Note: Within nine months of the publication of the mention of the grant of the European patent in the European PatentBulletin, any person may give notice to the European Patent Office of opposition to that patent, in accordance with theImplementing Regulations. Notice of opposition shall not be deemed to have been filed until the opposition fee has beenpaid. (Art. 99(1) European Patent Convention).

Printed by Jouve, 75001 PARIS (FR)

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(12) EUROPEAN PATENT SPECIFICATION

(45) Date of publication and mention of the grant of the patent: 23.07.2014 Bulletin 2014/30

(21) Application number: 01114449.0

(22) Date of filing: 15.06.2001

(51) Int Cl.:H01R 13/645 (2006.01) H01R 13/621 (2006.01)

H01R 43/18 (2006.01)

(54) Electrical connector

Elektrischer Verbinder

Connecteur électrique

(84) Designated Contracting States: DE FR GB IT

(30) Priority: 05.07.2000 US 609619

(43) Date of publication of application: 10.07.2002 Bulletin 2002/28

(73) Proprietor: Continental Automotive GmbH30165 Hannover (DE)

(72) Inventors: • Crisanti, Peter John

Windsor CT 06095 (US)

• Ruman, ErichWaterbury, CT 06708 (US)

• Dowden, David EdwardOntario, NY 14519 (US)

• Witzel, Donald GeorgePittsford, NY 14534 (US)

(56) References cited: EP-A- 0 954 068 WO-A-98/53530US-A- 4 402 897 US-A- 5 951 306US-A- 5 954 520

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Description

BACKGROUND OF THE INVENTION

Field Of The Invention

[0001] The present invention generally relates to elec-trical connectors for electrical devices, such as motorsor sensors. More particularly, the invention relates toelectrical connectors that include a flange having a singlenotch incorporated therein to adapt the connector to bemounted at a predetermined angle.

Discussion of the Prior Art

[0002] Electrical devices of many types may be usedin environments that require particular wiring routings toavoid physical interference with other components or en-vironmental hazards such as unwanted electrical inter-ference or contact with hot surfaces. For example, thisis readily apparent in the varying under-hood wiring lay-outs required in different motor vehicles having differentengines or under-hood systems configurations. Contin-uing with the example of use in a motor vehicle, somedevices, such as the motor of a specific idle air controlvalve, might find use in a variety of different vehicles.However, the different wiring routings required in differenttypes of vehicles may require different electrical connec-tor mounting angles to allow proper installation, operationand removal of the device and the wiring plug whichmates with the electrical connector on the device. Forinstance, the wiring plug for a vehicle of a first type mayneed to approach the connector for the device horizon-tally, while in a vehicle of a second type it may need toapproach the connector vertically or at some angle ther-ebetween. These two different vehicle applications maybe able to use the same motor or other device, but mayrequire different electrical connectors to provide the re-spective different mounting angles to accommodate thenecessary wiring routings.[0003] Rather than use entirely different electrical con-nectors for different vehicles, it is desirable to a havesingle main connector housing design having an extend-ed flange around the housing design into which a mount-ing notch may be formed to mount the connector at aspecific angle. Furthermore, rather than equip differentvehicles with different component connectors configuredto accept a wiring plug approaching from only one angle,it is desirable to have a single basic connector designthat can be easily adapted through the manufacturingprocess to provide one of a plurality of different mountingangles. Indeed, there are prior art electrical connectorsthat are manufactured to be adjustable between multipleangular positions. However, such connectors that haveadjustable mounting angles tend to be complex and ex-pensive to produce. Also, due to the nature of manufac-turing and assembly processes, it is undesirable to permita connector to have more than one mounting position

available. Therefore, to avoid the possibility of improperconnector installation and wiring routing, it is preferredto limit a connector to a single mounting angle. Moreover,for sealing and component integrity purposes, it is unde-sirable to have the connector housing consist of multiplehousing sections which hinge or rotate relative to eachother to obtain different connector mounting angles.[0004] In light of the shortcomings and undesirable fea-tures commonly found in prior art electrical connectorconstructions, there exists a need for electrical connec-tors of simple construction that has an extended flangeonto which a mounting notch can be formed, and thatcan be adapted through the manufacturing process toprovide one of a plurality of potential connector mountingangles. It further is desirable to have the connector in-clude a light-weight, molded dielectric housing. It furtheris advantageous to have the connector be adapted to beheld at a single mounting angle and be secured to a prod-uct assembly by means of a single fastener. The presentinvention overcomes disadvantages of prior connectors,while providing the above-mentioned desirable features.[0005] From US-A-5951306 a connector is known,which is mounted using a bolt as a mounting fastener toengage a notch.

