Technical field
[0001] The present invention relates to a wire to wire connector, and a method for providing
the wire to wire connector.
Background art
[0002] A wire to wire connector is used to realize a permanent connection between two single
wires, or between corresponding conductors in two cables, and is widely used in fields
such as motor vehicles, communications, consumer electronics, data processing and
industrial machinery.
[0003] A wire to wire connector generally comprises a connector casing, and a wire or cable
extending into the connector casing; a conductive core, i.e. conductor of the wire
or cable is electrically connected to a conductive pin of the wire to wire connector.
In general, it is necessary to ensure that there is a certain amount of stress cushioning
for the wire or cable at the position where the wire or cable extends into the connector
casing, to prevent excessive bending of the wire or cable at this position. In addition,
there must be water resistance at the position where the wire or cable extends into
the connector casing, to prevent water or moisture from entering the connector casing
and affecting the electrical connection. Furthermore, a region of joining between
a cable outer sheath and the connection casing must have a certain degree of visibility.
[0004] However, there is no wire to wire connector capable of meeting all three of these
requirements in the prior art; some have water resistance, but lack visibility and
stress release capability. Wire to wire connectors which meet the requirements for
visibility and stress release capability lack sufficient water resistance, or their
design does not even take this characteristic into consideration. In addition, it
is not possible to ensure reliable fixing of the position, within the connector casing,
of a conductive core and conductive pin of a wire or cable of a wire to wire connector
in the prior art, and shifting of either one of the two in the connector casing will
cause a bad electrical connection.
[0005] It is hoped that a new wire to wire connector structure which solves the abovementioned
technical problems can be provided.
Content of the invention
[0006] An object of the present invention is to provide a new wire to wire connector structure,
which can not only ensure that there is sufficient water resistance at a position
where a cable enters a connector casing, but can also prevent excessive bending of
a wire or cable entering the connector casing at said position, as well as being able
to ensure sufficient visibility of a region of joining between an outer sheath and
the casing, and enables the positions of a conductive core of the cable and a pin
in the connector casing to be fixed reliably so as to be unable to shift.
[0007] To this end, the present invention provides a wire to wire connector, comprising:
a cable, comprising at least one conductive core and an insulator surrounding the
at least one conductive core, with a core seal and a core plug being fitted round
the insulator of each conductive core in an interference fit; a connector casing,
defining a pin hole, with the cable extending into the connector casing from a near
side of the connector casing in a longitudinal direction, and the core seal and core
plug of the conductive core being fitted in an interfering manner to an inner surface,
defining the pin hole, of the connector casing; and at least one pin, the pin comprising
a pin body, a first crimping structure crimped to the core seal, a second crimping
structure crimped to a conductive outer surface of the conductive core, and a stop
structure preventing the pin from moving in the longitudinal direction.
[0008] Preferably, the core seal has a length overlapping both the corresponding conductive
core and the connector casing in the longitudinal direction, with the entire length
being located in the connector casing. The core plug of the conductive core is closer
than the core seal is to the near side of the connector casing in the longitudinal
direction. The core plug has a first part adapted to fit into the pin hole in an interfering
manner, and a second part adapted to abut an end face of the near side of the connector
casing.
[0009] Preferably, each of the first crimping structure and the second crimping structure
is at least one crimping clamping jaw projecting from the pin body. The stop structure
comprises a first stop structure for preventing movement of the pin from a far side
of the connector casing towards the near side in the longitudinal direction, and a
second stop structure for preventing movement of the pin in the opposite direction,
and correspondingly, the connector casing comprises a first stop protruding part and
a second stop protruding part adapted to abut the first stop structure and the second
stop structure respectively.
[0010] The wire to wire connector of the present invention further comprises an overmoulded
casing that is overmoulded on at least a part of the connector casing and on a part
of an outer sheath of the cable.
