Gasket

#The present invention relates to an electrical connection system using a gasket that adapts lower voltage connection systems for application in higher voltage systems.

#This application claims priority to U.S. provisional application 60/372,479 filed Apr. 15, 2002.

#In response to the need for more power in future vehicles, it is planned for the automotive design voltage to be increased from 14 VDC to 42 VDC. The main objectives for this change are the reduction of fuel consumption and the introduction of new features. Components and systems which work well at 14 VDC will not necessarily function at the higher DC voltage levels.

#The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:

#FIG. 1 illustrates a gasket of the present invention;

#FIG. 2 is a side view of a first connection system of the present invention before the connectors are mated;

#Referring to the figures wherein like numerals refer to like elements throughout the several views, FIG. 1 is a perspective view of a gasket 10. The gasket in FIG. 1 has an elongated shape with slits 12a, 12b to enable the gasket 10 to be inserted through terminal blades (not shown) without tearing the gasket material. The slits 12a, 12b do not extend completely through the gasket 10. This enables a terminal to perforate the partial slit when the gasket 10 is assembled to a device, but retains sealing capabilities if no terminal exists at that location. Alternately, the slits 12a, 12b can be designed to extend entirely through the gasket 10. The shape of the gasket 10 is typically designed so that the gasket 10 fits into a device (not shown) it is used to seal. The gasket is comprised of a cellular foam material that is either a closed-cell foam or, alternatively, an open-cell material that becomes closed-cell when compressed. The foam material may be comprised of silicone or some other material. It is desirable for the foam material to be compressible and to have a compression set that is low enough to enable sealing capabilities to be maintained through vibration and movement experienced in the application environment. One of many materials that may comprise the gasket of the present invention is BISCO™ BF-1000 cellular silicone. BISCO is a trademark of Rogers Corporation, Elk Grove Village, Ill.

#FIG. 2 illustrates a first sealed connection system 14 in an unmated state. The first sealed connection system 14 comprises a device 16 (in this example, a male connector) and a female connector 22. The gasket 10 is located inside the male connector 16 and forms a compression fit within the walls of a shroud 18 and male terminals 20a, 20b. Obviously, the female connector might alternatively be used to locate the gasket 10. Also, the gasket 10 may not form a compression fit within the walls of the shroud 18 and may instead be held within the male connector 22 by an adhesive (not shown), by a protrusion (not shown) on the male terminals 20a, 20b or through some other mechanism.

#FIG. 3 illustrates a first sealed connection system 14 as depicted in FIG. 2 in a mated state. The gasket 10 fills the voids between the terminals 20a, 20b, 24a, 24b.