SUMMARY OF THE INVENTION

[0006] The purpose and advantages of the inventionwill be set forth in and apparent from the description anddrawings that follow, as well as will be learned by practiceof the invention disclosed and claimed herein.[0007] The connector according to the invention is dis-closed in the independent claim 1.[0008] The present invention is generally embodied inan electrical connector. In accordance with one embod-iment of the invention, the connector comprises a hous-ing, a plurality of conductive terminals supported withinthe housing, and a flange extending outward from thehousing, the flange having a single mounting notch there-in that is formed during the manufacturing process toadapt the connector for use in a particular angular mount-ing position. In a preferred embodiment of the invention,the conductive terminals are over-molded into the con-nector housing, the flange and housing are monolithicallymolded of a dielectrical material, and the flange of theconnector extends outward from less than the entire pe-rimeter of the housing.[0009] The manufacture of the connector involvesmolding of the housing of the connector. The housing ismolded to incorporate a flange, and a mounting notch isformed in the flange to adapt the connector for use in aparticular angular mounting position. The mounting notchcan be formed in the flange in a number of ways. Themold of the housing may incorporate a moveable key toform the mounting notch. The movable key is placed ata predetermined position corresponding to the desiredlocation of the mounting notch before the housing is mold-ed, and when the housing is molded, the key creates a

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mounting notch on the flange corresponding to the de-sired mounting angle of the connector. The mold for thehousing may be configured to create a flange on thehousing without a mounting notch in the flange. Themounting notch is then machined onto the flange at apredetermined location corresponding to the desiredmounting angle of the connector. In still Multiple moldsmay be used, each mold designed to manufacture a spe-cific connector having a housing incorporating a flange,the flange having a mounting notch at a specific locationcorresponding to the desired mounting angle of the par-ticular connector. In a preferred embodiment of the in-vention, conductive terminals are over-molded into theconnector housing during the manufacturing process, theflange and housing are monolithically molded of a die-lectrical material, and the flange of the connector extendsoutward from less than the entire perimeter of the hous-ing.[0010] One skilled in the art will appreciate that thisinvention could be utilized in many different electricalconnector settings where a common device may requiredifferent particular mounting angles in different assemblysituations.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] In describing the preferred embodiment, refer-ence is made to the accompanying drawings wherein likeparts have like reference numerals, and wherein:

FIG. 1 is a front perspective view of an embodimentof an electrical connector in accordance with the in-vention.FIG. 2 is a bottom perspective view of the connectorshown in FIG. 1.FIG. 3 is a rear perspective view of the connector ofFIGS. 1 and 2 mated to the motor of an idle controlvalve.FIG. 4 is a rear view of the connector shown in FIG. 3.FIG. 5 is a side perspective view of the connectorand motor of FIG. 3 mounted to a mating housingshown in a schematic cross-section.

[0012] It should be understood that the drawings arenot to scale. It should also be understood that, as dis-cussed below, the present invention is not limited to theembodiment illustrated.

DETAILED DESCRIPTION OF THE PREFERRED EM-BODIMENT

[0013] Although one skilled in the art will appreciatethat the invention has potential for very broad applicationwith many electrical devices, an exemplary embodimentof a connector made in accordance with the invention isdisclosed herein in conjunction with a motor of an idle aircontrol valve for vehicle internal combustion engines.The idle air control valve, motor and engagement with a

