Present disclosure relates to water resistant electrical connectors. In particular, the present disclosure relates to water resistant USB connector receptacle for a vehicle.
Background
Electrical connectors are widely used to connect electrical or electronic devices with each other. For example, USB connecting ports are very common for connecting various electrical or electronic devices with each other. Generally, USB ports are also utilized for charging a power source, such as a battery, of the electronic device. Generally, vehicles are provided with USB ports for facilitating connecting or charging of various electronic devices carried by the passengers using the vehicle.
Generally, for connecting devices using a USB port a USB plug is inserted into a USB socket. USB socket may include different components according to different configuration^ of the USB socket. For example, in a USB socket provided in a vehicle, the USB socket may include a USB connector receptacle, a PCB having a charging circuit, an LED to indicate charging status, etc. In a vehicle such as a motorcycle, packaging of the components becomes critical as in motor cycle, the USB socket may be exposed to environmental elements such as water and dust.
In order to provide robustness and reliability of the USB sockets, sealing is required to protect electronic components of the USB socket. The sealing helps in protecting the components of the USB socket from vibration, dust, moisture and water ingress. In conventional USB sockets, generally the USB sockets have a PCB with a USB connector at its one end while all electronic components provided on the
A
other side of PCB. For example, see disclosure in Chinese patent document CN106998004. As shown in the document, the assembly has a housing 120 fitted with a PCB 140. The PCB 140 has a USB connector 130 at one end. During assembling process, the PCB 140 is inserted in the housing from a front open side of the housing. The other side of PCB has a terminal 160 soldered to it and taken

out from back side of housing through an opening. Generally, a grommet is provided in the opening that helps to seal the gap between housing and the terminal. The terminals of the wires (22) are connected to the vehicle battery for providing current to the USB receptacle.
The electronic components on the PCB occupy the empty space around the PCB and within the housing. To provide a sealing to the USB receptacle, empty space inside the housing is filled with some sealant, such as an epoxy or other glue, up to the level of USB receptacle from an opening at the front side of the housing. The shape of the housing is often configured for facilitating mounting of the USB receptacle with a panel on the vehicle. The overall shape and size is kept compact to save space on the vehicle panel. The compact shape of housing often restricts the PCB design in order to adjust electronic components to the center of PCB only. If large PCB components like capacitors, MOV and diode are used, the size of housing also need to be increased which increases the quantity of sealant.
Usually the sealant material is filled slightly above the soldered points of USB connector terminals to give them protection from moisture and to give strength. However, while filling, the sealant material may enter the USB connector cavity and rise to a certain height due to capillary action thus affecting the flexibility of terminals with which they press against the mating terminals of a plug. Another problem observed during the sealing process is that the height of sealant inside the housing cannot be controlled precisely due to variation in sealant viscosity, temperature, accuracy of potting machine, shrinkage of moulded parts, variation in size of electronic components, etc. Moreover, height of sealant is also subject to measurement errors because it rises on the wall of the housing and the USB connector due to capillary action. Accordingly, due to various problems as discussed above, exact quantity of sealant cannot be determined accurately. This can lead to impaired USB socket assembly.

Another problem involved in conventional technology is that an additional process of covering the USB connector and the housing with a top cover or cap is required after curing of sealant. All the above discussed problems in the sealing lead to a complex manufacturing process and also lead to a high failure rate of the produced receptacles. Therefore, there is a need to have better approach for sealing the electrical connectors.
Summary
An electrical connector assembly is disclosed. The electrical connector assembly has a PCB, a connector receptacle mounted on a PCB, a plurality of electronic components mounted on the PCB and a housing supporting the PCB in the housing. The housing defines a cavity having a fore end configured for positioning of the connector receptacle and allowing access to the connector receptacle from outside the housing, and a sealing means positioned in the housing. The sealing means is adapted to isolate the fore end from the back end for restricting a sealant from contacting the connector receptacle placed at the fore end, when the sealant is poured in from the back end.
In an aspect, the sealing means has a cover configured for placing on the PCB. The cover is configured to isolate the connector receptacle from the electrical components of the PCB.
In an aspect, the sealing means has a gasket placed at the fore end of the housing, the gasket defines an opening to receive the connector receptacle and a periphery of the opening is adapted to abut the PCB and the cover to isolate the connector receptacle from the electrical components of the PCB.
In an aspect, the housing defines an opening at the fore end for allowing access to the connector receptacle from outside the housing.

In an aspect, the electrical connector assembly has a cap pivotally coupled to the housing, the cap adapted to cover the opening.
In an aspect, the cover has a top plate adapted to be positioned over the PCB and a separator wall extending from the top plate. Rhe separator wall, a front end of the top plate and the PCB cover the connector receptacle from top, sides, back and bottom to isolate the connector receptacle from the electrical components.
In an aspect, the cover has male guides adapted to be received in female guides defined on the PCB for positioning and supporting the cover on the PCB.
In an aspect, the cover has lugs to engage the housing for retaining the cover in the housing.
In an aspect, the cover has an extended portion extending from a rear end of the top plate for harnessing wires coupled with the PCB.
In an aspect, the gasket has a front face adapted to abut the housing, a back face adapted to abut the cover and the PCB, and an inner wall defining the opening.
In an aspect, the gasket has semi-circular ribs on an outer peripheral wall of the gasket. The semi-circular ribs are adapted to abut the housing for a sealing a gap between the housing and the gasket.
In an aspect, the gasket defines a PCB groove on the back face of the gasket for abutting an end of the PCB for sealing a gap between the PCB and the gasket.
In an aspect, the gasket defines connector grooves on the inner wall for supporting the flanges of the connector receptacle.
In an aspect, the gasket is rectangular in shape.

In an aspect, the housing defines a seat for placing the gasket.
In an aspect, the housing defines guide channels for guiding the insertion of the 5 PCB into the housing and supporting the PCB inside the housing.
In an aspect, the housing defines guide channels for guiding the insertion of the cover into the housing and supporting the cover inside the housing.
10 In an aspect, the housing has a snap lock for retaining the cover in the housing.
In an aspect, the electrical connector assembly is adapted for mounting on a motorcycle.
15 Brief Description of Figures
FIG. 1 illustrates a perspective view of an electrical connector assembly in
accordance with an embodiment.
FIG. 2 illustrates a perspective view of the sub-assembly in accordance with an
embodiment. 20 FIG. 3 illustrates an exploded view of the electrical connector assembly in
accordance with an embodiment.
FIG. 4 illustrates a cross-section view of the USB assembly across the line 4-4 of
FIG. 5.
FIG. 5 illustrates a cross-section view of the USB assembly across the line 5-5 of 25 FIG. 4.
FIG. 6 illustrates a front perspective view of the gasket in accordance with an
embodiment.
FIG. 7 illustrates a cross section view of the gasket taken along a vertical plane in
accordance with an embodiment. 30 FIG. 8 illustrates a back-perspective view of the gasket in accordance with an
embodiment.
6

FIG. 9 illustrates a perspective view of the of the cover in accordance with an embodiment.
FIG. 10 illustrates a perspective view of the housing in accordance with an embodiment. 5
Description
Present disclosure provides for an electrical connector assembly. In the embodiment as illustrated herein, a USB connector assembly is shown. The USB connector assembly as disclosed herein may be used as a USB charging port for a 10 vehicle such as a motorcycle, or a USB port for connection with other components on a vehicle. It may be understood that the disclosure may be implemented in any other electrical connector as suitable.
FIG. 1 and FIG. 3 illustrate USB connector assembly, hereinafter referred to as the 15 USB assembly (10), in accordance with an embodiment. The term USB assembly is used for referring to a USB socket that is configured to receive a USB plug for a USB connection. As shown, the USB assembly (10) has a housing (12), a connector receptacle (18), a PCB (20), wires (22) with terminals (24),,a*rtf a cap (26) and a sealing means positioned in the housing (12). The USB assembly as 20 disclosed herein is configured for use in a motorcycle. However, the USB assembly in accordance with the present disclosure may be used in any other vehicle or any other environment as suitable.
The connector receptacle (18) and the terminals (24) of the wires (22) are secured 25 on the PCB (20) as known in the art. There may be other electrical or electronic (active or passive) components (not shown) such as capacitors or diodes on the PCB (20) as required. The PCB (20) may be made by any material as known in the art.
30 The sealing means as illustrated herein are a cover (14) and a gasket (16). The sealing means are components that seal a fore end (70) of a cavity defined by the
7

housing (12) from a back end (52) of the cavity, such that when a liquid sealant is poured in from the back end (52), the sealant does not contact the components such as the connector receptacle (18) placed at the fore end (70). As shown in FIGs. 1-5, the cover (14) is configured to be placed over the PCB (20), and the housing 5 (12) is configured to house the PCB (20) along with the cover (14). It may be understood that the electronic components mounted on the PCB are placed on the surface of a PCB and occupy a space above the PCB. The cover (14), the housing (12) and the PCB (20) are designed such that they together define a space that is configured for positioning various electronic or electrical components on the PCB 10 (20), and such that the space may be filled or potted using a sealant material (95) to seal the USB assembly (10) for protecting it from any water ingress, moisture, dust, etc. Insertion of sealant (95) into the spaces in cavity inside the housing (12) is discussed later herein.
15 FIG. 9 illustrates a perspective view of the cover (14) in accordance with an embodiment. As shown, the cover (14) has a top plate (28) having a rear end (30) and a front end (32). The cover (14) may be designed so as to adequately accommodate the components on the PCB (20) in a middle space (34) between the top plate (28) and the PCB (20). For example, the distance between the PCB (20)
20 and the top plate (28) may be adjusted according to the height of the electronic parts on the PCB (20) that has maximum height. This way the cover (14) acts as a partition in housing and regulates flow of sealant by preventing it from flowing to undesired area between housing and back side of the cover. Similarly, the gap between the PCB (20) and a lower wall (38) of the housing (12) may be configured
25 to achieve compactness of the overall assembly.
The cover (14) has a separator wall (40) that is disposed proximate to the front end (32). The separator wall (40) extends orthogonally from a surface of the top plate (28) and has two male guides (42) on a top face (48) of the separator wall (40). 30 Another male guide (42) is provided on the cover (14) that is positioned on a pillar (46) extending orthogonally from the top plate (28). All the male guides (42) are
8

configured to be received in corresponding female guides (44) provided on the PCB (20) to secure the cover (14) on the PCB (20) as shown in FIG. 2 and FIG. 5. Accordingly, all the male guides (42) are positioned along a common horizontal plane. In an embodiment, the male guides (42) or the female guides (44) may be 5 provided with crushing ribs (not shown) to ensure snug fit of the cover (14) on the PCB (20). The crushing ribs may get deformed when the male guides (42) are pushed into the female guides (44) to ensure proper engagement of the male guides (42) with the female guides (44). The provision of the male guides (42) and the female guides (44) ensure proper location and fitment of the cover (14) on the PCB 10 (20). Further, it should be ensured that no gap is provided between the separator wall (40) and the PCB (20) after the cover (14) is fitted on the PCB (20), in order to prevent flow of sealant (95) towards the connector receptacle (18).
The separator wall (40) is adapted such that the separator wall (40) runs around the 15 connector receptacle (18), and covers the connector receptacle (18) from four sides - top side, back side, left side and right side. The bottom side of the connector receptacle (18) is covered by the PCB (20). The separator wall (40) is also configured such that when the cover (14) is placed on the PCB (20), the top face (48) of the separator wall (40) abuts the PCB (20) next to the connector receptacle 20 (18) and forms separation between the connector receptacle (18) and the middle space (34) housing the other components on the PCB (20).
The front end (32) of the top plate (28) is configured to abut the gasket (16) (described later). The rear end (30) of the top plate (28) is provided with an
25 extended portion extending from the top plate (28), hereinafter referred to as the extension (50) for harnessing the wires (22). The rear end (30) is configured to jut out from the back end (52) of the housing (12) in an assembled state of the USB assembly (10), as shown in FIGs. 1,2 and 5. The wires (22), with its terminals (24) soldered to the PCB (20), may be secured on the extension (50) using any suitable
30 means. In the embodiment as shown, the wires (22) are secured using a cable tie (54). This way the wires (22) exit the USB assembly (10) always at fixed location.
9

This is another advantage of cover, otherwise generally, the extension (50) has to be made integral to the housing (12).
The cover (14) is further provided with two lugs (56) at two lateral ends of the rear 5 end (30). The lugs (56) are configured to engage with two snap locks (58) provided on the back end (52) of the housing (12), as shown in FIG. 1 and FIG. 4. The snap locks (58) may be flexible for facilitating engagement as known in the art.
Further, as shown in FIGs. 2, 3, 5 and 6, a flange (60) extends orthogonally from
10 the rear end (30) of the Cover (14). When the cover (14) is installed in the housing (12) the flange (60) abut a portion of the back end (52) of the housing (12) and covers the gap between the rear end (30) and an upper wall (62) of the back end (52) of the housing (12), as shown in FIG. 5, so, that no foreign particles or water ingress takes place in the space of the housing (12).
15
As shown in FIG. 10, the housing (12) may be provided with guide channels (64) to facilitate installation and also support the PCB (20) and the cover (14) in the housing (12) after installation. In the embodiment as shown, the housing (12) is provided with two sets of guide channels (64), i.e. one each for the PCB (20) and
20 the cover (14) to act as guides for insertion of the PCB (20) and the cover (14) inside the housing (12). The guide channels (64) may also support the cover (14) and the PCB (20) inside the housing (12) after insertion. The PCB (20) and the cover (14) may be provided with corresponding elongated ribs (66) to engage with the guide channels (64) as shown in FIG. 3 and FIG. 9. The guide channels (64)
25 and the elongated ribs (66) may be configured for a sliding engagement for insertion and supporting of the cover (14) and the PCB (20) firmly inside the housing (12). There should be minimum play or clearance between guide channels (64) of housing and the sub-assembly (96) to ensure that connector receptacle (18) is located exactly in a window (68) at the fore end of the housing (12), otherwise
30 if they are offset the plug may not enter properly into the connector receptacle (18).
10

The fore end (70) of the housing (12) is configured for installation of a cap (26) to cover the connector receptacle (18) when not in use. The cap (26) and installation of the cap (26) may be as known in the art. In the embodiment as shown, the cap (26) is installed on a bracket (72) on the fore end (70) of the housing (12) using a 5 torsion spring (74). The cap (26) is also provided with a pad (76) to cover the connector receptacle (18) when not in use. The fore end (70) is further provided with the window (68) to allow access to the connector receptacle (18) for inserting a plug (not shown) from the fore end (70) of the housing (12). The window (68) surrounds the connector receptacle (18) at the fore end (70) of the housing (12). 10 The wall of the window (68) extends orthogonally outwards from a front wall (78) of the housing (12) as shown in FIG. 5. The housing (12) may be configured for fitment with a panel as required. For example, the housing (12) may be configured for fitting on a panel on a vehicle such as a two wheeler.
15 As shown in FIG. 4 and FIG. 5, the gasket (16) is installed towards the fore end (70) of the housing (12) to seal a gap between the housing (12), the PCB (20) and the connector receptacle (18) as shown in FIG. 3. When installed, the gasket (16) abuts the front wall (78) of the housing (12). The housing (12) is provided with a seat (80) corresponding with the peripheral shape of the gasket (16) to support the
20 gasket (16) at the fore end (70). In the embodiment as illustrated in FIG. 6, the gasket (16) is formed of a shape corresponding to the housing (12), i.e. rectangular shape. In an alternate embodiment, the housing (12) and the gasket (16) may be formed in any other shape and suitable changes may be made in the design and shape as required. In the embodiment as shown, the housing (12) and the gasket
25 (16) are both substantially of rectangular shape. The gasket (16) may be made of any material suitable for a sealing engagement with the cover (14), the PCB (20), the connector receptacle (18) and the housing (12). For example, the gasket (16) may be made of rubber, plastic, silicone or any other suitable polymeric or non-polymeric material.
30
11

Further, referring to FIG. 6, FIG. 7, and FIG. 8, the gasket (16) has an opening (82) in the middle portion of the gasket (16). The opening (82) is defined by an inner wall (84) of the gasket (16). The opening (82) is configured to allow the connector receptacle (18) to pass through the opening (82) as shown in FIG. 4 and FIG. 6 and 5 allow abutting of the connector end of the PCB (20) with the gasket (16). In the embodiment as shown, the gasket (16) defines various grooves for accommodating portion of components engaging the gasket (16) and the opening (82) on the gasket (16). As shown, the inner wall (84) defines grooves to partially cover the spout window (68) as well as cover flanges of the connector receptacle (18). In the
10 embodiment as shown, the inner wall (84) has six connector grooves (86) provided on the inner wall (84) towards a front face (88) of the gasket (16) to accommodate the flanges of the connector receptacle (18). The connector grooves (86) ensure that during insertion of plug into the connector receptacle (18) the movement of the connector receptacle (18) is amply absorbed by the gasket to prevent any
15 damage to the plug or the components of the USB assembly (10) due to movement of the connector receptacle (18). Further, a PCB groove (90) extending laterally is provided on a back face (92) of the gasket (16) to support an end of the PCB (20) positioned towards the fore end (70), as shown in FIG. 5 and FIG. 8. Further, the epoxy filled via backside of connector does not enter into front USB receptacle
20 surrounding area, because gasket stops flowing of epoxy in that region, so the USB connector area is free from contact to the epoxy and accordingly also gives protection from damage due to epoxy.
Further, the gasket (16) is provided with a plurality of semi-circular ribs (94) 25 running along an outer peripheral wall of the gasket (16). The semi-circular ribs (94) abut a surface of the seat (80) to hermetically seal the gap, if any, between the gasket (16) and the surface of the seat (80). The outer dimensions of rubber gasket (16) are kept slightly bigger than the dimensions of the seat (80) in the housing (12) so as to provide required sealing compression to prevent sealant flow between 30 the two components.
12

Further, a method of manufacturing an electrical connector is disclosed. As an example, a method of manufacturing a USB assembly (10) is described herein. For manufacturing the USB assembly, first, the PCB (20) may be connected with the connector receptacle (18) and the terminals (24) of the wires (22) as shown in FIG. 5 5. Then the cover (14) may be placed on the PCB (20) with the male guides (42) of the cover (14) pushed into the female guides (44) provided on the PCB (20), as shown in FIG. 2 and FIG. 5. After this, the gasket (16) may be installed with its back face (92) towards the cover (14) and the back face (92) abutting the front end (32) of the cover (14) as shown in FIG. 2 and FIG. 5. FIG. 2 illustrates a sub-
10 assembly (96) of the components assembled at this stage. The dimensions of the inner wall (84) of the gasket (16) and the connector receptacle (18) are kept such that the inner wall (84) and connector receptacle (18) engage snugly so as to provide required sealing compression on it and does not allow any sealant flow between the two parts.
15
Further, the housing (12) may be pre-installed with the cap (26) or installed later as convenient. The assembly of components of the USB assembly (without the housing and the cap) is referred to as the sub-assembly (96). The sub-assembly (96) as shown in FIG. 2 can be now inserted into the housing (12) from the back
20 end (52) of the housing (12). For insertion, the elongated ribs (66) of the cover (14) and the PCB (20) may be engaged with the corresponding guide channels (64) and the sub-assembly (96) may be pushed inside the housing (12) from the back end (52) towards the fore end (70).
25 After insertion, the gasket (16) will abut the front wall (78) of the housing (12) as shown in FIG. 4 and FIG. 5, and simultaneously, the lugs (56) on the cover (14) shall engage the snap locks (58) provided on the back end (52) of the housing (12) as shown in FIG. 1. The locking engagement of the lugs (56) and the snap locks (58) ensure that the sub-assembly (96) is snugly retained in the housing (12). The
30 overall dimensions of the cover (14), the housing (12) and the gasket (16) may be designed such that on and after the locking engagement of the snap locks (58) and
13

the lugs (56), the gasket (16) is at least slightly squeezed or pressed between the front wall (78) of the housing (12) and the front end (32) of cover and the PCB (20) and retained in such state. This prevents the sub-assembly (96) from moving backwards and keeps continuous pressure over the gasket (16). The compression 5 of the gasket (16) from the front face (88) and the back face (92) will result in slight expansion of its periphery and ensure proper engagement of the semi-circular ribs (94) of the gasket (16) with the seat (80) of the housing (12), and of the inner wall (84) with the connector receptacle (18). This arrangement will also ensure that the sealing engagement is retained after installation of the sub-assembly (96) into the
10 housing (12). