diameter than the second rib.
26. A pass-through electrical connector assembly as defined in
claim 1 wherein the through-hole includes a shoulder and said barb
defines a base that overlies and engages the shoulder and has a
maximum diameter that is greater than the minimum diameter of the
through hole.
27. A pass-through electrical connector assembly comprising: a body
of an electrically insulative and somewhat yieldable plastic or
rubber material; at least one through-hole formed in said body; and
an electrically conductive pin forced into said through-hole and
retained in said body, said pin having: first and second ends each
having a recess therein constructed to receive and have permanently
attached thereto a separate electrically conductive wire; an
intermediate solid portion between said recesses constructed to
separate said wires and provide a fluid-tight seal between said
wires and said pin; a tip adjacent said first end of said pin, said
tip having at least one barb constructed to engage said body when
said pin is forced into said through-hole; a head formed adjacent
said second end of said pin, said head having a shoulder
constructed to engage said body when said pin is forced into said
through-hole; and a circumferentially continuous exterior surface
between said ends press-fit into said through-hole of said body
with an interference fit with said body and forming a fluid-tight
seal between said pin and said body; wherein said body has at least
two through-holes formed in said body and adjacent through-holes
are axially offset relative to each other so that the shoulders of
the pin received in adjacent through-holes are axially offset
relative to each other.
28. A pass-through electrical connector assembly comprising: a body
of an electrically insulative and somewhat yieldable plastic or
rubber material; at least one through-hole formed in said body; and
an electrically conductive pin forced into said through-hole and
retained in said body, said pin having: first and second ends each
having a recess therein constructed to receive and have permanently
attached thereto a separate electrically conductive wire; an
intermediate solid portion between said recesses constructed to
separate said wires and provide a fluid-tight seal between said
wires and said pin; a tip adjacent said first end of said pin, said
tip having at least one barb constructed to engage said body when
said pin is forced into said through-hole; a head formed adjacent
said second end of said pin, said head having a shoulder
constructed to engage said body when said pin is forced into said
through-hole; and a circumferentially continuous exterior surface
between said ends press-fit into said through-hole of said body
with an interference fit with said body and forming a fluid-tight
seal between said pin and said body; wherein said tip has a frusto
conical portion at said first end to facilitate insertion of said
pin into said through-hole.
29. A pass-through electrical connector assembly comprising: a body
of an electrically insulative and somewhat yieldable plastic or
rubber material; at least one through-hole formed in said body; and
an electrically conductive pin forced into said through-hole and
retained in said body, said pin having: first and second ends each
having a recess therein constructed to receive and have permanently
attached thereto a separate electrically conductive wire; an
intermediate solid portion between said recesses constructed to
separate said wires and provide a fluid-tight seal between said
wires and said pin; a tip adjacent said first end of said pin, said
tip having at least one barb constructed to engage said body when
said pin is forced into said through-hole; a head formed adjacent
said second end of said pin, said head having a shoulder
constructed to engage said body when said pin is forced into said
through-hole; and a circumferentially continuous exterior surface
between said ends press-fit into said through-hole of said body
with an interference fit with said body and forming a fluid-tight
seal between said pin and said body; wherein said tip is
diametrically smaller than said circumferentially continuous
surface of said pin.
30. A pass-through electrical connector assembly comprising: a body
of an electrically non-conductive and somewhat yieldable material;
at least two through-holes each formed in said body; and a separate
pin of an electrically conductive material forced into each one of
said through-holes and retained in said body, each said pin having:
a shank with opposed ends each constructed to receive and have
permanently attached thereto a separate wire; a solid portion
between said wires received on said opposed ends and providing a
fluid-tight seal between said wires and said pin; a tip formed
adjacent one end of said pin, said tip having at least one barb
constructed to engage said body when said pin is forced into said
through-hole; a head formed adjacent the other end of said pin,
said head having a shoulder constructed to engage said body when
said pin is forced into said through-hole; and an intermediate
portion of said shank having a circumferentially continuous
exterior surface press-fit within said through-hole of said body
with an interference fit with said body thereby forming a
fluid-tight seal between said pin and said body.
31. A pass-through electrical connector assembly as defined in
claim 20 wherein said body is made of a plastic material.
32. A pass-through electrical connector assembly as defined in
claim 20 wherein said body is received in a complementary hole in a
flange and said body has a snap latch constructed to engage said
flange.