[0011] The present invention also provides a method for providing the wire to wire connector
described above, comprising: removing a certain length of an outer sheath and an insulator
from a cable, such that each conductive core exposes a section of conductor in preparation
for making an electrical connection; fitting a core seal and a core plug round the
insulator of the conductive core; crimping the conductive core to a pin so as to fix
the two together and establish an electrical connection therebetween; mounting a connector
casing from a near side of the connector casing in a longitudinal direction, until
the pin and the connector casing cannot move further relative to each other; moving
the core plug towards the connector casing along the insulator of the conductive core,
until the core plug cannot move further; and forming an overmoulded casing by overmoulding
on at least a part of the connector casing and on a part of the outer sheath of the
cable. A crimping step comprises crimping a first crimping structure of the pin onto
a peripheral surface of the core seal of the conductive core, and crimping a second
crimping structure onto a conductive peripheral surface of the conductive core.
[0012] The provision of the crimping structure for the pin ensures the electrical connection
between the pin and the conductive core and the firmness of the relationship therebetween;
the provision of the stop structure for the pin ensures that the pin will not shift
relative to the connector casing; the provision of the core seal and core plug on
the conductive core ensures that external water and moisture will not enter the connector
casing and so will not destroy the internal electrical connection, and also ensures
that when overmoulding is performed, high pressure liquid will not enter the interior
of the connector casing and cause shifting of the pin and the conductive core of the
cable; and the provision of the overmoulded casing separate from the connector casing
ensures the necessary visibility of the region of joining between the outer sheath
and the casing, and ensures that there will not be excessive bending of the cable
at the position of entry to the connector casing.
Description of the accompanying drawings
[0013] A more complete understanding of and familiarity with the abovementioned and other
aspects of the present invention will be acquired through the following detailed explanation,
which makes reference to the accompanying drawings, wherein:
Fig. 1 is a three-dimensional drawing of a wire to wire connector according to the
present invention as a whole.
Fig. 2 is an exploded view of the wire to wire connector of fig. 1.
Fig. 3 is a front view of the wire to wire connector of fig. 1.
Fig. 4 is an enlarged longitudinal sectional view, obtained long line A-A, of a part
of the wire to wire connector of fig. 3.
Figs. 5a - 5e are schematic diagrams of the steps of the method for providing a wire
to wire connector according to the present invention.
Particular embodiments
[0014] A wire to wire connector according to the present invention is described below with
reference to the accompanying drawings.
[0015] The wire to wire connector of the present invention may be a wire to wire connector
for an eBike adapter, or may be used in various fields such as motor vehicles, electronics
or machinery, as stated in the prior art. In addition, it should be understood that
the figures merely show one example of the structure of the wire to wire connector
of the present invention, and are not intended to limit the scope of protection of
the present invention.
[0016] Referring to figs. 1 - 4, a wire to wire connector 100 of the present invention mainly
comprises a connector casing 10, an overmoulded casing 20, a cable 30, and an internal
conductive pin 70 (as shown in figs. 2 and 4). The cable 30 may be an optical cable
or electrical cable of any form.
[0017] The connector casing 10 comprises a first connector casing part 110 and a second
connector casing part 120. An outer profile of the second connector casing part 120
is contracted inwards in comparison with an outer profile of the first connector casing
part 110. The connector casing 10 comprises a near side 125, close to the cable 30
and defined by the second connector casing part 120, and a far side 115, far from
the cable 30 and defined by the first connector casing part 110; the near side 125
and far side 115 are opposite one another in a longitudinal direction L. A pin hole
15 (as shown in fig. 2) runs through the connector casing 10.
[0018] The cable 30 comprises an outer sheath 32, at least one e.g. multiple conductive
cores 34 accommodated in the outer sheath 32, and an insulator 36 in which each conductive
core 34 is sheathed. At one end of the cable 30 which enters the second connector
casing part 120, a certain length of the outer sheath 32 is removed. On an electric
cable section from which the outer sheath 32 has been removed, a shorter length of
the insulator 36 is removed so as to reveal an exposed section of each conductive
core 34, in preparation for making an electrical connection.