connector are described in detail in U.S. Patent Applica-tion Serial No. 09/240,527.[0014] Referring to the drawings of the exemplary em-bodiment and referring to FIGS. 1-5, the connector 10includes a housing 12. The housing 12 is preferably con-structed of monolithically injection molded dielectric ma-terial such as polybutylene terephthalate or other suitablematerial. As best seen in FIG. 2, supported within theconnector is at least one conductive terminal 14. Termi-nals 14 are typically of metallic construction such as cop-per alloy or the like. Depending on the design criteria andpreferred method of manufacturing, the terminals 14 maybe over-molded in place in the housing 12 or may beinserted into preformed terminal cavities in housing 12.In this embodiment, the terminals 14 shown in FIG. 5 areconnected conventionally to coil windings on the motor16.[0015] In this embodiment, the connector 10 is of theright-angle type. In essence, the housing has a socket18 for receipt of a wiring plug (not shown) at an angleperpendicular to the connector’s mating engagementwith the electrical device, motor 16, shown in FIGS. 3and 5. Thus, terminals 14 extend through the housing toachieve conductive engagement with the wiring plug atone end and with the motor at the other end. To accom-plish this, the terminals 14 may have a bend somewherealong their length, or if the terminals are straight, the con-nector must be constructed to have the mating engage-ment at one of the ends approach from an angle relativeto the surface along the length of the terminals.[0016] The connector 10 further includes a flange 20extending outward from at least a portion of the peripheryof connector housing 12. In the embodiment shown, theflange 20 and housing 12 are dielectric material mono-lithically molded such that the flange 20 extends outwardfrom the housing 12 in the area opposite the socket 18where a wiring plug may mate with the connector 10. Theflange 20 has a single mounting notch 22 formed into theflange 20 to allow the connector to be mounted in a par-ticular angular mounting position and secured using asingle mounting fastener 24, such as a bolt, shown inFIG. 5. Also, while the flange 20 may be monolithicallymolded with the housing 12, it also may be constructedof a different material and joined to the housing 12. Forinstance, the flange 20 may be metallic and over-moldedto be integrally linked to the housing 12.[0017] In the embodiment shown, a single mountingnotch 22 is shown at a predetermined position to permita mounting fastener 24 to pass through the mountingnotch 22 to provide for securement of the connector 10to the mating assembly structure 26 while preventing ro-tation of the connector 10 relative to the mating assembly26. The mounting fastener 24 is shown schematically asa conventional bolt. However, connectors in accordancewith the invention may be constructed to be combinedwith fasteners of virtually any desirable material andstructure.[0018] The flange 20 may be formed around the com-

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plete periphery of the housing 12 to allow the mountingnotch 22 to be situated at any angle throughout a 360degree arc or, as shown in FIGS. 1-5, the flange 20 mayproject from less than the complete periphery. The pre-ferred embodiment shows a low-profile connector 10wherein the socket 18 is located close to the flange 20.[0019] In the embodiment shown, sealing engagementbetween the connector 10 and the mating assembly 26is achieved by use of an O-ring seal 28, best seen in FIG.5, which rests in a groove 30 in the connector housing,as seen in FIGS. 1 and 2. The O-ring seal 28 engages abore 32 in mating assembly 26. Although the preferredembodiment shows an O-ring 28 in a groove 30 engaginga bore 32, the connector 10, the mating assembly 26 andthe seal 28 therebetween may be of various shapes, con-figurations and constructions to provide sealing engage-ment between a surface of the connector and a surfaceof the mating assembly. Moreover, one of skill in the artwill appreciate that, depending on the environment andanticipated use, the connector may not require a seal, ormay have a seal of a different type between the connectorand the mating assembly. Also, it will be appreciated thatthe connector could be configured to provide sealed en-gagement with the electrical device, such as the motorof the idle air control valve shown.[0020] In accordance with the preferred embodiment,the connector 10 has a single mounting notch 22, per-mitting installation only at one preselected angle to pre-vent improper installation at a different angle. However,during the manufacture of the connector 10, the mountingnotch 22 can be formed anywhere along the peripheryof the flange 12 to allow the connector 10 to be mountedat any specific angle. Hence, all connectors requiring aparticular connector mounting angle to achieve a partic-ular wiring routing will have the mounting notch 22 formedat the same location on the flange 20, while connectorsrequiring a different mounting angle and resultant differ-ent wiring routing will have the mounting notch 22 formedon a different portion of the flange 20.[0021] The housing 12 of the connector 10 is manu-factured using a mold. The mounting notch 22 can beformed in the flange 20 using a number of methods. Inone example the mounting notch 22 is formed in theflange 20 of the housing 12 by having a movable key thatis inserted into the mold at a predetermined location.Thus, a single mold can be used to manufacture the hous-ing 12 of the connector 10, and the movable key allowsthe mounting notch 22 to be formed at different locationson the flange 20. In effect, this single mold allows themanufacture of a number of connectors that can be fur-ther processed so that each is adapted for mounting ata different angle.[0022] In another example the mounting notch 22 isformed in the flange 20 after the housing 12 of the con-nector 10 has been molded. Thus, a single mold can beused to manufacture the housing 12 having a flange 20with no mounting notch 22 molded in the flange 20. Afterthe housing 12 has been molded, a mounting notch 22

