CA2061243C - Connector and method for sealed pass-through of insulated electrical conductors - Google Patents
Connector and method for sealed pass-through of insulated electrical conductorsInfo
- Publication number
- CA2061243C CA2061243C CA002061243A CA2061243A CA2061243C CA 2061243 C CA2061243 C CA 2061243C CA 002061243 A CA002061243 A CA 002061243A CA 2061243 A CA2061243 A CA 2061243A CA 2061243 C CA2061243 C CA 2061243C
- Authority
- CA
- Canada
- Prior art keywords
- connector
- electrical conductors
- seal
- sealant
- conductors
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G15/00—Cable fittings
- H02G15/013—Sealing means for cable inlets
Abstract
The invention provides a connector for passing continuous insulated electrical conductors such as pins or multi-stranded wire through a surface or bulkhead, while preventing leakage of liquids and gases along the conductors, especially between gaps in the strands. An exemplary connector of the invention comprises a body having seal-zone openings in which a sealant is applied to and cured around a compressed bared section of multi-stranded wire. The body contains strain relief members adjacent to the sealed openings to provide longitudinal as well as transverse strain relief. A sealant member and radially spaced clasps are located around the sealed openings and strain relief members so that the connector may be removably twist-locked onto a bulkhead without disturbing the sealed wires.
The invention also provides a method for achieving the sealed pass-through of electrical conductors.
The invention also provides a method for achieving the sealed pass-through of electrical conductors.
Description
2~6 ~ ~3 , CO~NECTOR A~D METHOD FOR SEALED PASS-THROUGH
OF I~SULAT~D ~r~cTRIcAr~ CO~DUCTORS
FIELD OF THE I~VENTIO~
1 The invention relates to the field of electrical 2 connectors, and more particularly to a pass-through connector 3 and method for passing insulated electrical conductors such as 4 pins or multi-stranded wires through a surface or bulkhead.
~A~K~ROUND ~F THE INVENTION
The electrical systems of automobiles, boats, aircraft, and 6 other vehicle5 present numerous wiring problems. It is often 7 necessary that wires must run through compartments without 8 introducing environ~ental leakage between or from the 9 compartments. Devices and methods for passing electrical wiring through a surface such as a wall or bulkhead are 11 frequently sought. The connections between in-tank fuel pumps 12 and fuel level sensors to the electrical wiring harness outside 13 of the fuel tank are especially problematic, because the 14 openings in the gas tank, through which the wires must pass, pose leakage problems due to pressurized gas vapors and 16 capillary seepage of liquid fuel along the insulated wires.
~a 1 In the manufacture of automotive fuel tanks, a current 2 practice is to rivet brass posts perpendicularly through round 3 holes in a steel plate which is subsequently fastened to a 4 larger opening in the fuel tank. The posts themselves are sealed to the steel plate by tight attachment through 6 individual plast~c grommets. A further plastic shell is 7 assembled in the area of the posts to aid subsequent attachment 8 of electrical wires and to protect the posts from mechanical 9 damage. Wires are simultaneously connected to the posts on the other side of the plate during riveting, and this is 11 facilitated by crimping eyelets beforehand to the end of the 12 wires which are slipped over the posts prior to riveting the 13 posts to the plate. The wires are then connected inside the 14 tank to the fuel pump and level sensor. Outside of the tank, wires must be attached to the posts after the tank is mounted 16 to the automobile.
17 One problem with the current practice of fuel tank 18 connections is that a blind connection is required. The 19 hook-up is typically made between the harness wiring and in-tank devices without the installer being able to see 21 precisely which connections are being made. The connection 22 also creates servicing problems because the tank must often be 23 removed during servicing of the vehicle, requiring 24 disconnection of the wires fr~m the p^sts.
1 Although the use of ~jumper~ wires or short wires connected 2 to the posts prior to installation of the fuel tank might solve 3 the blind attachment and service problems, another connection 4 is required along the electrical path between the jumpers and the wire harness. Additional connections are not particularly 6 desirable. Every` connection tends to degrade the electrical 7 integrity of the system and to increase costs.
8 Jumper wires are normally used either wholly within the 9 fuel tank or outside of it, and therefore do not solve the problem of capillary seepage, which in current applications 11 results from fuel seeping between the-perpendicular posts and 12 the plastic grommets and between the plastic grommets and the 13 steel plate.
14 A further seepage problem arises when stranded wire is passed through a grommet, because leak paths around and between 16 the strands may be created due to the fle~ible movement of the 17 stranded wire.
18 A connector is therefore required for passing insulated 19 electrical conductors through a surface or bulkhead while preventing leakage of liquids and gases.
