FIELD OF THE DISCLOSURE

The present invention relates to the field of connectors, e.g., for data transmission connections with data processing circuitry, particularly to be used in environments where they are subjected to moisture and contacts with liquids.

BACKGROUND OF THE DISCLOSURE

Data processing devices, including devices for data transmission or data collection, typically comprise terminal blocks or connector parts for allowing connection of the device to a transmission cable, a docking station or another data processing device. In some environments such data devices are subjected to moisture or liquids. For devices like pedometers or stepcounters, or body movement measuring devices which are worn during sporting, e.g. with swimming, data transmission contact points should be watertight. These devices typically have data transmission contacts to upload the collected data to a computer, e.g., via a docking station. In a possible test to examine the degree of watertightness, such devices are submerged for one hour at a depth of 1 meter. After one hour, it is examined if any water droplets have entered the tested device. If droplets are observed, the device is rejected.

SUMMARY OF THE DISCLOSURE

An object of the present invention is to provide a watertight connector, e.g., for a data processing device comprising one or more watertight data transmission contact leads. More particular, the device should be able to withstand the above-mentioned test.

This object is achieved with a connector comprising one or more leads comprising at least one part embedded in a moulded polymeric material wherein the embedded part of the lead is provided with at least one anchoring means. The embedding in the polymeric material encapsulates the leads in a leak-tight manner, thus providing a waterproof sealing of the device at the location of the leads. The polymeric material embeds the fixation means which results in a firm anchoring of the leads into the moulded material.

The fixation means can for example be an opening formed into the lead. This way, the polymeric material passes the one or more openings which results in an anchoring of the leads. By virtue of this feature, tightness is also improved since when the polymeric material cools down after molding, it tends to shrink in and around the opening providing more pressure around the leads.

The fixation means can also be a broadened part of the lead. If water would still pass the leads via a crack or craze of slight split between the lead and the embedding material, the water will have to pass a longer way before it reaches the interior of the device.

In a particular embodiment, the fixation means include at least one opening and at least one broadened part. The opening can for instance be positioned within the broadened part, e.g., in its centre.

In order to prevent local mechanical stresses, the broadened part can for example be a rounded part or a polygonal part with rounded corners. The benefit of rounded corner is that it prevents development of stress concentration areas near the opening .

The polymeric material embedding the leads can be any suitable mouldable polymeric material, such as polycarbonate, polyvinyl chloride (PVC) , polyethylene (HDPE or LDPE) , polypropylene, polystyrene, POM, PTFE, PEEK, or any other suitable plastic material. The polymeric material can for instance be moulded by injection moulding. In a particular embodiment, one or more of the leads can be bent into a C-shape with a mid-section and two bent arms, wherein the leads are embedded near the one or more openings, leaving the outer ends of the bent arms and one side of the midsection free.

The outer end of one of the bent arms can be bent to be parallel with the C-shapes mid-section. Optionally, this bent outer end has a bent tip.

The invention also relates to a method of manufacturing a connector wherein first a carrier strip is made carrying a number of leads each being provided with at least one section having an anchoring means, such as an opening and/or a broadened part or projection, wherein the leads are bent into a C-shape, and wherein of each lead the section having one or more fixation means is embedded by moulding in a polymeric material, and the carrier strip is removed.

Optionally, two carrier strips are used, carrying the leads between them, and both carrier strips are removed after embedding the lead sections having a fixation means by moulding the polymeric material.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1: shows a connector according to the invention;

Figure 2: shows a cross section of the connector of Figure 1 ;

Figure 3A: shows in detail the encapsulated section of a lead of the connector of Figure 1 ;

Figure 3B and Figure 3C: show a cross-sectional view of the encapsulated section of the lead along line A and B respectively;

Figure 4 : shows a carrier strip for the manufacturing of leads to be used in the connector of Figure 1;

Figure 5: shows a bent set of six leads for a connector according to Figure 1. DETAILED DESCRIPTION OF EMBODIMENTS

Figures 1 and 2 show a connector 1 with a front part 2 forming a U-shape with two profiled legs 3, 4 which can be slid into and attached to a housing of a data collecting or processing device, such as a pedometer. The front part 2 is made of a plastic material, such as a polycarbonate, and can for instance be made by injection moulding.

Embedded in the polycarbonate are leads 5, bent in a C- shape with a base mid section 6 and two parallel legs 7, 8 bent under right angles with respect to the mid section 6. The end 9 of leg 8 is bent under right angles with respect to leg 8 to be parallel to the mid-section 6. The outer end 10 of end 9 is bent in a direction pointing away from the mid-section 6. Close to mid-section 6 the leads 5 are provided with openings 11, 12. Around these openings 11, 12 the leads are embedded in by the polycarbonate. The mid-section 6 is covered by the polycarbonate at one side, but the surface directed away from the legs 7, 8 is not covered by the polycarbonate.

Figure 3A shows opening 11, 12 in more detail. The leads are provided with a broadened part 13 around the openings 11, 12. The fixation means of the lead has an eye-of-needle shape, comprising a first proximal main branch which bifurcates into two secondary branches parallel to the main branch and finally these two secondary branches merge to provide a main distal branch. The transition from the broadened section 13 to the rest of the lead is formed by rounded corners 14 which are advantageous in order to lower local stress applied by the contact on the moulded material.

Figure 3B corresponds to a cross-section view of the lead along line A, in a region located outside the broadened part 13 of the lead. The lead in this region has a cross- sectional area Sl

In reference of Figure 3C, is shown a cross-sectional view of the lead along line B, situated in the broadened part 13. In this region the lead presents two portions, separated by the opening 11, having respectively cross-sectional area S2 and S3. According to a preferred embodiment, the ratio Sl/(S2+S3)is substantially equal to 1. Indeed, by virtue of this design, the electrical current travelling through the lead is evenly distributed in the broadened region of the lead which is advantageous in term of heat dissipation and of contact resistance .

Figure 4 shows in plan view a ladder-type strip 15 comprising two carrier strips 16, 17 carrying leads 5 to be used for a connector as shown in Figure 1. Two sets of three leads 5 with a gap between the sets are cut off from the strip 15 and bent into a C-shape, as shown in Figure 5. This C-shape is embedded in the front part 2. Then the remaining parts of the carrier strips 16, 17 are cut-off and the longest leg 8 of the C-shape is bent twice to form the profiled contact lead 5 as shown in Figures 1 and 2.