Connector overmold spacer
View Patent ↗A connector assembly includes a terminal crimped to an electrical conductor. The terminal is retained in a terminal area of a connector housing. A cable seal is positioned within an opening of the connector housing that leads to the terminal area. A spacer at a rear side of the connector housing provides a mechanical barrier to prevent injected thermoplastics from entering the terminal area during an overmolding process.
1. A method of fabricating a connector assembly comprising the steps of:
(a) attaching a terminal to an electrical conductor;
(b) positioning a seal and a spacer around the electrical conductor;
(c) inserting the terminal into a terminal area of a connector housing and positioning the spacer near a rear side of the connector housing;
(d) overmolding at least a portion of the electrical conductor and the connector housing with a thermoplastic material; and
(e) sealing the terminal area against intrusion of the thermoplastic material.
2. The method as recited in claim 1 , wherein said step (a) comprises:
crimping the terminal to the electrical conductor.
3. The method as recited in claim 1 , wherein, said step (b) comprises:
positioning a first piece and a second piece of the spacer around the electrical conductor.
4. The method as recited in claim 1 , wherein said step (c) comprises:
inserting the seal at least partially within an opening that leads to the terminal area of the connector housing.
5. The method as recited in claim 1 , wherein said step (d) comprises:
inserting the connector assembly into a mold and injecting the thermoplastic material into the mold.
6. The method as recited in claim 1 , wherein said step (b) and said step (c) are performed prior to said step (d).
7. A method of sealing a housing of a connector assembly, comprising:
(a) positioning a first spacer piece around an electrical conductor;
(b) positioning a second spacer piece around the electrical conductor;
(c) inserting a seal at least partially within the housing;
(d) sliding the first spacer piece and the second spacer piece near a rear side of the housing; and
(e) sealing a terminal area of the housing against intrusion of a thermoplastic material.
8. The method as recited in claim 7 , wherein said step (a) comprises:
attaching a terminal to the electrical conductor.
9. The method as recited in claim 8 , wherein said step (c) comprises:
inserting the terminal into the terminal area of the housing.
10. The method as recited in claim 8 , wherein said step (e) comprises:
inserting the connector assembly into a mold and injecting the thermoplastic material into the mold.
11. The method as recited in claim 10 , wherein said step (e) comprises:
overmolding at least a portion of the housing with the thermoplastic material.
12. The method as recited in claim 7 , wherein said steps (a) through (d) are performed prior to said step (e).