`` 2061243 SUMMARY OF THE I~VE~TION
1 In surmounting the disadvantages of the prior art, the 2 invention provides a connector for passing insulated electrical 3 conductors through a surface, bulkhead, or mounting structure 4 while preventing the capillary seepage of liquids and the efflux of pressur~zed gases. In an e~emplary embodiment, a 6 connector is provided which comprises a hard body having 7 openings in which a sealant is placed and allowed to cure 8 around stripped sections of passed-through insulated 9 multi-stranded wires. A seal is therefore created around and 10- between the strands. The strands may be further compressed 11 into a tight geometry to deform the strand shapes and minimize 12 gaps between the strands. The compression of the strands may 13 also be used to control the manner in which the sealant is 14 wicked into and flowed through the strand bundle. Strain relief members support the insulated wires on either side of 16 the body immediately adjacent to the seal-zone openings. An 17 O-ring and annularly spaced clasp members are located 18 circumferentially around the seal-zone openings and strain 19 relief members to permit the connector to be removably twist-locked onto a bulkhead or port without weakening the 21 integrity of the seal-zone.
` 206 ~ 243 1 The invention also provides a method by which the 2 pass-through of electrical conductors is obtained. An 3 e~emplary method involves stripping a cylindrical section of 4 insulated multi-stranded wires, compressing the e~posed bundle into a tight geometry in the openings of the body to minimize 6 gaps between the s~trands, and applying a sealer and allowing it 7 to cure.
DESCRIPTION OF THE DRAWINGS
8 A more complete understanding of the present invention and 9 the attendant advantages and features thereof will be more readily understood by reference to the following detailed 11 description when considered in conjunction with the 12 accompanying drawings, wherein:
13 Fig. 1 is an e~ploded perspective view of the connector, 14 O-ring seal, and mounting hole of the invention;
Fig. 2 is a side view of the connector along a plane 16 parallel to the plane of a surface to which the connector is 17 mounted;
18 Fig. 3 is a further side view of the connector along the 19 same plane shown in Fig. 2;
Fig. 4 is a top view of the connector;
1 Fig. 5 is a bottom view of the connector;
2 Fig. 6 is a cross-sectional view along line 6 of Fig. 4 3 showing the bared section of insulated conductors passing 4 through the connector;
Fig. 7 is a cross-sectional view along line 7 of Fig. 2 6 showing the pass-through seal-zone openings in the connector;
7 Fig. 8 is a cross-sectional view of one of the pass-through 8 seal-zone openings as shown in Fig. 7 with multi-stranded wires 9 compressed to conform tightly within the geometry of the pass-through seal-zone opening; and 11 Fig. 9 is a cross-sectional view of the connector along 12 line 9 of Fig. 6.
DETAILED D~SCRIPTION OF THE I~VE~TIO~
13 Referring now to the drawings, wherein like numerals are 14 used throughout to designate corresponding features, Fig. 1 shows a connector l0 in an e~emplary embodiment of the 16 invention which comprises a body ll having seal-zone openings 17 designated generally as at 12 for permitting continuous 18 insulated electrical conductors 13, such as multi-stranded 19 wire 12, to pass through the body 11 while providing a seal to prevent capillary seepage of fluid and efflu~ of gases around 1 and between strands. While bared wire strands are shown in the 2 seal-zone openings 12, the invention may also be used with 3 other electrical conductors, such as single-stranded wire, 4 pins, tubes, or rods. The use of the sealant with the bared section of such electrical conductors provides advantages even 6 though multi-strands are not involved, because capillary 7 leakage due to fuels or pressurized gases still poses a problem 8 for the seal-zone between the body (opening) and conductor 9 (whether insulated or bared). The insulated conductors may be terminated by pin terminals such as plugs 13a or jack ends 13b.
11 The pass-through body 11, which is preferably made of hard 12 material such as plastic or other electrically insulating 13 substance, is comprised of a first side 19 and a second side 15 14 with seal-zone openings 12 which pass through from one side to the other. The material which comprises the pass-through 16 body 11 prevents direct shorting of the wires to the steel 17 plate or other metallic bodies. In an e~emplary embodiment of 18 the invention, the body 11 has a generally flat shape which is 19 parallel to the surface 50 upon which the connector 10 is mounted and through which electrical conductors 13 are passed.
21 Strain relief members 16 and 17 connected to both sides of the 22 body 11 provide strain relief to the insulated conductors 13 1 passing through the seal-zone openings 12. Strain relief is 2 provided longitudinally along the wires as well as transversely 3 (or a~ially) when the connector is twist-locked into a bulkhead 4 or surface port 50. A protruding or raised annular portion 18 on the body 11 may be shaped to conform to the access port 51 6 or opening located on the surface or bulkhead 50 on which the 7 connector 10 is to be mounted. The raised annular portion 18 8 may contain a locking mechanism 19, such as spaced clasping 9 members or ledges 19, which lockably engage with corresponding annular flanges 5Z in the access port 51. A sealant member, 11 such as a gasket or preferably an 0-ring 20 comprised of 12 elastomeric material such as nitrile, which is the preferred 13 material for providing resistance to gasoline, permits a 14 liquid- and gas-proof seal between the body 11 and surface 50.
The locking mechanism 19 is preferably configured to permit the 16 connector 10 to be removably twist-locked to the surface 50.