33. A pass-through electrical connector assembly as defined in
claim 20 wherein said body is made of a low permeation
material.
34. A pass-through electrical connector assembly as defined in
claim 30 wherein said tip is diametrically smaller than said
intermediate portion of said shank.
35. A pass-through electrical connector assembly as defined in
claim 30 wherein the maximum diameter of said barb is larger than
the maximum diameter of said circumferential surface of said
intermediate portion of said shank.
36. A pass-through electrical connector assembly as defined in
claim 30 wherein said shoulder of said head is diametrically larger
than said intermediate portion of said shank.
37. A pass-through electrical connector assembly as defined in
claim 30 wherein said maximum diameter of said intermediate portion
is larger than said minimum diameter of said through-hole.
38. A method of forming a pass-through electrical connector
assembly comprising: providing a body of an electrically
non-conductive and somewhat yieldable plastic or rubber material
having at least one through-hole therein with a shoulder adjacent
to the through-hole, providing an electrically conductive pin
having a shank with opposed ends and at least one of the ends
constructed to receive and have permanently attached thereto an
electrically conductive wire, a tip having a barb adjacent one end,
a head having a shoulder adjacent the other end, and an
intermediate portion having a circumferentially continuous exterior
surface with a maximum diameter larger than the minimum diameter of
the through-hole of the body; inserting the tip of the pin into the
through-hole and forcing the barb into and through the through-hole
with the barb disposed over a portion of said shoulder adjacent to
the through-hole and the intermediate portion into the through-hole
to provide an interference fit of at least the circumferentially
continuous exterior surface in the body providing a fluid-tight
seal between the pin and the body.
39. The method of claim 38 which also comprises providing a blind
hole with a circumferentially continuous sidewall opening into the
pin, inserting an electrically conductive wire into the blind hole
and permanently attaching at least a portion of the wire in the
blind hole to the pin.
40. The method of claim 39 which also comprises soldering at least
a portion of the wire in the blind hole to the pin.
41. The method of claim 39 which also comprises crimping the pin to
firmly engage and permanently retain at least a portion of the wire
in the blind hole.
42. The method of claim 38 which comprises prior to inserting the
pin into the through-hole, the steps of providing a blind hole in
the pin which opens onto one end of the pin and has a
circumferentially continuous sidewall, inserting one end of an
electrically conductive wire into the blind hole, and permanently
attaching at least a portion of the wire in the blind hole to the
pin.
43. The method of claim 38 which also comprises prior to inserting
the pin into the through-hole in the body, the steps of providing
in the pin a first blind hole opening onto one end of the pin and
having a circumferentially continuous sidewall, and a second blind
hole opening onto the other end of the pin and having a
circumferentially continuous sidewall, with the intermediate
portion disposed between the blind holes, inserting one end of a
first conductive wire into one of the blind holes, inserting one
end of a separate second conductive wire into the other blind hole,
permanently attaching at least a portion of the wire in each blind
hole to the pin, and subsequently inserting one of the wires into
the through-hole so that after the step of inserting the pin into
the through-hole of the body is completed the first and second
wires extend out of and beyond generally opposed ends of the
body.
44. A pass-through electrical connector assembly comprising: a body
of an electrically insulative and somewhat yieldable polymeric
material; at least one through-hole formed in said body; and an
electrically conductive pin forced into said through-hole and
retained in said body, said pin having: first and second ends each
having a recess therein constructed to receive and have permanently
attached thereto a separate electrically conductive wire; an
intermediate solid portion between said recesses constructed to
separate said wires and provide a fluid-tight seal between said
wires and said pin; a tip adjacent said first end of said pin, said
tip having at least one barb constructed to engage said body when
said pin is forced into said through-hole; a shoulder adjacent said
second end of said pin and constructed to engage said body when
said pin is forced into said through-hole; and a circumferentially
continuous exterior surface between said ends, including at least
one radially outwardly extending rib, press-fit into said
through-hole of said body with an interference fit with said body
and forming a fluid-tight seal between said pin and said body.
45. A pass-through electrical connector assembly as defined in
claim 44 wherein the circumferentially continuous exterior surface
includes more than one radially outwardly extending rib.
46. A pass-through electrical connector assembly as defined in
claim 45 wherein each rib is spaced from each other rib.
47. A pass-through electrical connector assembly as defined in
claim 44 wherein said at least one rib is disposed between the barb
and the shoulder.
