GB2303501A

GB2303501A - Connector

Info

Publication number: GB2303501A
Application number: GB9514401A
Authority: GB
Inventors: John Nicholas Hall
Original assignee: STANDARD PROD Ltd
Current assignee: STANDARD PROD Ltd
Priority date: 1995-07-14
Filing date: 1995-07-14
Publication date: 1997-02-19
Anticipated expiration: 2015-07-14
Also published as: GB2303501B; GB9514401D0

Description

CONNECTOR This invention relates to a connector intended to connect two penetrable portions of electrically conductive material, which are normally spaced from each other and are separated by an electrically insulating material, to two external electrical conductors respectively.

Sealing devices are known which are intended to seal, for instance, window openings in motor vehicles or sunroof s in motor vehicles.

Where the closure member in a sunroof in a vehicle, or a pane of glass in a window in a vehicle, is moved by an electrically-powered motor there is the danger that a finger of a person within the vehicle or another object might be trapped by the closure member or pane of glass as it approaches the end of its travel during the closing mode. In order to reduce or obviate this risk, it is known for seals to be associated with, or preferably to incorporate, a so-called anti-trap sensor which, when it senses a finger or other object being trapped by the closing closure member or closing pane of glass sends a signal to external circuitry which can cause the motor driving the closure member or pane of glass firstly to stop and then to reverse, so as to release the trapped finger or other object.

Different types of anti-trap sensor are known but one type includes two normally spaced-apart electrically conductive components which are held apart by one or more electrically insulating components.

When a finger or other object becomes trapped, the two electrically conductive components are caused to undergo relative movement towards each other until they touch, so as to complete a circuit which can be detected by the aforementioned external circuitry.

The electrically conductive components of the anti-trap sensor can be formed of, for instance, an elastomeric material incorporating conductive material, and there may be embedded in each of the two electrically conductive components an electrical conductor, such as a copper wire.

In, for example, the movable window in the driver's door of a motor vehicle the anti-trap sensor can be associated with the seal in the region of the "A" pillar and the top rail, and there is need for the electrically conductive components including, if present, the electrically conductive wires of the sensor to be connected effectively to external conductors forming part of the external circuitry so as to enable any closing of the circuit, caused by distortion of the anti-trap sensor, to be signalled to the external circuitry.

According to one aspect of the present invention, there is provided a connector intended to connect two penetrable portions of electrically conductive material, which are normally spaced from each other and are separated by an electrically insulating material, to two external electrical conductors respectively, the connector comprising: an electrically insulating member having two opposing faces; a first electrically conductive member secured to one of the two opposing faces and provided with (i) at least one lug capable of penetrating and being folded onto one of the portions of electrically conductive material and (ii) a tab for securing the first conductive member to one of the two external electrical conductors; and a second electrically conductive member secured to the other of the opposing faces and provided with (i) at least one lug capable of penetrating and being folded onto the other of the portions of electrically conductive material and (ii) a tab for securing the second conductive member to the other of the two external electrical conductors, the first and second electrically conductive members normally being insulated from each other by the electrically insulating member.

Conveniently the first electrically conductive member is substantially identical to the second electrically conductive member and is arranged in mirror image thereto, with the electrically insulating member separating the first and second electrically conductive members.

The electrically insulating member can take the form of a planar or board-like member, with the first and second electrically conductive members secured appropriately, by some adhesive or other bonding system, to the opposing faces of the electrically insulating member.

The electrically insulating member can be formed from, for example, fibreglass board, epoxy resin or card.

The material from which the first and second electrically conductive members are formed can be, for example, steel, brass or tinned copper.

Conveniently, but not necessarily, the electrically insulating member is at least over part of its length of oblong rectangular shape, with the major axis intended to lie parallel to the major axis of the anti-trap sensor.

Preferably each of the first and second electrically conductive members has more than one lug capable of penetrating the first or second (respectively) portions of electrically conductive material forming part of the anti-trap sensor.

Preferably, but not necessarily, each of the first and second electrically conductive members has a first pair of lugs lying on opposing sides of the major axis of the connector, with a narrow slot present between the two lugs in each pair such that, when the portions of electrically conductive material forming part of the anti-forming trap sensor are provided with their own electrical conductors, and when the pairs of lugs penetrate the portions of material, the conductors forming part of the anti-trap sensor can move down through the respective slots, possibly coming to rest near the blind ends of the slots and further possibly contacting the edges of the lugs.

Each of the first and second electrically conductive members may also be provided with other lugs which are laterally spaced some way from the central axis of the connector and which, once the lugs have penetrated the respective portion of electrically conductive material, can be folded over towards each other, with the first-mentioned pair of lugs being folded towards the laterally spaced-apart lugs.

The tab present in each of the first and second electrically conductive members can be conventional and can be connected to the external electrical conductor by means of welding or a suitable crimping tool.

