Electrical connector

#This invetnion relates to a NAFI type electrical connector having a metal sheath and pin-protection skirt assembly. More particularly, it relates to an integral connector sheath providing numerous advantages over the connectors previously in use.

#In connectors of this type, metal pins are embedded in a small plastic bar, which forms the body of the connector, with one end of each pin extending from one surface of the body to make a removable connection with a female connector and the other end extending from another surface of the plastic body to make permanent connection with desired circuit components. The plastic body is provided with an opening near each end to receive a keying pin for aligning a mating connector.

#In conventional NAFI connectors, two metal strips cemented to opposite sides of the plastic body form skirts extending beyond the body to provide mechanical protection for the connector pins. These metal strips are the source of numerous difficulties with these connectors. The strips, secured by cement, sometimes come loose from the plastic body after the connector has been installed. The electronic modules that are permanently attached to the connector are generally of such value that it is not practical to discard the unit, and the skirt along with any other damaged elements must be repaired. To minimize the chance either of the skirts will pull loose, the connectors are routinely subjected to a six-pound pull test on each corner of the metal strip. The testing of each unit in this manner and the resulting failure of a number of units adds materially to the cost of the connectors. Moreover, since the metal strips are secured solely by means of adhesive, a considerable amount of adhesive is required and the build up of adhesive between the strip and the plastic body frequently causes dimensional problems. Moreover, the cement sometimes creeps into the area of the connector pins and interferes with electrical contact or prevents proper mating of the two connectors.

#These and other objects of the invention will be apparent from the following description of a preferred embodiment of the invention considered in conjunction with the following drawings, in which:

#FIG. 1 is an exploded perspective view of a connector embodying the invention;

#FIG. 2 is an elevational view of the connector of FIG. 1 with certain parts cut away to show the interior construction of the connector;

#In the connector shown in FIGS. 1, 2, and 3, two rows of pins, generally indicated at 2, are embedded, by molding, into a plastic body 4, each of the pins having a connection portion 2a extending from one surface of the body 4 and adapted for making a removable connection with an individual receptacle of a female connector (not shown). The opposite end portion 2b of each pin extends from the opposite surface of the body 4 and is adapted for making permanent connection to any desired electrical circuitry. The connector may be of any length and include any desired number of connection pins.

#To provide reinforcement for the body 4 and protection for the exposed connection pins 2a, a sheath, generally indicated at 6, is fitted over and cemented to the plastic body 4. The sheath 6 is formed of aluminum, such as 6063-T5 or T6, extruded as an H-shaped section. This H-shaped section includes two connecting bridges 7a and 7b, two downwardly-extending parallel flanges 6b and 6c, and two upwardly-extending parallel pin-protection skirts 6d and 6e. A central part of the cross of the H-shaped extrusion, between the bridges 7a and 7b, is removed, as by punching, to leave a rectangular opening 8 that allows the connection pins 2a to extend into the space between the skirts 6d and 6e. This opening 8 is slightly less in width than the transverse distance between the opposing skirts 6d and 6e to leave two longitudinal inwardly extending ribs, as shown at 6f and 6g in FIG. 3, along each side of the sheath. These ribs typically project about 0.020 inches and are dimensioned to mate nicely with notches 2f and 2g formed along the edges of the body by a raised area on the central part of the surface of the body 4. These ribs provide added strength for the sheath and insure proper positioning of the sheath 6 on the body 4.

#The flanges 6b and 6c are secured to the side surfaces of the body 4 by a small amount of a suitable cement, such as an epoxy or other glue. Because the flanges 6b and 6c are maintained rigidly in position by the mechanical construction of the assembly, only a very small amount of cement is applied and this small amount is less than that which would cause either dimensional problems or the creeping of the cement into the pin area, both of which are recurring problems with the separate skirts heretofore in use.