Description
FIELD OF THE INVENTION
This invention relates to electrical connectors and, more
specifically, to a pass-through electrical connector.
BACKGROUND OF THE INVENTION
A pass-through electrical connector for a fluid-holding tank
usually comprises electrical wires carried by a body where the
wires are sealed to prevent the fluid from passing through the
wires. The body is then sealed within a flange of the fluid-holding
tank. Various pass-through electrical connectors are known, such as
those manufactured by Pave Technology Company and Noma Automotive.
The electrical connector by Pave comprises wound wire strands with
a cover portion stripped away and the strands sealed together by
soldering them in the stripped region. The sealed wire is then
pulled through a hole formed in a body and an epoxy is poured into
the hole to create a final seal between the soldered strands and
the body. The electrical connector by Noma comprises a plastic body
that is injection molded around wound wire strands with the cover
removed. A sealant is then incorporated, by a vacuum, into every
crevice along the length of the wire strands to suitably seal the
wire within the molded body. While such electrical connectors are
generally effective and reliable, what is needed is a smaller,
low-cost, manufacturing-friendly alternative for passing electric
current through a flange or article and particularly of a
fluid-holding tank.
SUMMARY OF THE INVENTION
A pass-through electrical connector assembly having at least one
conductive connector pin received with an interference fit in a
through-hole in a non-conductive body to seal and retain the pin in
the body. Each pin has a shank with a tip and at least one barb
adjacent one end and a head and a shoulder adjacent the other end.
A blind hole in each end of the pin is constructed to receive a
separate electrically conductive wire and a solid portion of the
pin between the blind holes provides a seal between the wires and
the holes. The body is of a somewhat flexible or resilient material
and each through-hole in its unstressed state has a minimum
diameter slightly smaller than the diameter of a circumferentially
continuous portion of the shank so that when the pin is forced into
the through-hole, a seal is formed between at least this
circumferential portion and the body with an interference fit. If
desired, the body may then be sealed to a mating flange or other
portion of a fluid holding tank. If desired, the body may be an
integral portion of an article, such as a fuel pump module, a fluid
holding tank, a plastic fuel tank or the like.
Objects, features and advantages of this invention include a
pass-through electrical connector assembly and method of making it
which is highly leak resistant, reliable, may be made as an
integral portion of a product, and is relatively small, of simple
design, easy and inexpensive to manufacture and assemble and in
service has a long useful life.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of this invention
will be apparent from the following detailed description of the
preferred embodiments and best mode, appended claims, and
accompanying drawings in which:
FIG. 1 is a perspective view of a first embodiment of the
pass-through electrical connector assembly of the present
invention;
FIG. 2 is a full sectional view taken along line 2--2 of the
pass-through electrical connector assembly shown in FIG. 1;
FIG. 3 is a side view of an electrically conductive pin used in the
pass-through electrical connector assembly shown in FIG. 2;
FIG. 3A is a side view of a second variation of the electrically
conductive pin showing a multiple-barb configuration and a tapered
shank portion;
FIG. 3B is a side view of a third variation of the electrically
conductive pin for receiving an elastomeric seal on the shank of
the pin;
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 3
showing blind holes in the ends of the electrically conductive pin
separated by a solid center portion, which forms a fluid-tight seal
between the holes and conductive wires to be received in the holes
and attached to the pin;
FIG. 5 is an upper portion of the pass-through electrical connector
assembly of FIG. 2 showing a cover attached to the body to seal the
body with the mating flange and to pinch-seal the wires;
FIG. 6 is a bottom portion of a modified pass-through electrical
connector assembly of FIG. 2 showing a snap latch formed in the
body for retaining the body in the mating flange;
FIG. 7 is an upper portion of the pass-through electrical connector
assembly of FIG. 6 showing an annular flange formed on the body for
retaining and sealing the body to the mating flange;
FIG. 8 is a fragmentary cross-sectional view of a second embodiment
of the pass-through electrical assembly of the present invention in
which each electrically conductive pin is forced directly through
the mating flange or wall of an article;
FIG. 9 is a side view of a third embodiment of the pass-through
electrical connector assembly of the present invention showing a