[0019] A core seal 40 and a core plug 50 are disposed on each conductive core 34. The core
seal 40 and core plug 50 are made of an insulating material, and not only form an
interference fit with the insulator 36 of the conductive core 34, but also form an
interference fit with an inner surface, defining the pin hole 15, of the second connector
casing part 120. This structure not only fixes the conductive core 34 firmly in the
connector casing 10, but can also have the effect of sealing the insulator 36 of the
conductive core 34 against the inner surface of the connector casing 10.
[0020] Preferably, in order to enhance the fixing and sealing effects mentioned above, and
furthermore prevent water or moisture from entering an electrical connection point
of the conductive core 34 and the pin 70, the core seal 40 has a certain length overlapping
both the conductive core 34 and the connector casing 10 in the longitudinal direction
L, as shown in the exploded view of fig. 2 and in the sectional view of fig. 4, and
this entire length is located in the connector casing 10, specifically in the second
connector casing part 120. More preferably, the core seal 40 comprises an outwardly
protruding interference part 46 forming an interference fit with the inner surface
defining the pin hole 15 (fig. 2) and an inwardly protruding interference part 48
forming an interference fit with the conductive core 34 (fig. 4).
[0021] The core plug 50 has a first part 52 adapted to fit into the inner surface defining
the pin hole 15 in an interfering manner, and a second part 54 adapted to abut an
end face of the near side 125 of the second connector casing part 120. An outer profile
of the first part 52 is smaller in dimensions than an outer profile of the second
part 54.
[0022] The structures described above of the core plug 50 and the core seal 40 ensure the
water resistance of electrical connection points inside the wire to wire connector
100 according to the present invention, and resolve the problem of possible shifting
of the conductive core 34 of the cable 30 in the connector casing 10.
[0023] The interference fit structure and abutment structure of the core plug 50 also ensure
that injection liquid does not enter the pin hole 15 of the connector casing 10 in
the process of forming the overmoulded casing 20, thereby solving the technical problem
that high liquid injection pressure during forming of the overmoulded casing 20 will
cause shifting of the pin 70 and the conductive core 34, as stated in the prior art.
The positions of the pin 70 and conductive core 34 in the pin hole 15 can be fixed
reliably, so an electrical connection therebetween is more reliable.
[0024] According to the present invention, the pin 70 of the wire to wire connector 100
has a crimping structure for fixing the position of the pin 70 and realizing an electrical
connection between the pin and the conductive core 34.
[0025] Specifically, as shown in figs. 2 and 4, the pin 70 comprises a pin body 75, a first
crimping structure 72 for crimping to the core seal 40 of the conductive core 34,
a second crimping structure 74 for crimping to the conductive core 34, a first stop
structure 76 for preventing shifting of the pin 70 from the far side 115 of the connector
casing 10 towards the near side 125 in the longitudinal direction L, and a second
stop structure 78 for preventing shifting of the pin 70 from the near side 125 of
the connector casing 10 towards the far side 115 in the longitudinal direction L.
[0026] More specifically, the first crimping structure 72 is adapted to be crimped to a
peripheral surface of the core seal 40 between a peripheral surface of the core seal
40 and the inner surface defining the pin hole 15. For example, the first crimping
structure 72 may take the form of at least one clamping jaw projecting transversely
from the pin body 75; for example, two, three or more clamping jaws are provided,
in order to be reliably fixed in a press-fit to the peripheral surface of the core
seal 40.
[0027] The second crimping structure 74 is crimped directly to a conductive outer surface
of the conductive core 34, thereby establishing an electrical connection between the
two. Similarly to the first crimping structure 72, the second crimping structure 74
may also take the form of at least one clamping jaw projecting transversely from the
pin body 75; for example, two, three or more clamping jaws are provided, in order
to be reliably fixed in a press-fit to a peripheral surface of the conductive core
34. In order to make the electrical connection between the pin 70 and the conductive
core 34 firmer and more reliable, the dimensions of the second crimping structure
74 are designed so that there is a sufficiently large crimping area between the second
crimping structure and the conductive core 34.
[0028] As shown in the figures, the first stop structure 76 is a stop arm structure which
extends radially outwards and obliquely in the longitudinal direction L from the far
side 115 towards the near side 125, starting at a peripheral surface of the pin 70.
For example, there may be one, two or more stop arms. Correspondingly, the inner surface
of the connector casing 10 that defines the pin hole 15 comprises an inwardly protruding
part 66, and an end face 68 thereof is adapted to engage the first stop structure
76.
[0029] The second stop structure 78 takes the form of an inwardly protruding inclined face,
adapted to abut an inwardly protruding inclined face 62 on the inner surface defining
the pin hole 15.
[0030] Of course, those skilled the art will understand that the crimping structures and
stop structures of the pin 70 are not limited to the specific structural forms described
above and shown in the figures. On the contrary, any crimping structure and stop structure
capable of realizing an expected function may be used.
[0031] According to the present invention, the provision of two crimping structures can
ensure the correct position of the pin 70 of the wire to wire connector 100 according
to the present invention in the pin hole 15, and a reliable electrical connection
between the pin 70 and the conductive core 34 of the cable 30. The provision of two
stop structures ensures that the pin 70 can be accurately mounted to the connector
casing 10 and ensures that the pin 70 cannot shift in the connector casing 10 in the
longitudinal direction L.
[0032] A method for providing the wire to wire connector 100 according to the present invention
is described below with reference to figs. 5a - 5e.
[0033] Fig. 5a shows a first step of the method, removing a certain length of the outer
sheath 32 from the cable 30, and removing a shorter length of the insulator 36 on
an electric cable section from which the outer sheath 32 has been removed, such that
each conductive core 34 exposes a section of conductor in preparation for making an
electrical connection.
[0034] In a second step shown in fig. 5b, a core seal 40 and a core plug 50 are fitted round
each conductive core 34, specifically on the insulator 36 thereof.
[0035] Then, as shown in fig. 5c, the conductive core 34 is electrically connected to the
pin 70. This step includes crimping the first crimping structure 72 of the pin 70
to the peripheral surface of the core seal 40 of the conductive core 34, and crimping
the second crimping structure 74 to the conductive peripheral surface of the conductive
core 34. In this way, an installation sub-assembly is formed.
[0036] In fig. 5d, the abovementioned sub-assembly A is mounted into the connector casing
10 from the near side 125 of the connector casing 10 in the longitudinal direction
L. In this step, the entire sub-assembly A is moved into the pin hole 15 in the longitudinal
direction L, until the second stop structure 78 of the pin 70 abuts the corresponding
inclined face 62 of the connector casing 10; at the same time, the second stop structure
76, as an extending arm structure, engages the end face 68 of the inwardly protruding
part 66. Due to this installation requirement, apart from the outer profile dimensions
of the extending arm 76 of the pin 70, the outer profile dimensions of other parts
of sub-assembly A should be smaller than the smallest inner profile dimensions of
the inwardly protruding part 66 of the connector casing 10.
[0037] In a fifth step of the method shown in fig. 5e, each core plug 50 is moved towards
the connector casing 10 along the insulator 36 of the conductive core 34, such that
the first part 52 of the core plug 50 is fitted to an inner surface of the second
connector casing part 120 in an interfering manner and such that the second part 54
of the core plug abuts an end face 122 of the near side 125 of the second connector
casing part 120 (fig. 4).
[0038] Finally, as shown in fig. 5f, using overmoulding technology, the overmoulded casing
20 is formed on at least a part of the second connector casing part 120 and on a part
of the cable 30, specifically the outer sheath 32. This step realizes reliable sealing
between the connector casing 10, specifically the second connector casing part 120,
and the outer sheath 32 of the cable 30; in addition, the injection moulded casing
20 can have the effect of stress release, such that the cable 30 will not be subjected
to excessive bending stress, and at the same time, the visibility of the region of
joining between the outer sheath and the casing is increased.
[0039] The present invention has been illustrated and described above with reference to
multiple particular embodiments, but is not intended to be restricted to the details
shown in the drawings. A feature described in relation to one embodiment may be combined
with a feature described in another embodiment to obtain a new embodiment. Various
amendments could be made without deviating from the scope of the present invention.