17 The sealant member 20 and locking mechanism 19 can be located 18 on either side of the body 11.
19 8races 21 and 22 provide structural support to the strain relief members 16 under which an access channel 26 is provided 21 for the purpose of facilitating the application of a sealant 22 into the seal-zone openings 12 containing the bared 23 conductors. The access channel 26 also permits the ~ires to be 24 compressed together to minimize aaps ketwoon tho s~rands.
. ` 20~ 1 243 1 Fig. 2 is a side view of the connector 10 wherein an O-ring 2 20 is held on the body 11 by an annularly grooved projection 3 member 20a. The cross-section of the O-ring 20 is shown with a 4 generally ~ shape, but other cross-sectional shapes, such as a round cross-sectional shape, may also be used. The side view 6 of Fig. 2 furthe~ illustrates releasable locking clasp members 7 19 spaced around the annular raised portion 18. It also illustrates the manner in which the strain relief members 16 9 and 17 may be shaped as towers which gradually taper in diameter as the distance from the seal-zone openings 12 11 increases to provide gradual strain relief to the insulated 12 conductors 13. The strain relief towers 16 and 17 are 13 preferably melted or molded to provide a rudimentary seal with 14 the insulation of the conductors 13. The insulation may be of high-density polyethylene or polypropylene. Other materials 16 such as polyvinylchloride (PVC) may also be used.
17 Braces 21 and 22 located on side 14 of the body 11 provide 18 manual means for axially twisting the connector to effectuate 19 the twist-on locking of the connector 10 to the surface port ~shown in Fig. 1).
1 Fig. 3 shows the connector 10 of Fig. 2 without the 2 O-ring. The shape of the annularly grooved projection 3 member 20a, used for retaining an O-ring, may be more easily 4 seen. The annular spacing of the releasable clasp members 19 is also shown.
6 Fig. 4 shows t side lS of the connector 10 in a view 7 perpendicular to the plane of the body 11. In an e~emplary 8 embodiment of the invention, the body 11, the annularly grooved 9 projection member 20a for retaining the O-ring (as seen in Fig.
2), and the annular raised portion 1~ containing the clasp 11 members 19 are preferably arranged as concentrically as 12 possible on the body 11. The insulated conductors 13 and 13 strain relief towers 17 are preferably placed close to the 14 center of the body 11.
Fig. S shows the other side 14 of the connector 10 in which 16 braces 21 and 22 are diametrically opposed on either side of 17 the centrally located passed-through conductors 13 and strain 18 relief towers 17. The braces 21 and 22 may act as wing nuts to 19 provide a structure for a~ially twist-locking the connector body 11 into a port or receptacle.
20b 1 243 1 Fig. 6 is a cross-sectional view of insulated continuous 2 multi-stranded electrical wire conductors 13 in an e~emplary 3 embodiment of the invention. The bared section of stranded 4 wires shown are compressed along the plane of view. The cross-sectional profile of the body 11, annularly grooved 6 projection members~ 20a, annular raised portion 18, and strain 7 relief members/towers 16 and 17 suggest the structural 8 integrity afforded to the passed-through conductors 13. A
g channel, designated generally as at 26 in Figs. 2 and 6, allows application of sealant to the bared wires and provides access 11 means for compressing wires together during molding of the body 12 11 and seal-zone openings 12. When the connector 10 is used in 13 conjunction with fuel tanks or other compartments, the side 14 14 of the connector 10 having the channel 26 is preferably disposed inwardly of the fuel tank to prevent the bared wire 16 sections from o~idizing.
17 Fig. 7 shows seal-zone openings 12 in an esemplary 18 embodiment of the invention which are generally rectangular in 19 shape. Fig. 8 shows a magnified view of one of the openings 12 through which a bared multi-stranded wire is passed. A sealant 21 is applied to the conductors 13 to prevent leakage of fluids 22 and gases around the conductors 13 and, where multi-stranded -; 206 1 243 1 wire is used, to prevent leakage through gaps between the 2 strands. Preferably, the sealant is of the type which can be 3 applied through wicking action.
4 Fiq. 9 is a side view of the connector along line 9 of Fig. 6. The insulated multistranded wire 13 has a bare section 6 which spans the channel 26 between the strain relief member 16 7 and body 11. As the bare section enters the seal-zone 8 openings 12 in tlle body 11, the bare wires are compressed or 9 pinched together to minimize gaps between and around the strands.
11 The structural features and advantages of the invention may 12 be further explained by a description of the exemplary methods 13 by which the sealed pass-through of the electrical conductors 14 is achieved. First, a conductor must be provided with center insulation that has been bared or stripped. Stripping a 16 section of insulation will allow disposition of a sealer with 17 capillary action to enter or to be in~ected into the body 18 openings between the body and conductor. Where multi-stranded 19 wire is used, the sealant must be able to flow between strands and wire bundles. Multi-stranded wire is preferred for its 21 ability to fle~ and is expected to be most frequently used in 22 the application of the invention.
1 Insulation may be removed by any means known in the art.
2 This may include cutting the insulation, abrading off the 3 insulation using stripping tools, and burning or melting the 4 insulation using a heat source, such as a torch or laser.