stepped configuration of a multiple-pin connector;
FIG. 10 is a full sectional view taken along line 10--10 of the
pass-through electrical connector assembly of FIG. 9;
FIG. 11 is a view of one end of the body of the pass-through
electrical connector assembly of FIG. 9;
FIG. 12 is a view of the other end of the body of the pass-through
electrical connector assembly of FIG. 9;
FIG. 13 is a cross-sectional side view of the body of the
pass-through electrical connector assembly of FIG. 9 taken along
line 13--13 of FIG. 11;
FIG. 14 is a cross-sectional side view of the body of the
pass-through electrical connector assembly of FIG. 9 taken along
line 14--14 of FIG. 11; and
FIG. 15 is a cross-sectional side view taken along line 15--15 of
FIG. 12;
FIG. 16 is a side view of an alternate electrically conductive pin
which may be used in a pass-through electrical connector
assembly;
FIG. 17 is a cross-sectional view taken generally along line 17--17
of FIG. 16; and
FIG. 18 is an enlarged fragmentary view of the pin of FIG. 16.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring in more detail to the drawings, FIGS. 1-3 illustrate a
pass-through electrical connector assembly 10 of a first embodiment
of the invention. The connector assembly 10 has a pair of pins 12
(only one of which is shown) each forced with an interference fit
through a separate through-hole 14 preformed in a body 16. Each pin
12 is made of an electrically conductive metal and is electrically
connected to separate electric wires 30 and 32 which extend from
opposite ends of the pin and the body to provide an electrically
conductive path through the body. The body is made of an
electrically non-conductive or insulating material which is
somewhat yieldable or flexible and preferably somewhat resilient
such as a plastic resin or synthetic hard rubber material. The body
may be made in one piece with the through-holes therein by suitable
injection molding dies and methods.
As shown in FIGS. 2-4, each pin 12 has a shank 26 with a tip 18
adjacent one end and a head 20 adjacent the other end. A blind bore
22, 24 at each end and preferably co-axial with the shank is
constructed and arranged to receive separate electrically
conductive wires 30 and 32 which are separated by a solid central
portion 28 of the shank to provide a fluid tight seal between the
blind holes and the wires. Preferably, the wires are permanently
attached to the pin by soldering, brazing, crimping, cold rolling
or some other technique. Preferably, after the wires are attached,
the pin 12 and its associate wire 30 is inserted with the tip end
18 first into an associated through-hole 14 and pressed therein
with an interference fit to provide a seal between the pin and the
body and permanently retain the pin in the body. If desired, the
body of the connector assembly may then be inserted into a
complementary mating hole 33 through a mounting flange 34 or a part
of an article in which the connector is utilized such as a fuel
pump module or a fuel tank.
The pin 12 is made of or coated with a suitable electrically
conductive material such as one that is typically used for
electrical terminals. Preferably, the pin 12 is made of tin plated
brass. Since the pin 12 is constructed to receive the wires 30, 32
in the blind holes 22, 24, respectively, the size and shape of the
pin 12 and its component parts (i.e., the tip 18, head 20 and shank
26) are usually determined based on the wire gage and/or means by
which the wires 30, 32 are attached to the pin. Alternatively, one
or both of the ends of the pin may be solid and shaped to receive
thereon a mating terminal. The length of each blind hole 22, 24
extends substantially into, but not through, the pin 12, thereby
leaving the solid intermediate portion 28. Regardless of whether
the pin has a blind hole in either or both ends, the solid
intermediate portion 28 adequately separates the wires 30, 32 and
provides a fluid-tight seal between the wires 30, 32 and the pin
12.
To pilot, center and align the connector pin 12 as it is being
inserted into an associated hole 14, as shown in FIG. 3,
preferably, the tip 18 has a frusto-conical end 36 which blends
into a cylindrical mid-portion 38 which in turn blends into a barb
40. Preferably, the end 36 is tapered at about 10.degree. to
15.degree. inwardly relative to the axis of the cylindrical portion
38 which preferably has a diameter somewhat smaller than the
minimum diameter of its associated through-hole 14 in the body.
Preferably, the barb 40 is frusto-conical, tapers outwardly from
the cylindrical portion 38, preferably at an angle 10.degree. to
15.degree., and has a maximum diameter at its base 44 which is
greater than the minimum diameter of its associated through-hole 14
so that in assembly the barb retains the pin in the body. During
insertion, this also allows the barb 40 to scrape and "clean" the
through-hole 14 of any foreign particles or other material which
may improve the seal between the pin and this area of the body.
When the pin is completely pressed into and seated in the
through-hole 14, preferably, the base 44 will also overlie and
engage a shoulder 60 of the through-hole to facilitate retention of
the pin in the body. Preferably, the pin 12 also has an undercut or
groove 48 at the base 44 of the barb 40 into which an adjacent
portion of the body material flows to further enhance sealing and
retention of the pin in the body.
In most applications, a pin 12 with a single barb 40 is believed to
be satisfactory for achieving the desired fluid-tight seal and
retention of the pin in the body 16 of the connector assembly.
However, for some applications, better sealing may be obtained with
a pin 12' as shown in FIG. 3A having two or more barbs 40 (i.e., a
multiple-barb construction). With this modified pin 12', during
insertion into its associated through-hole 14 in the body, improved
scraping and cleanliness of the through-hole may be obtained which
may remove more foreign material or particles in the through-hole
as the barbs pass therethrough, thereby improving the seal between
the pin and the body.
As shown in FIG. 3, the shank 26 has a central portion 46 with a
circumferentially continuous and cylindrical exterior surface with
a diameter slightly larger than the minimum diameter of the
through-hole 14 so that when the pin 12 is pressed into and sealed
in the through-hole, there is an interference fit between the
central portion 46 and the body 16 which provides a fluid-tight
seal between them. In some applications, this seal may be improved
and resistance to removal of the pin increased, as shown in FIG.
3A, by forming a central portion 46' with a slight taper in the
reverse direction so that the diameter of the portion 46'
progressively decreases from the recess 48 to the head portion 20.
In some applications, it may be desirable to further improve the
fluid-tight seal and/or permeation resistance by providing, as
shown in FIG. 3B, an O-ring between the pin and the body which may
be received in an annular groove 47 in the central portion 46 of
the shank. For hydrocarbon fuel system applications, the O-ring
should be preferably a fluorocarbon for hydrocarbon permeation
resistance. The groove 48 may also provide a space for receiving
any dirt particles or material from the body 16 that are displaced
and not completely removed from the hole when the barb or barbs 40
are pushed through the hole 14 during insertion of the pin into the
body.
To facilitate insertion of the pin 12, 12' into the body, the head
20 preferably has a cylindrical end portion 50 and an annular
flange 52 extending radially outwardly thereof which provides a
shoulder or surface 53 which in assembly bears on a portion of the
surface 17 of the body immediately adjacent the hole 14 in which
the pin is received. To facilitate retention of the pin in the
body, preferably, the axial distance between the shoulder 53 and
the base 44 of the barb 40 is substantially equal to the axial
distance between the bottom surface 17 and the shoulder 60 of the
body engaged by the barb. In assembly, this construction captures
the pin 12 in the body 16 so that it cannot be removed. If it is
desired to attach the wire 32 to the head 20 by a mating terminal,
the end portion 50 may include a thread, knurl or a rib for
receiving a complementary end of the mating terminal over the end
portion 50 of the head.
As shown in FIG. 2, the body 16 of the pass-through electrical
connector assembly 10 of the first embodiment is a separate
one-piece housing member made of a plastic or synthetic rubber
material and if used in a fuel system is compatible with fuel. For
use in fuel systems, the body 16 is preferably made of a low
hydrocarbon permeation material. More preferably the body 16 is
made of acetal (e.g., Delrin or Celcon), polyamide (Nylon) or
polyphthalimide (Amodel) resins, having a tensile strength in the
range of 150,000 psi to about 550,000 psi for unfilled resins.
Glass-filled resins can have tensile strengths in the range of
150,000 psi to 2,000,000 psi. Preferably, the material of the body
16 also has good creep resistance so that the interference fit
between the body and the pin is maintained. The body 16 is
generally cylindrically shaped but may have other shapes, such as
an oval or rectangular shape, depending on the shape of the opening
of the mating flange 34 in which the body 16 will be received. The
size of the body 16 is usually determined based on the number, size
and layout of the pins/wires needed for the electrical connector
assembly 10.
As shown in FIG. 2, the end 45 of the through-hole 14 communicates
with a clearance or access hole or counterbore 56. The access hole
56 forms the shoulder 60 on which the base 44 of the barb 40 bears
when the pin 12 is assembled in the through-hole 14. Since the tip
18 comprises a flying lead for the wire 30, the access hole 56 may
be filled with a sealing material or sealant, such as silicone,
epoxy or potting compound to prevent contamination of the wire 30
by dirt particles. Another hole or counterbore 58 may be formed at
the top of the access hole 56 that can receive a grommet (not
shown) or a sealant for further protection of the wires 30 from
foreign particles and contaminants.