1. Wire to wire connector (100), comprising:
a cable (30), comprising at least one conductive core (34) and an insulator (36) surrounding
the at least one conductive core (34), with a core seal (40) and a core plug (50)
being fitted round the insulator (36) of each conductive core (34) in an interference
fit;
a connector casing (10), defining a pin hole (15), with the cable (30) extending into
the connector casing (10) from a near side (125) of the connector casing (10) in a
longitudinal direction (L), and the core seal (40) and core plug (50) of the conductive
core (34) being fitted in an interfering manner to an inner surface, defining the
pin hole (15), of the connector casing (10); and
at least one pin (70), the pin (70) comprising a pin body (75), a first crimping structure
(72) crimped to the core seal (40), a second crimping structure (74) crimped to a
conductive outer surface of the conductive core (34), and a stop structure preventing
the pin (70) from moving in the longitudinal direction (L).
2. Wire to wire connector (100) according to Claim 1, wherein the core seal (40) has
a length overlapping both the corresponding conductive core (34) and the connector
casing (10) in the longitudinal direction (L), with the entire length of the core
seal (40) being located in the connector casing (10).
3. Wire to wire connector (100) according to Claim 2, wherein the core plug (50) of the
conductive core (34) is closer than the core seal (40) is to the near side (125) of
the connector casing (10) in the longitudinal direction (L).
4. Wire to wire connector (100) according to Claim 3, wherein the core plug (50) has
a first part (52) adapted to fit into the pin hole (15) in an interfering manner,
and a second part (54) adapted to abut an end face (122) of the near side (125) of
the connector casing (10).
5. Wire to wire connector (100) according to any one of Claims 1 - 4, wherein each of
the first crimping structure (72) and the second crimping structure (74) is at least
one crimping clamping jaw projecting from the pin body (75).
6. Wire to wire connector (100) according to any one of Claims 1 - 5, wherein the stop
structure comprises a first stop structure (76) for preventing movement of the pin
(70) from a far side (115) of the connector casing (10) towards the near side (125)
in the longitudinal direction (L), and a second stop structure (78) for preventing
movement of the pin (70) in the opposite direction, and correspondingly, the connector
casing (10) comprises a first stop protruding part and a second stop protruding part
adapted to abut the first stop structure (76) and the second stop structure (78) respectively.
7. Wire to wire connector (100) according to any one of Claims 1 - 6, wherein the connector
casing (10) has a first connector casing part (110) defining the far side (115), and
a second connector casing part (120) defining the near side (125) and the pin hole
(15) and having an outer profile that is contracted inwards relative to the first
connector casing part (110).
8. Wire to wire connector (100) according to any one of Claims 1 - 7, further comprising
an overmoulded casing (20) that is overmoulded on at least a part of the connector
casing (10) and on a part of an outer sheath (32) of the cable (30).
9. Wire to wire connector (100) according to any one of Claims 1 - 8, wherein the core
seal (40) and core plug (50) are formed of an insulating material.
10. Method for providing the wire to wire connector (100) according to any one of Claims
1-9, comprising:
removing a certain length of an outer sheath (32) and an insulator (36) from a cable
(30), such that each conductive core (34) exposes a section of conductor in preparation
for making an electrical connection;
fitting a core seal (40) and a core plug (50) round the insulator (36) of the conductive
core (34);
crimping the conductive core (34) to a pin (70) so as to fix the two together and
establish an electrical connection therebetween;
mounting a connector casing (10) from a near side (125) of the connector casing (10)
in a longitudinal direction (L), until the pin (70) and the connector casing (10)
cannot move further relative to each other;
moving the core plug (50) towards the connector casing (10) along the insulator (36)
of the conductive core (34), until the core plug (50) cannot move further; and
forming an overmoulded casing (20) by overmoulding on at least a part of the connector
casing (10) and on a part of the outer sheath (32) of the cable (30).
11. Method according to Claim 10, wherein a crimping step comprises crimping a first crimping
structure (72) of the pin (70) onto a peripheral surface of the core seal (40) of
the conductive core (34), and crimping a second crimping structure (74) onto a conductive
peripheral surface of the conductive core (34).