Note: Descriptions are shown in the official language in which they were submitted.
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Polarized Electrical Connector
and Method of Manufacture
Bac~ground of the Invention
The present invention is directed to a variably
polari~ed electrical connector and to the method of
manufacture thereof. More particularly, the present
invention is directed to an electrical connector
having a receptacle portion and a plug portion each
of which includes one orientation defining means and
each of which has either a pin socket array or a pin
array having a defined angular orientation such that
both the pin array and the pin socket array and the
receptacle and plug themselves must have the
appropriate orientation for the connector to be
assembled.
There are many electrical connectors known in
the art which have various polarizing features such
that connectors are not inappropriately assembled.
These various polarization features include
selectabl~ locatin~J external tabs as indicated in the
prior art F;gure 1 herein, such that the plug portion
has a series o~ outwardly extending tabs which engage
the tab slots defined by the receptacle. By
positioning these tabs it may be assured that the
plug and receptacle are appropriately oriented before
being assembled to each other and that the plug is
being assembled to the correct receptacle. Such
connectors require a series o~ molds to be developed
including a series of plug molds having appropriate
tabs and a series of receptacle molds having portions
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defining tab slots, one mold for each receptacle and
for each plug for each desired combination. Another
manner of fabrication is to have common plug and
receptable molds with polarizing inserts which can be
selectively positioned as desired to obtain plugs and
receptacles having tabs and tab slots appropriately
positioned.
In many automotive applications, it is desirable
to provide connectors which eliminate the possibility
of the assembler or repair person from inadvertently
making inappropriate electrical connections. For
this purpose, the various connectors are polarized
such that unless the tabs or other features of the
connectors mate, the electrical connection cannot be
made~ It has been identified to be extremely
desirable to provide this feature where multiple
connectors are positioned adjacent each other
providing an opportunity for incorrect connections.
The herein described connector utilizes a
combination oE two orientation means to assure that
inadverten~ assembly between an inappropriate plug
and receptacle is prevented. The herein designed
connector also uses a single pair of molds, one being
rotatable relative to the other, to manufacture all
of the receptacles and a separate pair for all of the
plugs notwithstanding that the pin array or the pin
socket array contained within the receptacle or plug
may be at distinct angular orientations relative to
the receptacle or plug. In this manner, a specific
means is provided to assure alignment between the
receptacle and plug in terms of a tab and slot,
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however, the pin array and pin socket connections are
additionally angled relative to the receptacle and
plug such that this angular relationship must also be
substantially identical to allow the connector to be
assembled. If this angular relationship is not
substantially identical, then the connector may not
be assembled and the repair person or assembler
realizes he is attempting to make an improper
electrical connection.
By the use of a single set of molds, one being
rotatable relative to the other, the cost of having
multiple sets of molds each with different
configurations is avoided. Likewise, the cost of
changing the molds and the molding machine or of
other assembly steps is eliminated.
Summary of the Invention
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It is an object of the present invention to
provide a polarized electrical connector for
connectin~ multiple circuits to each other.
It is another object of the present invention to
provide an electrical connector which may be
assembled only in a predetermined orientation such
that only the connections as desired can be made when
the connector is assembled.
It is a yet further object of the present
invention to provide a polarized connector such that
the polarity of the plug and the polarity of the
receptacle must match before the operator may
assemble the connector thereby preventing inadvertent
assembly of inappropriat0 plugs to receptacles.
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It is a still further object of the present
invention to provide a polarized electrical connector
which may be manufactured in various configurations
from a single set of molds.
It is another object of the present invention to
provide a safe, economical, reliable, easy to
manufacture and assemble, fail-safe and functional
electrical connector.
Other objects will be apparent from the
description to follow and the appended claims.
An electrical connector is described which
includes a receptacle having an annular shell
including a first orientation defining means and a
core having a second orientAtion defining means
including a pin socket array having a selected
angular orientation relative to the first orientation
defining means. Further disclosed is a plug
including a first mating means positioned to mate
with the Eirst orientation defining means and a pin
array having the same selected angular orientation
rela~ive to the first mating means as the pin socket
array has to the first orientation defin~ng means,
said pin array being conEigured to mate with the pin
socket array such that upon assembly of the connector
the first orientation defining means and the first
mating means and the pin socket array and the pin
array respectively mate if the selected angular
orientation of the pin socket array to the first
orientation defining means and the pin array to the
first mating means are substantially identical.
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Also disclosed is a method of manufacturing
variably polarized connectors using a common set of
molds. This method includes locating a first mold at
a first angular orientation such that the first mold
defines a cavity for the formation of the portion of
the connector including a first orientation defining
means. The second mold is located relative to the
first mold, said second mold defining a cavity for
the formation of a portion of the connector including
a pin socket array or a pin array having a distinct
angular orientation. The method then includes
rotating the molds relative to each other to define a
combined cavity with a specific angular orientation
between the first orientation defining means and the
pin socket array or pin array and thereafter forming
a connector using the first and second molds. 5aid
connector has variable polarization depending upon
the relative mold positions when the connector is
formed.
Brlef Description oE the Drawln~s
Figure 1 is a perspective view of a prior art
connector.
Figure 2 is a perspective view of a receptacle
including the pin socket array located in an angular
position relative to the remainder of the receptacle.
Figure 3 is a perspective view of a plug
designed to mate with the receptacle of Figure 2 and
showing the pin array in identical angular position
to the pin socket array of Figure 2.
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Figure 4 is a perspective view of a receptacle
having the pin socket array in a different angular
posltion.
Figure 5 is a perspective view of a receptacle
having the pin socket array in yet a third angular
position.
Figure 6 is a perspective, partially cut away
view of a pair of molds use~ul for manufacturing
receptacles.
Description of the Preferred Embodiment
The invention herein will be described with
reference to a specific connector made from a
receptacle and a plug. It is to be understood that
although specific orientation means such as a tab
extending into a slot are disclosed for positioning
the plug relative to the receptacle, that other
similar angular positioning and verification
arrangements may suitably provide the same
relationship~
Although it is assumed herein that the
electrical connèctor is made from a plastic material,it is to be understood that other materials also may
be utilized. It is further to be understood that the
drawings only show a molded part and do not show the
electrical conductors to be inserted within the
receptacle for engagement with the pins. The
omission is purely for the sake of clarity in the
drawings and the description, since any known
conductors could be appropriately provided.
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It is also to be understood that the manner in
which one mold may be rotated relative to another
mold or the choice of which mold is rotated are
matters of design choice.
In prior art Figure 1, there may be seen a
receptacle 10 having an annular shell 18 which
defines locator tabs 14 and 16 and latch tab 12. The
receptacle further includes core 20 defining a pin
receiving socket 22 all located within the center of
shell 18 in referenced annular space 24. The
combination of the locator tabs and the latch tab act
to cooperate with a plug (not shown) having extending
tabs which mate in terms of position with the locator
tabs and latch tabs to effectively polarize the plug
with respect to the receptacle.
Figure 2 discloses receptacle 30 according to
the herein invention and includes shell 36 defining
latch tab 32 which includes tab slots 38 and 34.
Shell 36 defines an internal annular space 46 in
which core 40 is mounted. Core 40 defines a series
of pin sockets 42 arranged collectively to form pin
socket array 44 having a specific orientation
relative to tab slot 38. The pin socket array is
also designed such that not only does it have a
desired angular relationship with the tab slot, but
such that a plug having projecting pins may only
engage the pin socket array in a desired manner.
Latch tab 32 defines tab slot 38 to which a
projecting tab of the plug may be engaged. Latch tab
~30 32 also defines slot 34 at the top of tab slot 38
through which a projection extending from the plug
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may be engaged to secure the receptacle to the plug
to prevent inadvertent disengagement between the plug
and receptacle.
Figure 3 is a perspective view of plug 50 which
S is designed to mate with receptacle 30. Plug 50 has
annular body 56 defining a central cavity 58 in which
pin array 62 consisting of pins 60 is secured.
Extending from the exterior of annular body 56 is tab
52 including projection 54. The pin array 62 of plug
50 is designed to have the same angular orientation
relative to tab 52 as the pin socket array 44 of
receptacle 30 has relative to tab slot 38.
To make an electrical connection, the plug and
receptacle are aligned with tab 52 of the plug being
positioned to slide within tab slot 38 of the
receptacle. The ascembler then verifies that pin
array 62 is appropriately, angularly oriented to mesh
with pin socket array 44 such that as the plug is
inserted into the receptacle, the pins of the pin
array mate with the pin sockets of the pin socket
array. If upon a:Lignment oE tab 52 with tab slot 38,
it is apparent that the pin array of the plug is at a
different angular orientation than the pin socket
array of the receptacle, the assembler then realizes
that that plug and the receptacle are not designed to
be connected one to the other and that he should look
for a different receptacle for which to engage that
particular plug.
Figures 4 and 5 are similar receptacles to
Figure 3 wherein the pin socket array is arranged at
a different angular orientation. Receptacle 70 of
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Figure 4 includes tab slot 74 and core 76 having pin
socket array 78 with pin sockets 79, the pin socket
array being arranged in a generally vertical
direction when the tab is in the 12 o'clock position.
In Figure 5, receptacle 80 has shell 82, tab 84, and
core 86 having pin socket array 88 and pin sockets 89
with the pin socket array being arranged and at an
angle of approximately 315 with the tab portion
being considered to be at 0. In like comparison,
the pin socket array of Figure 2 is arranged at an
angle of 45.
Referring now to Figure 6 which is a partially
perspective and partially cut away view of a pair of
molds utilized to form a receptacle. Primary mold
100 includes outer wall 102 and inner wall 104 which
between them define cavity 106 which would correspond
with the shell of the receptacle. Additionally,
inner wall 104 de~ines therewithin cavity 116 which
receives the material to form a portion of the core
oE the receptacle. Injection line 110 is shown for
injecting plastic material into the mold.
Secondary mold 120 assists in forming the pin
socket array portion of the core of the receptacle.
Outer wall 122 defines a cylindrical area from which
pin socket mold bars 124 extend such that openings
are left after molding for the pin sockets.
Secondary mold 120 includes year 130 mounted thereto
such that the mold may be rotationally driven to
various positions. Injection line 126 for supplying
plastic to the mold is provided and includes rotary
joint 128.
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The two molds are assembled together (not shown)
such that the open end of secondary mold 120 abuts
wall 104 of primary mold 100 such that the pin socket
array portion of the core is formed within cavity 116
S shown in primary mold 100. It may also be seen that
by rotating gear 130, the relative position of
secondary mold to the primary mold and henee the
angular position of the pin array relative to the tab
formed in the shell may be determined.
Although not shown, a like pair of molds may be
utilized for forming the plug and one o said molds
may be rotatable relative to the other. In this
manner, an entire series of plugs and receptacles may
be formed using a common set of molds placed at
difrerent angular orientations for each different
plug or receptacle to be formed.
The invention has been described herein with
reference to a particular embodiment although those
skilled in the art will recognize that variations and
modifications can be effected within the spirit and
scope of the invention.