The electrically conductive material and, for that matter, the electrically insulating material, forming part of the anti-trap sensor can be stretched to a considerable extent which is necessary because the hollow zone normally present between the portions of electrically conductive material in the anti-trap sensor needs to be enlarged considerably to allow the connector of the present invention to be inserted into the enlarged hollow zone, after which suitable implements can cause the two portions of electrically conductive material, forming part of the anti-trap sensor, to be forced towards each other in such a manner that all lugs present penetrate the respective portion of electrically conductive material, whereafter the lugs are bent over in the appropriate direction to form a secure contact between the lugs and that material.During the same exercise, or previously or subsequently, the external electrical conductors can be appropriately positioned with regard to the tabs which are then crimped and otherwise secured to the external electrical conductors so as to complete the operation.

According to another aspect of the present invention, there is provided an anti-trap sensor having two penetrable portions of electrically conductive material, which are normally spaced apart and which are separated by an electrically insulating material; and, secured to the anti-trap sensor, a connector in accordance with the first-mentioned aspect of the present invention, with the lugs penetrating the penetrable portions of electrically conductive material, respectively, and with the tabs secured to external electrical conductors.

For a better understanding of the present invention and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which: Figure 1 is a perspective view of one embodiment of connector in accordance with the present invention; Figure 2 is a side view of the connector of Figure 1; Figure 3 is a plan view of the connector of Figure 1; Figure 4 is a perspective view of an anti-trap sensor to which has been secured a connector substantially identical to that shown in Figure 1; and Figure 5 is a plan view of a stamped metal blank intended, after folding, to serve as a component of a different embodiment of connector in accordance with the present invention.

Referring firstly to the connector shown in Figures 1, 2 and 3, the connector is generally indicated by the reference numeral 1. A major component of the connector is an electrically insulating member 2 which is generally of rectangular oblong shape and which has an upper face 3 and a lower face 4.

Secured by adhesive (not shown), or any other form of bonding, to the upper face 3 of the insulating member 2 is a first, upper, electrically conductive member generally indicated by the reference numeral 5.

This member 5 has a planar component 6 which is bonded to the upper face 3 of the insulating member 2. At one end region of the first electrically conductive member 5 are two upwardly directed lugs 7 and 8 spaced apart by a narrow slot 9 which terminates at a blind end.

At an intermediate point along the first electrically conductive member 5 and on opposite sides thereof, are two more upstanding tags 11 and 12.

Towards the opposite end region of the first electrically conductive member 5 there is a tapered portion 13 leading to a tab 14 used for securing an external electrical conductor.

Secured to the lower face 4 of the electrically insulating member 2 is a second, lower, electrically conductive member generally indicated by the reference numeral 15. The member 15 is identical to the first member 5 and is oriented in mirror image disposition.

The components 16 to 24 of the second electrically conductive member 15 correspond to the components 6 to 14, respectively, of the first electrically conductive member 5, although that the four lugs and tab are downwardly projected.

In use of the connector shown in Figures 1 to 3, the connector is held adjacent a free end region of an anti-trap sensor, such as that generally indicated by the reference numeral 30 in Figure 4. The sensor 30 has a hollow component 31 to take up over-travel of a closing window pane and has a main anti-trap part generally indicated by the reference numeral 32 which comprises a first portion of electrically conductive material 33 (in which is embedded an electrical conductor 34), an opposing, normally spaced apart, second portion of electrically insulating material 35 and, between the opposing end regions of the two portions 33, 35 of electrically conductive material, two portions of electrically insulating material 36, 37.

By the aid of means (not shown) the two portions 33, 35 of electrically conductive material are forced well apart, whereafter the connector 1 is inserted into the open end region of the anti-trap part 32 and then the electrically conductive portions 33 and 35 are released and are forced over the sharp lugs 7, 8, 11, 12, 17, 18, 21 and 22, all eight of which penetrate the respective material and are then turned over and forced onto the outward side of those portions 33 and 35 of electrically conductive material, the internal conductor 34 having travelled down the slot 9, and with the other internal conductor (not shown) having travelled down the slot 19.

At the same time, or before or after, two external electrical connectors 41, 42 are secured by crimping or otherwise, to the tabs 14, 24 respectively.

The eight lugs, when suitably folded over onto the adjacent portions of electrically conductive material not only form a secure mechanical connection but also a good electrical connection with that material.

The internal electrica' conductors, such as that shown at 34, have a good interference fit with the regions adjacent the slots 9 and 19, to ensure a good electrical contact.

Figure 5 shows a blank intended, after being suitably folded, to serve as an electrically conductive member forming part of a connector in accordance with the present invention. In Figure 5 the components numbered 5A, 6A, llA, 12A, 13A and 14A are substantially identical to the corresponding components numbers 5, 6, 11, 12, 13 and 14, respectively, in Figure 1, and, for the sake of brevity, will not be described in detail. The component 5A has two additional lugs 50 and 51 positioned on the same side as, but spaced from, the lugs 11A and 12A, but does not have lugs corresponding to the lugs 7 and 8 shown in Figure 1. This arrangement has the advantage of simpler assembly into the anti-trap sensor but loses the feature of contact with the internal electrical conductor (indicated as 34 in Figure 1). In this embodiment there will be two components like 5A in back-to-back arrangement on opposing sides of a suitable insulating member (like 2 in Figure 1). The component 5A could have an overall length, as measured along its greatest major axis, such that it does not interfere with the active area of the anti-trap system.

Dependent on the geometry of the system this could be typically 10mum.

Claims

1. A connector intended to connect two penetrable portions of electrically conductive material, which are normally spaced from each other and are separated by an electrically insulating material, to two external electrical conductors respectively, the connector comprising: an electrically insulating member having two opposing faces; a first electrically conductive member secured to one of the two opposing faces and provided with (i) at least one lug capable of penetrating and being folded onto one of the portions of electrically conductive material and (ii) a tab for securing the first conductive member to one of the two external electrical conductors; and a second electrically conductive member secured to the other of the opposing faces and provided with (i) at least one lug capable of penetrating and being folded onto the other of the portions of electrically conductive material and (ii) a tab for securing the second conductive member to the other of the two external electrical conductors, the first and second electrically conductive members normally being insulated from each other by the electrically insulating member.

2. A connector according to claim 1, wherein the first electrically conductive member is substantially identical to the second electrically conductive member and is arranged in mirror image thereto, with the electrically insulating member separating the first and second electrically conductive members.

3. A connector according to claim 1 or 2, wherein the electrically insulating member takes the form of a planar or board-like member, with the first and second electrically conductive members secured appropriately, by some adhesive or other bonding system, to the opposing faces of the electrically insulating member.

4. A connector according to claim 1, 2 or 3, wherein the electrically insulating member is formed from fibreglass board, epoxy resin or card.

5. A connector according to any preceding claim, wherein the material from which the first and second electrically conductive members are formed is steel, brass or tinned coper.

6. A connector according to any preceding claim, wherein the electrically insulating member is, at least over part of its length, of oblong rectangular shape, with the major axis intended to lie parallel to the major axis of the anti-trap sensor.

7. A connector according to any preceding claim, wherein each of the first and second electrically conductive members has more than one lug capable of penetrating the first or second (respectively) portion of electrically conductive material forming part of the anti-trap sensor.

8. A connector according to claim 7, wherein each of the first and second electrically conductive members has a first pair of lugs lying on opposing sides of the major axis of the connector, with a narrow slot present between the two lugs in each pair such that, when the portions of electrically conductive material forming part of the anti-forming trap sensor are provided with their own electrical conductors, and when the pairs of lugs penetrate the portions of material, the conductors forming part of the anti-trap sensor can move down through the respective slots, to come to an interference fit with regions of the lugs adjacent the slots.

9. A connector according to claim 8, wherein each of the first and second electrically conductive members is provided with other lugs which are laterally spaced some way from the central axis of the connector and which, once the lugs have penetrated the respective portion of electrically conductive material, can be folded over towards each other, with the firstmentioned pair of lugs being folded towards the laterally spaced-apart lugs.

10. A connector substantially as hereinbefore described with reference to, and as illustrated in, Figures 1 to 3, or Figure 5, of the accompanying drawings.

11. An anti-trap sensor having two penetrable portions of electrically conductive material, which are normally spaced apart and which are separated by an electrically insulating material; and, secured to the anti-trap sensor, a connector in accordance with any one of claims 1 to 10, with the lugs penetrating the penetrable portions of electrically conductive material, respectively, and with the tabs secured to external electrical conductors.

12. An anti-trap sensor connected by a connector to two external conductors, substantially as hereinbefore described with reference to, and as illustrated in, Figure 4 of the accompanying drawings.

13. A method of connecting an anti-trap sensor to two external conductors, which method comprises stretching the electrically conductive material and the electrically insulating material, forming part of the anti-trap sensor, to enlarge to a considerable extent the hollow zone normally present between the portions of electrically conductive material so as to allow the connector according to any one of claims 1 to 10 to be inserted into the enlarged hollow zone, after which the two portions of electrically conductive material, forming part of the anti-trap sensor, are forced towards each other in such a manner that all lugs present penetrate the respective portion of electrically conductive material, whereafter the lugs are bent over in the appropriate direction to form a secure contact between the lugs and that material; and which also comprises positioning the external electrical conductors appropriately with regard to the tabs which are then crimped and otherwise secured to the external electrical conductors.