Preferably, each pin 12 is pressed into the body 16 at ambient
temperature and with the wires 30, 32 pre-attached to the pin. Wire
32 and the tip 18 are first inserted generally coaxially into the
end of an associated through-hole 14 and then a force is applied to
the head 20 of the pin 12 in the direction of the tip 18 to press
the tip 18 and the barb 40 into and through the through-hole 14.
The barb 40 cleans the through-hole 14 as it passes through it and
then bears on the shoulder 60 at the end 45 of the through-hole 14
and the flange 52 engages the bottom surface 17 of the body at the
first end 43 of the through-hole 14. Once all of the pins 12 have
been seated in the body 16, a sealant can then be introduced into
the access holes 56 to protect the wires 30.
After all the pins 12 have been seated in the body 16, the body can
be assembled to the mating flange 34. Preferably, the outer
diameter of the body 16 is equal to or slightly larger than the
inner diameter of the mating hole 33 in the flange 34. Thus, the
body 16 can be pressed into the hole in the mating flange 34 and
retained in and sealed to the flange 34 by frictional engagement.
Alternatively, the body can have a diameter slightly smaller than
the mating hole 33 in the flange and be retained and sealed
therein. As shown in FIG. 2, retention and sealing may be provided
or improved by providing the body 16 with annular grooves 62 that
receive elastomeric seals, such as O-rings 64 which in assembly are
compressed and prevent fluid from leaking or permeating between the
body 16 and the flange 34.
Since the pass-through electrical connector assembly 10 is formed
separately from the mating flange 34 and the mating flange can have
a number of different configurations and orientations, the body 16
and/or the mating flange 34 may include additional features to
provide a good seal between them. As shown in FIG. 5, the mating
flange 34 may include an appropriate groove or recess 70 that
receives an O-ring 72 providing a seal between the body 16 and the
mating flange 34. The O-ring 72 can then be retained further by a
cover 74 that can be threaded or snapped onto the body 16 such as
by a rib 76 received in a complementary groove or threads in the
body 16. The cover 74 also can be used to gather and organize the
flying leads of the wires 30 attached to the pins 12 to create a
pinch-seal. The gathered wires 30 can then be easily attached to,
for example, another electrical terminal.
If frictional retention of the body 16 in the mating flange 34 is
insufficient, as shown in FIG. 6, the body 16 may include a snap
latch 80 which is preferably annular and engages the bottom surface
82 of the mating flange 34. The latch is preferably integral with
the body 16 and has an axially projecting flexible and resilient
finger 86 with a shoulder 88 which in assembly engages the body and
a sidewall 90 which tapers outwardly of the free end of the finger
to facilitate assembly. When the body 16 is inserted into the hole
33 of the mating flange, the tapered surface 90 flexes the finger
generally radially inwardly until the finger snaps outwardly so
that the latch 88 overlaps the surface 82 of the flange to retain
the body therein. As shown in FIG. 7, to further facilitate the
retention, the body 16 may have an annular flange or head 94 which
in assembly overlies the flange 34. If desired, an O-ring 98 may be
received in an annular groove 96 in the head 94 to provide a
further seal between the body and the mating flange. Other lathe
cut or molded seals with rectangular, X or other cross-sections,
may also be used.
FIG. 8 illustrates a second embodiment of the present invention of
a pass-through electrical connector assembly 100 with at least one
pin 12 received in a through-hole 120 in a flange or a wall 122 of
a plastic material of an article such as fuel pump module or a
plastic fuel tank. Each pin 12 is press fit into an associated hole
120 and retained therein by its barb 40 and flange 52. Since this
connector assembly 100 does not have a separate body 16, the fluid
and permeation sealing function is performed by the seal between
the wires 30, 32 and the pin 12, and the seal between the pin 12 in
the hole 120 in the plastic flange or wall 122 which is provided by
the interference fit between them. The connector assembly may
utilize any and all the pin arrangements of FIGS. 3, 3A, 3B and
4.
In electrical connectors having two or more pins which are only
slightly spaced apart radially, it may be desirable to generally
axially offset or stagger adjacent pins to insure that none of the
pins touch or contact each other which might short out or interrupt
an electrical connection or circuit. FIGS. 9-15 illustrate a third
embodiment of this invention in an electrical connector assembly
200 having four connector pins 12 with adjacent pins sufficiently
axially offset in a body 202 so that the seated pins do not contact
each other even though the flanges 52 of the head portions are in
close proximity and even may be radially overlapped. As best shown
in FIG. 15, in body 202, adjacent holes 14a and 14b are axially
offset or stepped relative to each other a distance greater than
the axial extent or thickness of the flange 52 of the head portion
of the pins so that when seated in the body, the pins do not
contact or engage each other. Except for being axially offset or
stepped, the through holes 14a, 14b have essentially the same
construction and arrangement as the through holes 14 in the body 16
of the connector assembly 10. At the leading end, the holes 14a
open into a generally planar face 214 of a recess 216 in the body
202 and each hole 14b opens into a counterbore 218 which forms a
shoulder 220 and opens into the face 214.
When insulating the pins in the body 202, a pin 12 is inserted and
seated in each of the through holes 14b before pins 12 and inserted
in the through-holes 14a. When installed and seated in the body,
the flange 52 of the pin in each hole 14a preferably bears on the
face 212 and the flange 52 of the pin in each hole 14b preferably
bears on the shoulder 220 formed by the counterbore 218.
Preferably, the body 202 has a common clearance or access hole or
opening 204 and a common hole or counterbore 206 for all of the pin
tips 18 and flying lead wires 30 which, after the pins are seated
therein, may be filled with a grommet or sealant 208 (FIG. 10) such
as silicone, epoxy or potting compound for the flying lead wires
emerging from each pin. If desired, grooves 222 may be provided in
the body 202 for each receiving an O-ring 224 to provide a seal
between the connector assembly 200 and a complementary hole in a
flange or article in which it is mounted or received.
FIGS. 16-18 illustrate another presently preferred implementation
of an electrically conductive pin 12'' that may be used in a
pass-through electrical connector assembly. The pin 12'' preferably
is constructed similarly to the pin 12, with the same reference
numbers used to indicate like parts. For example, the pin 12''
preferably includes blind bores 22, 24, on opposed sides or ends of
a solid portion 28, a tip 18 with a frusto-conical end 36, a
cylindrical mid-portion 38, a barb or barbs 40, base 44, central
portion 46, recess 48, end portion 50, flange 52, and shoulder 53,
by way of example without limitation.
In the area of the pin 12'' disposed within a corresponding hole
(e.g. 14 or 120), at least one rib extends radially outwardly from
the adjacent surfaces of the pin 12''. As best shown in FIG. 18,
preferably a first rib 250 and a second rib 252 are provided
axially spaced apart and extending outwardly from the central
portion 46 between the base 44 and shoulder 53. While shown as
parallel to each other and perpendicular to an axis 253 of the pin
12'', the ribs 250, 252 may be inclined relative to each other, to
the axis, or both. The ribs 250, 252 are circular in the
implementation shown, but they may be otherwise shaped, and may
have wave-like or other profile, as desired. The first rib 250 is
located closer to the base 44, and may have an outer diameter that
is slightly smaller than the outer diameter of the second rib 252
to facilitate insertion of the pin 12'' into a hole since the first
rib 250 leads and will travel further within the hole than the
second rib 252 given the direction of insertion of the pin 12''.
Each rib 250, 252 preferably includes a leading edge 254, 256,
respectively, disposed at a relatively shallow angle to provide a
smooth transition from the central portion 46 to a maximum outer
diameter section of the rib 250, 252, and a trailing edge 258, 260,
respectively, disposed at a steeper angle from the central portion
46 to the maximum outer diameter section. Each rib 250, 252
preferably is formed in one-piece with the rest of the pin 12''.
The ribs 250, 252 provide circumferentially continuous areas of
increased interference or compression of the material of the body
to improve the seal between the body and pin 12''. Otherwise, the
pin 12'' may be utilized in the same fashion as the pin 12, and may
have wires connected thereto in similar manner.
Persons of ordinary skill will appreciate that the axially offset
arrangement of adjacent pins 12, 12', 12'' illustrated in connector
assembly 200 may also be utilized in a connector assembly formed
directly in a flange or article which does not have a separate body
in which the pins 12, 12', 12'' are mounted and carried. Skilled
persons will also appreciate that various modification and changes
may be made from the preferred embodiments disclosed herein and/or
even though some connector assemblies may not contain all of the
features and advantages of the preferred embodiments they still
will be within the scope and spirit of the connector assemblies and
methods defined by the following claims.
* * * * *