is machined into the flange 20 at a predetermined loca-tion. The machining of the mounting notch 22 can bedone using any of a number of methods known in the art,including drilling, grinding, or punching the mountingnotch 22. Thus, a single mold can be used to manufacturethe housing 12 of the connector 10, and the mountingnotch 22 can be machined at different locations on theflange 20. In effect, this single mold allows the manufac-ture of a number of different connectors for mounting ata variety of angles.[0023] In still another example, a number of separatemolds can be used, with each mold being configured tomold the housing 12 with a flange 20 having a mountingnotch 22 located on a different position on the flange 20.Thus, each mold allows the manufacture of a differentconnector for mounting at a specific angle.[0024] It will be appreciated that the mounting notch22 need not be of any particular shape or size, so longas it may receive a fastener or projection from the matingassembly that will assist in securing the connector 10 tothe mating assembly 26 or in determining the mountingangle of the connector 10 relative to the assembly.[0025] Hence, connectors 10 adapted for use in differ-ent mounting angle positions can be easily manufacturedby incorporating a housing 12 having a mounting notch22 on a flange 20 around the housing 12. This can bedone using a single mold and either having a movablekey to create the mounting notch 22 when the connectorhousing 12 is molded, or removing material from theflange 20 to create a notch 22 on the flange 20 after theconnector housing 12 has been molded. This preventsthe need for additional tooling and corresponding linesof equipment to manufacture and handle a variety of dif-ferent single-purpose connectors, while adding a minormanufacturing step of either moving a mold key to prop-erly orient the mounting notch 22 or machining the mount-ing notch 22 at a proper location. In an alternate examplemultiple molds may be utilized to manufacture the con-nectors 10, each having a mounting notch 22 at differentlocations on the flange 20. Moreover, if desired, a reduc-tion of parts can be achieved by using a single fastener24 to both orient the connector 10 to the correct mountingangle and to secure the connector 10 to the mating as-sembly 26.[0026] The construction of a connector in accordancewith the present invention provides numerous benefits.As seen in the exemplary embodiment, it provides a sim-ple, cost effective, yet highly efficient single connectorstructure. One skilled in the art will appreciate that thepresent invention could be utilized in various alternativeembodiments involving electrical devices that may becommon in some respects but that require differentmounting angles in different settings.[0027] Although, for the purpose of explanation, useof the present invention has been depicted in a connectormated to a motor of an idle air control valve and whichis mounted to a product assembly, it will be understoodthat the invention may be embodied in a variety of ad-

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vantageous constructions of electrical connectors. Also,it should be understood that any of a variety of seals andfastening mechanisms, dimensions and suitable materi-als of construction may be used to satisfy the particularneeds and requirements of the end user. It will be appar-ent from consideration of the specification and practiceof the invention disclosed herein that other variations ofthe exemplary devices depicted may be made withoutdeparting from the scope of the invention.

Claims

1. An electrical connector (10) comprising:

a housing (12), one or more conductive termi-nals (14) supported within the housing (12), anda flange (20), wherein the flange (20) extendsoutward from at least a portion of the peripheryfrom the housing (12), the flange (20) having asingle mounting notch (22) therein to permit theconnector (10) to be adapted for use in only onespecific angular mounting position using a boltas a single mounting fastener to engage thenotch.

2. An electrical connector (10) as claimed in Claim 1,wherein the conductive terminals (14) are over-molded into the housing (12).

3. An electrical connector (10) as claimed in Claim 1,wherein the housing (12) further comprises terminalcavities for receipt of the conductive terminals(14).

4. An electrical connector (10) as claimed in Claim 1,wherein the flange (20) and housing (12) are mon-olithically molded of a dielectric material.

5. An electrical connector (10) as claimed in Claim 1,wherein the flange (20) extends outward from lessthan the entire perimeter of the housing (12).

6. An electrical connector (10) as claimed in Claim 1,wherein the mounting notch (22) permits a fastenerto engage the flange (20) to mount the connector(10) at a predetermined angle.

7. An electrical connector (10) as claimed in Claim 1,wherein the electrical connector (10) is a right angleconnector.

8. An electrical connector (10) as claimed in Claim 7,wherein a first end of the terminals (14) is located ata first housing end and extends in a first directionand a second end of the terminals (14) is located ata second housing end and extends in a second di-rection which is perpendicular to the first direction.

Patentansprüche

1. Elektrischer Verbinder (10), umfassend:

ein Gehäuse (12), eine oder mehrere leitendeKlemmen (14), welche im Gehäuse (12) gehal-ten werden und einen Flansch (20), wobei sichder Flansch (20) nach außen von wenigstenseinem Abschnitt des Umfangs vom Gehäuse(12) erstreckt, wobei der Flansch (20) eine ein-zelne Befestigungskerbe (22) darin aufweist,um es dem Verbinder (10) zu ermöglichen, fürden Einsatz in nur einer bestimmten winkeligenBefestigungsposition unter Verwendung einerSchraube als einzigem Befestigungsmittel aus-gelegt zu sein, um die Kerbe in Eingriff zu brin-gen.

2. Elektrischer Verbinder (10) nach Anspruch 1, wobeidie leitenden Klemmen (14) ins Gehäuse (12) ein-gegossen sind.

3. Elektrischer Verbinder (10) nach Anspruch 1, wobeidas Gehäuse (12) des Weiteren Klemmenausneh-mungen für die Aufnahme der leitenden Klemmen(14) umfasst.

4. Elektrischer Verbinder (10) nach Anspruch 1, wobeider Flansch (20) und das Gehäuse (12) einstückigaus einem dielektrischen Material gussgeformt sind.

5. Elektrischer Verbinder (10) nach Anspruch 1, wobeisich der Flansch (20) nach außen von weniger alsdem gesamten Umfang des Gehäuses (12) er-streckt.

6. Elektrischer Verbinder (10) nach Anspruch 1, wobeidie Befestigungskerbe (22) es einem Befestigungs-mittel erlaubt, in den Flansch (20) einzugreifen, umden Verbinder (10) in einem vorbestimmten Winkelanzubringen.

7. Elektrischer Verbinder (10) nach Anspruch 1, wobeider elektrische Verbinder (10) ein rechtwinkeligerVerbinder ist.

8. Elektrischer Verbinder (10) nach Anspruch 7, wobeiein erstes Ende der Klemmen (14) an einem erstenGehäuseende angeordnet ist und sich in eine ersteRichtung erstreckt und ein zweites Ende der Klem-men (14) an einem zweiten Gehäuseende angeord-net ist und sich in eine zweite Richtung erstreckt,welche senkrecht zur ersten Richtung ist.

Revendications

1. Connecteur (10) électrique comprenant :

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un boîtier (12), une ou plusieurs bornes (14) con-ductrices supportées dans le boîtier (12) et unebride (20), la bride (20) s’étendant vers l’exté-rieur à partir d’au moins une partie de la péri-phérie du boîtier (12), la bride (20) ayant uneencoche (22) unique de montage pour permet-tre au connecteur (10) d’être adapté en vued’être utilisé dans seulement une position angu-laire précise de montage en utilisant une chevillecomme fixation unique de montage pour péné-trer dans l’encoche.

2. Connecteur (10) électrique suivant la revendication1, dans lequel les bornes (14) conductrices sont sur-moulées dans le boîtier (12).

3. Connecteur (10) électrique suivant la revendication1, dans lequel le boîtier (12) comprend, en outre,des cavités de borne pour la réception des bornes(14) conductrices.

4. Connecteur (10) électrique suivant la revendication1, dans lequel la bride (20) et le boîtier (12) sontmoulés monolithiquement en un matériau diélectri-que.

5. Connecteur (10) électrique suivant la revendication1, dans lequel la bride (20) s’étend vers l’extérieursur moins que tout le périmètre du boîtier (12).

6. Connecteur (10) électrique suivant la revendication1, dans lequel l’encoche (22) de montage permet àune fixation de pénétrer dans la bride (20) pour mon-ter le connecteur (10) à un angle déterminé à l’avan-ce.

7. Connecteur (10) électrique suivant la revendication1, dans lequel le connecteur (10) électrique est unconnecteur à angle droit.

8. Connecteur (10) électrique suivant la revendication7, dans lequel une première extrémité des bornes(14) est placée à une première extrémité du boîtieret s’étend dans une première direction et une secon-de extrémité des bornes (14) est placée à une se-conde extrémité du boîtier et s’étend dans une se-conde direction qui est perpendiculaire à la premièredirection.

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REFERENCES CITED IN THE DESCRIPTION

This list of references cited by the applicant is for the reader’s convenience only. It does not form part of the Europeanpatent document. Even though great care has been taken in compiling the references, errors or omissions cannot beexcluded and the EPO disclaims all liability in this regard.

Patent documents cited in the description

• US 5951306 A [0005] • US 240527 A [0013]