Anaerobic sealer liquid, such as Loctite, is applied to the 6 bare wire in the ~absence of air and allowed to cure. Copper 7 wire is a preferable conductor because it acts as a catalyst 8 for curing certain anaerobic sealers. Preferably, the sealer 9 has both low surface tension for quick entry among the strands and thi~otropicity in that it tends to cease diffusing beyond 11 the point at which it is too thin to provide a seal membrane.
12 A formula with high viscosity may require pressure to encourage 13 movement of sealer into the wire bundle. The balance between 14 fluidity and thickness is application dependent. In addition, heat may be used to cure the sealer.
16 In a further e~emplary embodiment of the invention wherein 17 multi-stranded wire is used, a preferred method of applying the 18 sealer involves compressing or forging the strand bundles into 19 a tight geometry to minimize gaps between strands. This helps to prevent capillary action from drawing out the sealer so thin 21 that a barrier membrane cannot be formed. A preferred shape 22 for the cross-section of the stripped wire bundle is a 23 rectangle with V-notches piercing inward along the longer faces 1 of the rectangle, as seen in Figs. 7 and 8. The form or shape 2 of the cross-section may vary in accordance with the wire and 3 sealant used. In a further e~emplary method of the invention, 4 the wires may be stripped, inserted into the pass-through body S as the openings are being molded around the inserted wires, and 6 the wires compres~ed together at the same time.
7 The device and method of the invention is suited for use in 8 automotive applications, and particularly for connecting an g in-tank fuel pump and level sensors to the wire harness system of the automobile which is designated generally as at 25 in 11 Fig. 1. The surface or bulkhead 50 shown in Fig. 1 may be 12 connected to a plate which is attached to the fuel tank with 13 the connector 10 disposed inward of the fuel tank such that 14 pressure within the tank will press the body 11 against the O-ring 20 to contribute to the efficacy of the sealing. In 16 fuel tank applications, it is required that the materials which 17 comprise the connector 10, including the O-ring or other 18 sealant member 20, be impervious to the fuel.
The invention is not to be limited by what has been 21 particularly shown and described, e~cept as indicated by the 22 appended claims.
OF I~SULAT~D ~r~cTRIcAr~ CO~DUCTORS
FIELD OF THE I~VENTIO~
1 The invention relates to the field of electrical 2 connectors, and more particularly to a pass-through connector 3 and method for passing insulated electrical conductors such as 4 pins or multi-stranded wires through a surface or bulkhead.
~A~K~ROUND ~F THE INVENTION
The electrical systems of automobiles, boats, aircraft, and 6 other vehicle5 present numerous wiring problems. It is often 7 necessary that wires must run through compartments without 8 introducing environ~ental leakage between or from the 9 compartments. Devices and methods for passing electrical wiring through a surface such as a wall or bulkhead are 11 frequently sought. The connections between in-tank fuel pumps 12 and fuel level sensors to the electrical wiring harness outside 13 of the fuel tank are especially problematic, because the 14 openings in the gas tank, through which the wires must pass, pose leakage problems due to pressurized gas vapors and 16 capillary seepage of liquid fuel along the insulated wires.
~a 1 In the manufacture of automotive fuel tanks, a current 2 practice is to rivet brass posts perpendicularly through round 3 holes in a steel plate which is subsequently fastened to a 4 larger opening in the fuel tank. The posts themselves are sealed to the steel plate by tight attachment through 6 individual plast~c grommets. A further plastic shell is 7 assembled in the area of the posts to aid subsequent attachment 8 of electrical wires and to protect the posts from mechanical 9 damage. Wires are simultaneously connected to the posts on the other side of the plate during riveting, and this is 11 facilitated by crimping eyelets beforehand to the end of the 12 wires which are slipped over the posts prior to riveting the 13 posts to the plate. The wires are then connected inside the 14 tank to the fuel pump and level sensor. Outside of the tank, wires must be attached to the posts after the tank is mounted 16 to the automobile.
17 One problem with the current practice of fuel tank 18 connections is that a blind connection is required. The 19 hook-up is typically made between the harness wiring and in-tank devices without the installer being able to see 21 precisely which connections are being made. The connection 22 also creates servicing problems because the tank must often be 23 removed during servicing of the vehicle, requiring 24 disconnection of the wires fr~m the p^sts.
1 Although the use of ~jumper~ wires or short wires connected 2 to the posts prior to installation of the fuel tank might solve 3 the blind attachment and service problems, another connection 4 is required along the electrical path between the jumpers and the wire harness. Additional connections are not particularly 6 desirable. Every` connection tends to degrade the electrical 7 integrity of the system and to increase costs.
8 Jumper wires are normally used either wholly within the 9 fuel tank or outside of it, and therefore do not solve the problem of capillary seepage, which in current applications 11 results from fuel seeping between the-perpendicular posts and 12 the plastic grommets and between the plastic grommets and the 13 steel plate.
