Encapsulated Electrical Connector (Patent No: 711340)

Inventor: Gardener, Reginald H.

Location: Edmonton

Comments: N/A

Description: CLAIMS:

1. The method for assembling an electrical cable connector which method comprises, first forming a first assembly by the steps of:

(a) placing a plurality of electrical contacts into a first perforated disc of an inert dimensionally stable material with the contacts adjacent the front face thereof;
(b) Placing a perforated flexible diaphragm adjacent the rear face of the said first disc and in tandem therewith;
(c) Placing a second perforated disc of an inert dimensionally stable material adjacent the rear face of said flexible diaphragm and in tandem therewith;
(d) Passing a plurality of electrically conducting insulated wires through a grommet formed of a thermoplastic synthetic material which is compatible with the insulation of said wires;
(e) Forming an electrical connection between each said wire and an associated one of said electrical contacts;
Forming a second assembly by the step of:
(f) placing said first assembly into a hollow metallic shell provided with an internal groove, said second assembly including an O-ring set in said groove whereby said first assembly may later be sealed to said metal shell;
and then forming the final assembly by the steps of:
(g) placing said second assembly in a longitudinally split mold having a frusto-conical cavity therein and entrance means thereinto whereby a portion of the said grommet, said wires and a portion of said second perforated disc are exposed within said cavity, and whereby a portion of said metallic shell, and a portion of said grommet are gripped by said mold;
(h) rigidly locating the elements of the said assembly with respect to each other;
(i) injection molding, under relatively high pressure, a molten thermoplastic material into the cavity of said mold;
(j) cooling said thermoplastic material;
(k) removing the mold;

whereby there is formed environmental protection by said molded thermoplastic material encasing said exposed insulated wires, the electrical connection between said wires and said electrical contacts, said exposed second perforated disc and a portion of said grommet.

2. The method of claim 1 wherein the synthetic thermoplastic material forming the insulation on the wires, the synthetic thermoplastic material forming the grommet and the synthetic thermoplastic material being injection molded are all the same material, whereby, due to the heat and pressure generated by the molding, the synthetic thermoplastic insulation of the wire is softened and the synthetic thermoplastic material of the grommet is softened and upon cooling a homogenous molecular bond is formed between said insulation, said grommet and said injection molded environmental protection is obtained.
3. A method for assembling a female electrical cable connector, which method comprises first forming a first assembly by the steps of:
(a) placing a plurality of electrical sockets into a first perforated disc of an inert dimensionally stable material with the sockets wholly contained within the disc but exposed at the front face thereof;
(b) placing a perforated flexible diaphragm adjacent the rear face of said first disc, and in tandem therewith;
(c) placing a second perforated disc of an inert dimensionally stable material adjacent the rear face of said flexible diaphragm, and in tandem therewith;
(d) passing a plurality of electrically conducting insulated wires through a grommet formed of a thermoplastic synthetic material which is compatible with the insulation on said wires;
(e) forming an electrical connection between each said wire and an associated one of said electrical sockets;

forming a second assembly by the steps of:
(f) sliding an O-ring a selected distance over the body of said first disc;
(g) placing said first assembly and said O-ring into a hollow metallic shell provided with an internal groove, whereby said O-ring is set in said groove whereby said first assembly may later be sealed to said metal shell;

and then forming the final assembly by the steps of:
(h) placing said second assembly in a longitudinally split mold having a frusto-conical cavity therein and entrance means thereinto, whereby a portion of the said grommet, said wires and a portion of said second perforated disc are exposed within said cavity, and whereby a portion of said metallic shell, and a portion of said grommet are gripped by said mold;
(i) rigidly locating the elements of the pressure, a molten thermoplastic material in the cavity of said mold;
(j) cooling said thermoplastic material;
(k) removing the mold;

whereby there is formed environmental protection by said molded thermoplastic material encasing said exposed insulated wires, the electrical connection between said wires and said electrical contacts, said exposed second perforated disc and a portion of said grommet; and wherein the synthetic thermoplastic material forming the insulation on the wires, the synthetic thermoplastic material forming the grommet and the synthetic thermoplastic material being injection molded are all the same material, whereby, due to the heat and pressure generated by the molding, the synthetic thermoplastic insulation of the wire is softened and, the synthetic thermoplastic material of the grommet is softened and, upon cooling a homogenous molecular bond is formed between said insulation, said grommet and said injection molded environmental protection is obtained.

4. A method for assembling a male electrical cable connector, which method comprises first forming a first assembly by the steps of:
(a) placing a plurality of electrical pins into a first perforated disc of an inert dimensionally stable material with the pins protruding from the front face thereof;
(b) placing a perforated flexible diaphragm adjacent the rear face of said first disc and in tandem therewith;
(c) placing a second perforated disc of an inert dimensionally stable material adjacent the rear face of the said flexible diaphragm and in tandem therewith;
(d) passing a plurality of electrically conducting insulated wires through a grommet formed of a thermoplastic synthetic material which is compatible with the insulation on said wires;
(e) forming an electrical connection between each said wire and an associated one of said electrical pins;
forming a second assembly by the steps of:

(f) placing an O-ring a selected distance within a hollow metallic shell provided with an internal circular groove whereby said O-ring is set in said groove: and
(g) placing said first assembly into said hollow metallic shell whereby said first assembly may later be sealed to said metal shell;

and then forming the final assembly by the steps of:
(h) placing said second assembly in a longitudinally split mold having a frusto-conical cavity therein and entrance means thereinto, whereby a portion of the said grommet, said wires and a portion of said second perforated disc are exposed within said cavity, and wherein a portion of said metallic shell, and a portion of said grommet are gripped by said mold;
(i) rigidly locating the elements of the said assembly with respect to each other;
(j) injection molding, under relatively high pressure, a molten thermoplastic material into the cavity of said mold;
(k) cooling said thermoplastic material;
(l) removing the mold;

whereby there is formed environmental protection by said molded thermoplastic material encasing said exposed insulated wires, the electrical connection between said wires and said electrical contacts, said exposed second perforated disc and a portion of said grommet; and wherein the synthetic thermoplastic material forming the insulation on the wires, the synthetic thermoplastic material forming the grommet and the synthetic thermoplastic material being injection molded are all the same material, whereby due to the heat and pressure generated by the molding, the synthetic thermoplastic insulation of the wire is softened and upon cooling, a homogeneous molecular bond is formed between said insulation, said grommet and said injection molded environmental protection is obtained.

5. An assembled electrical cable connector comprising:
(a) a hollow metallic shell provided with an internal circular groove;
(b) a first perforated disc of inert dimensionally stable material rigidly secured within said metallic shell;
(c) a plurality of electrical contacts rigidly secured to end within the perforations of said first disc and adjacent the front face thereof;
(d) an O-ring set within said circular groove and in contact with said first perforated disc;
(e) a flexible perforated diaphragm adjacent the rear face of said first disc, in tandem therewith and rigidly secured within said metallic shell;
(f) a second perforated disc of inert dimensionally stable material adjacent the rear face of said diaphragm, in tandem therewith and rigidly secured within said metallic shell;
(g) a plurality of insulated electrically conducting wires encased by a grommet formed of a thermoplastic synthetic material which is compatible with the insulation on said wires, each wire having an electrical connection to an associated one of said electrical contacts;
(h) an injection molded synthetic thermoplastic material solid casing rigidly embracing a portion of said grommet, the terminal portion of said wires and said electrical contacts, the rear face of said second perforated disc and said metallic shell.

6. The assembled electrical connector of claim 5 wherein the synthetic thermoplastic material forming the insulation on the wires, the synthetic thermoplastic material forming the grommet and the synthetic thermoplastic material being injection molded are all the same material, whereby, due to the heat and pressure generated by the molding, the synthetic thermoplastic insulation of the wire is softened and the synthetic thermoplastic material of the grommet is softened and, upon cooling, a homogeneous molecular bond is formed between said insulation, said grommet and said injection molded environmental protection is obtained.
7. The assembled electrical cable connector of claim 5 wherein the connector is a female connector, wherein the electrical contacts are sockets which are wholly contained within said first disc but exposed at the front face thereof and wherein the synthetic thermoplastic material forming the insulation on the wires, the synthetic thermoplastic material forming the grommet and the synthetic thermoplastic material being injection molded are all the same material, whereby, due to the heat and pressure generated by the molding, the synthetic thermoplastic material of the grommet is softened and, upon cooling, a homogeneous molecular bond is formed between said insulation, said grommet and said injection molded environmental protection is obtained.
8. The assembled electrical cable connector of claim 5 wherein the connector is a male connector, wherein the electrical contacts are pins protruding from the front face of said first disc and wherein the synthetic thermoplastic material forming the insulation on the wires, the synthetic thermoplastic material forming the grommet and the synthetic thermoplastic material being injection molded are all the same material, whereby due to the heat and pressure generated by the molding, the synthetic thermoplastic insulation of the wire is softened and the synthetic thermoplastic material of the grommet is softened and, upon cooling, a homogeneous molecular bond is formed between said insulation, said grommet and said injection molded environmental protection is obtained.