14 A further seepage problem arises when stranded wire is passed through a grommet, because leak paths around and between 16 the strands may be created due to the fle~ible movement of the 17 stranded wire.
18 A connector is therefore required for passing insulated 19 electrical conductors through a surface or bulkhead while preventing leakage of liquids and gases.
`` 2061243 SUMMARY OF THE I~VE~TION
1 In surmounting the disadvantages of the prior art, the 2 invention provides a connector for passing insulated electrical 3 conductors through a surface, bulkhead, or mounting structure 4 while preventing the capillary seepage of liquids and the efflux of pressur~zed gases. In an e~emplary embodiment, a 6 connector is provided which comprises a hard body having 7 openings in which a sealant is placed and allowed to cure 8 around stripped sections of passed-through insulated 9 multi-stranded wires. A seal is therefore created around and 10- between the strands. The strands may be further compressed 11 into a tight geometry to deform the strand shapes and minimize 12 gaps between the strands. The compression of the strands may 13 also be used to control the manner in which the sealant is 14 wicked into and flowed through the strand bundle. Strain relief members support the insulated wires on either side of 16 the body immediately adjacent to the seal-zone openings. An 17 O-ring and annularly spaced clasp members are located 18 circumferentially around the seal-zone openings and strain 19 relief members to permit the connector to be removably twist-locked onto a bulkhead or port without weakening the 21 integrity of the seal-zone.
` 206 ~ 243 1 The invention also provides a method by which the 2 pass-through of electrical conductors is obtained. An 3 e~emplary method involves stripping a cylindrical section of 4 insulated multi-stranded wires, compressing the e~posed bundle into a tight geometry in the openings of the body to minimize 6 gaps between the s~trands, and applying a sealer and allowing it 7 to cure.
DESCRIPTION OF THE DRAWINGS
8 A more complete understanding of the present invention and 9 the attendant advantages and features thereof will be more readily understood by reference to the following detailed 11 description when considered in conjunction with the 12 accompanying drawings, wherein:
13 Fig. 1 is an e~ploded perspective view of the connector, 14 O-ring seal, and mounting hole of the invention;
Fig. 2 is a side view of the connector along a plane 16 parallel to the plane of a surface to which the connector is 17 mounted;
18 Fig. 3 is a further side view of the connector along the 19 same plane shown in Fig. 2;
Fig. 4 is a top view of the connector;
1 Fig. 5 is a bottom view of the connector;
2 Fig. 6 is a cross-sectional view along line 6 of Fig. 4 3 showing the bared section of insulated conductors passing 4 through the connector;
Fig. 7 is a cross-sectional view along line 7 of Fig. 2 6 showing the pass-through seal-zone openings in the connector;
7 Fig. 8 is a cross-sectional view of one of the pass-through 8 seal-zone openings as shown in Fig. 7 with multi-stranded wires 9 compressed to conform tightly within the geometry of the pass-through seal-zone opening; and 11 Fig. 9 is a cross-sectional view of the connector along 12 line 9 of Fig. 6.
DETAILED D~SCRIPTION OF THE I~VE~TIO~
13 Referring now to the drawings, wherein like numerals are 14 used throughout to designate corresponding features, Fig. 1 shows a connector l0 in an e~emplary embodiment of the 16 invention which comprises a body ll having seal-zone openings 17 designated generally as at 12 for permitting continuous 18 insulated electrical conductors 13, such as multi-stranded 19 wire 12, to pass through the body 11 while providing a seal to prevent capillary seepage of fluid and efflu~ of gases around 1 and between strands. While bared wire strands are shown in the 2 seal-zone openings 12, the invention may also be used with 3 other electrical conductors, such as single-stranded wire, 4 pins, tubes, or rods. The use of the sealant with the bared section of such electrical conductors provides advantages even 6 though multi-strands are not involved, because capillary 7 leakage due to fuels or pressurized gases still poses a problem 8 for the seal-zone between the body (opening) and conductor 9 (whether insulated or bared). The insulated conductors may be terminated by pin terminals such as plugs 13a or jack ends 13b.
11 The pass-through body 11, which is preferably made of hard 12 material such as plastic or other electrically insulating 13 substance, is comprised of a first side 19 and a second side 15 14 with seal-zone openings 12 which pass through from one side to the other. The material which comprises the pass-through 16 body 11 prevents direct shorting of the wires to the steel 17 plate or other metallic bodies. In an e~emplary embodiment of 18 the invention, the body 11 has a generally flat shape which is 19 parallel to the surface 50 upon which the connector 10 is mounted and through which electrical conductors 13 are passed.
21 Strain relief members 16 and 17 connected to both sides of the 22 body 11 provide strain relief to the insulated conductors 13 1 passing through the seal-zone openings 12. Strain relief is 2 provided longitudinally along the wires as well as transversely 3 (or a~ially) when the connector is twist-locked into a bulkhead 4 or surface port 50. A protruding or raised annular portion 18 on the body 11 may be shaped to conform to the access port 51 6 or opening located on the surface or bulkhead 50 on which the 7 connector 10 is to be mounted. The raised annular portion 18 8 may contain a locking mechanism 19, such as spaced clasping 9 members or ledges 19, which lockably engage with corresponding annular flanges 5Z in the access port 51. A sealant member, 11 such as a gasket or preferably an 0-ring 20 comprised of 12 elastomeric material such as nitrile, which is the preferred 13 material for providing resistance to gasoline, permits a 14 liquid- and gas-proof seal between the body 11 and surface 50.
The locking mechanism 19 is preferably configured to permit the 16 connector 10 to be removably twist-locked to the surface 50.
17 The sealant member 20 and locking mechanism 19 can be located 18 on either side of the body 11.
19 8races 21 and 22 provide structural support to the strain relief members 16 under which an access channel 26 is provided 21 for the purpose of facilitating the application of a sealant 22 into the seal-zone openings 12 containing the bared 23 conductors. The access channel 26 also permits the ~ires to be 24 compressed together to minimize aaps ketwoon tho s~rands.
. ` 20~ 1 243 1 Fig. 2 is a side view of the connector 10 wherein an O-ring 2 20 is held on the body 11 by an annularly grooved projection 3 member 20a. The cross-section of the O-ring 20 is shown with a 4 generally ~ shape, but other cross-sectional shapes, such as a round cross-sectional shape, may also be used. The side view 6 of Fig. 2 furthe~ illustrates releasable locking clasp members 7 19 spaced around the annular raised portion 18. It also illustrates the manner in which the strain relief members 16 9 and 17 may be shaped as towers which gradually taper in diameter as the distance from the seal-zone openings 12 11 increases to provide gradual strain relief to the insulated 12 conductors 13. The strain relief towers 16 and 17 are 13 preferably melted or molded to provide a rudimentary seal with 14 the insulation of the conductors 13. The insulation may be of high-density polyethylene or polypropylene. Other materials 16 such as polyvinylchloride (PVC) may also be used.
17 Braces 21 and 22 located on side 14 of the body 11 provide 18 manual means for axially twisting the connector to effectuate 19 the twist-on locking of the connector 10 to the surface port ~shown in Fig. 1).
1 Fig. 3 shows the connector 10 of Fig. 2 without the 2 O-ring. The shape of the annularly grooved projection 3 member 20a, used for retaining an O-ring, may be more easily 4 seen. The annular spacing of the releasable clasp members 19 is also shown.
6 Fig. 4 shows t side lS of the connector 10 in a view 7 perpendicular to the plane of the body 11. In an e~emplary 8 embodiment of the invention, the body 11, the annularly grooved 9 projection member 20a for retaining the O-ring (as seen in Fig.
2), and the annular raised portion 1~ containing the clasp 11 members 19 are preferably arranged as concentrically as 12 possible on the body 11. The insulated conductors 13 and 13 strain relief towers 17 are preferably placed close to the 14 center of the body 11.
Fig. S shows the other side 14 of the connector 10 in which 16 braces 21 and 22 are diametrically opposed on either side of 17 the centrally located passed-through conductors 13 and strain 18 relief towers 17. The braces 21 and 22 may act as wing nuts to 19 provide a structure for a~ially twist-locking the connector body 11 into a port or receptacle.
20b 1 243 1 Fig. 6 is a cross-sectional view of insulated continuous 2 multi-stranded electrical wire conductors 13 in an e~emplary 3 embodiment of the invention. The bared section of stranded 4 wires shown are compressed along the plane of view. The cross-sectional profile of the body 11, annularly grooved 6 projection members~ 20a, annular raised portion 18, and strain 7 relief members/towers 16 and 17 suggest the structural 8 integrity afforded to the passed-through conductors 13. A
g channel, designated generally as at 26 in Figs. 2 and 6, allows application of sealant to the bared wires and provides access 11 means for compressing wires together during molding of the body 12 11 and seal-zone openings 12. When the connector 10 is used in 13 conjunction with fuel tanks or other compartments, the side 14 14 of the connector 10 having the channel 26 is preferably disposed inwardly of the fuel tank to prevent the bared wire 16 sections from o~idizing.
17 Fig. 7 shows seal-zone openings 12 in an esemplary 18 embodiment of the invention which are generally rectangular in 19 shape. Fig. 8 shows a magnified view of one of the openings 12 through which a bared multi-stranded wire is passed. A sealant 21 is applied to the conductors 13 to prevent leakage of fluids 22 and gases around the conductors 13 and, where multi-stranded -; 206 1 243 1 wire is used, to prevent leakage through gaps between the 2 strands. Preferably, the sealant is of the type which can be 3 applied through wicking action.
4 Fiq. 9 is a side view of the connector along line 9 of Fig. 6. The insulated multistranded wire 13 has a bare section 6 which spans the channel 26 between the strain relief member 16 7 and body 11. As the bare section enters the seal-zone 8 openings 12 in tlle body 11, the bare wires are compressed or 9 pinched together to minimize gaps between and around the strands.
11 The structural features and advantages of the invention may 12 be further explained by a description of the exemplary methods 13 by which the sealed pass-through of the electrical conductors 14 is achieved. First, a conductor must be provided with center insulation that has been bared or stripped. Stripping a 16 section of insulation will allow disposition of a sealer with 17 capillary action to enter or to be in~ected into the body 18 openings between the body and conductor. Where multi-stranded 19 wire is used, the sealant must be able to flow between strands and wire bundles. Multi-stranded wire is preferred for its 21 ability to fle~ and is expected to be most frequently used in 22 the application of the invention.
1 Insulation may be removed by any means known in the art.
2 This may include cutting the insulation, abrading off the 3 insulation using stripping tools, and burning or melting the 4 insulation using a heat source, such as a torch or laser.
Anaerobic sealer liquid, such as Loctite, is applied to the 6 bare wire in the ~absence of air and allowed to cure. Copper 7 wire is a preferable conductor because it acts as a catalyst 8 for curing certain anaerobic sealers. Preferably, the sealer 9 has both low surface tension for quick entry among the strands and thi~otropicity in that it tends to cease diffusing beyond 11 the point at which it is too thin to provide a seal membrane.
12 A formula with high viscosity may require pressure to encourage 13 movement of sealer into the wire bundle. The balance between 14 fluidity and thickness is application dependent. In addition, heat may be used to cure the sealer.
16 In a further e~emplary embodiment of the invention wherein 17 multi-stranded wire is used, a preferred method of applying the 18 sealer involves compressing or forging the strand bundles into 19 a tight geometry to minimize gaps between strands. This helps to prevent capillary action from drawing out the sealer so thin 21 that a barrier membrane cannot be formed. A preferred shape 22 for the cross-section of the stripped wire bundle is a 23 rectangle with V-notches piercing inward along the longer faces 1 of the rectangle, as seen in Figs. 7 and 8. The form or shape 2 of the cross-section may vary in accordance with the wire and 3 sealant used. In a further e~emplary method of the invention, 4 the wires may be stripped, inserted into the pass-through body S as the openings are being molded around the inserted wires, and 6 the wires compres~ed together at the same time.
7 The device and method of the invention is suited for use in 8 automotive applications, and particularly for connecting an g in-tank fuel pump and level sensors to the wire harness system of the automobile which is designated generally as at 25 in 11 Fig. 1. The surface or bulkhead 50 shown in Fig. 1 may be 12 connected to a plate which is attached to the fuel tank with 13 the connector 10 disposed inward of the fuel tank such that 14 pressure within the tank will press the body 11 against the O-ring 20 to contribute to the efficacy of the sealing. In 16 fuel tank applications, it is required that the materials which 17 comprise the connector 10, including the O-ring or other 18 sealant member 20, be impervious to the fuel.
The invention is not to be limited by what has been 21 particularly shown and described, e~cept as indicated by the 22 appended claims.
Claims (25)
1. A connector for passing insulated electrical conductors through a surface, comprising:
a body having a first side, a second side, and at least two spaced seal-zone openings for passing insulated electrical conductors between said first and second sides;
insulated electrical conductors located in and passing through said at least two spaced seal-zone openings, said conductors having sections located within said seal-zone openings which are bare of insulation;
sealant located in said at least two spaced seal-zone openings;
strain relief members for providing strain relief to said insulated conductors adjacent said at least two spaced seal-zone openings on both of said body sides;
a sealant member mounted on said body around said at least two spaced seal-zone openings and said strain relief members;
and a lock mechanism for releasably mounting the body to the surface through which said insulated electrical conductors are passed.
a body having a first side, a second side, and at least two spaced seal-zone openings for passing insulated electrical conductors between said first and second sides;
insulated electrical conductors located in and passing through said at least two spaced seal-zone openings, said conductors having sections located within said seal-zone openings which are bare of insulation;
sealant located in said at least two spaced seal-zone openings;
strain relief members for providing strain relief to said insulated conductors adjacent said at least two spaced seal-zone openings on both of said body sides;
a sealant member mounted on said body around said at least two spaced seal-zone openings and said strain relief members;
and a lock mechanism for releasably mounting the body to the surface through which said insulated electrical conductors are passed.
2. The connector of claim 1 wherein said insulated electrical conductors are wires.
3. The connector of claim 2 wherein said wires are multi-stranded and said sealant located in said at least two spaced seal-zone openings is further located between strands.
4. The connector of claim 3 wherein said bare strands passing through said at least two spaced seal-zone openings compressed together to minimize gaps between strands and said sealant is further located between said compressed bare strands.
5. The connector of claim 4 wherein said compressed bare strands are compressed in a generally rectangular cross-sectional shape and said at least two spaced seal-zone openings are correspondingly conformed tightly to said bare strands.
6. The connector of claim 5 wherein said generally rectangular shape of said compressed bare wire sections further comprises V-notches along the two longer faces of the generally rectangular cross-section, and said at least two spaced seal-zone openings are correspondingly shaped to conform tightly to said compressed bare strands.
7. The connector of claim 1 wherein said electrical conductors are pins.
8. The connector of claim 1 wherein said electrical conductors are tubes.
9. The connector of claim 1 wherein said insulation of said electrical conductors is high density polyethylene or polypropylene.
10. The connector of claim 1 wherein said body is made of plastic.
11. The connector of claim 1 wherein said body is further comprised of a flat surface comforming to the surface through which said electrical conductors are to be passed.
12. The connector of claim 1 wherein said sealant is curable by anaerobic means.
13. The connector of claim 1 wherein said sealant is comprised of material which is applied by flowing means.
14. The connector of claim 1 wherein said strain rellef members are connected to said body and have extended portions for enclosing said insulated conductors adjacent said seal-zone openings.
15. The connector of claim 14 wherein said extended strain relief members enclosing said conductors are tapered.
16. The connector of claim 1 wherein said strain relief members are shaped as towers.
17. The connector of claim 1 further comprising a raised annular member on said body for mounting said sealant member.
18. The connector of claim 1 wherein said sealant member further comprises an elastomeric O-ring.
19. The connector of claim 1 wherein said body, said insulation of said stranded wires, said strain relief members, said sealant member, and said locking mechanism are made of material which is impervious to gasoline.
20. The connector of claim 1 wherein the insulated stranded electrical wires are terminated with pin terminals.
21. The connector of claim 1 wherein said locking mechanism comprises a raised annular member having spaced clasps for rotatably engaging the connector in a hole which has flanges corresponding to said spaced clasps for twist-lockably engaging said connector at said flanges.
22. The connector of claim 21 further comprising a receptacle port for twist-lockably receiving said raised annular member, said receptacle port having spaced flanges for engagement with said spaced clasps of said annular member, whereby said connector is twist-lockably engaged.
23. The connector of claim 1 wherein said body and said strain relief members located on one of two said body sides form an access port.
24. A method for passing continuous insulated electrical conductors through a surface, comprising the steps of:
providing a body having a first side, a second side, and at least two spaced seal-zone openings for passing electrical conductors through said body from one side to the other side;
providing continuous insulated electrical conductors;
baring insulation from a section of said electrical conductors and inserting the bared section through said seal-zone openings;
applying sealer to said seal-zone openings containing said bare sections of said conductors and allowing said sealer to cure therein;
providing strain relief to the insulated electrical conductors passing through said seal-zone openings; and providing means for locking and sealing said body to the surface through which the electrical conductors are intended to be passed.
providing a body having a first side, a second side, and at least two spaced seal-zone openings for passing electrical conductors through said body from one side to the other side;
providing continuous insulated electrical conductors;
baring insulation from a section of said electrical conductors and inserting the bared section through said seal-zone openings;
applying sealer to said seal-zone openings containing said bare sections of said conductors and allowing said sealer to cure therein;
providing strain relief to the insulated electrical conductors passing through said seal-zone openings; and providing means for locking and sealing said body to the surface through which the electrical conductors are intended to be passed.
25. The method of claim 24 wherein the step of providing continuous insulated electrical conductors comprises providing multi-stranded wire, and further comprises allowing the sealant to fill gaps between strands.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US07/656,560 US5170017A (en) | 1991-02-15 | 1991-02-15 | Connector and method for sealed pass-through of insulated electrical conductors |
| US07/656,560 | 1991-02-15 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2061243A1 CA2061243A1 (en) | 1992-08-16 |
| CA2061243C true CA2061243C (en) | 1995-07-18 |
Family
ID=24633572
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002061243A Expired - Fee Related CA2061243C (en) | 1991-02-15 | 1992-02-14 | Connector and method for sealed pass-through of insulated electrical conductors |
Country Status (5)
| Country | Link |
|---|---|
| US (1) | US5170017A (en) |
| EP (1) | EP0499533B1 (en) |
| JP (1) | JP3030319B2 (en) |
| CA (1) | CA2061243C (en) |
| DE (1) | DE69213274T2 (en) |
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-
1991
- 1991-02-15 US US07/656,560 patent/US5170017A/en not_active Expired - Lifetime
-
1992
- 1992-02-11 DE DE69213274T patent/DE69213274T2/en not_active Expired - Fee Related
- 1992-02-11 EP EP92400365A patent/EP0499533B1/en not_active Expired - Lifetime
- 1992-02-14 CA CA002061243A patent/CA2061243C/en not_active Expired - Fee Related
- 1992-02-14 JP JP4059637A patent/JP3030319B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| DE69213274D1 (en) | 1996-10-10 |
| JP3030319B2 (en) | 2000-04-10 |
| US5170017A (en) | 1992-12-08 |
| JPH05252641A (en) | 1993-09-28 |
| EP0499533A3 (en) | 1993-09-15 |
| EP0499533A2 (en) | 1992-08-19 |
| EP0499533B1 (en) | 1996-09-04 |
| DE69213274T2 (en) | 1997-03-20 |
| CA2061243A1 (en) | 1992-08-16 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |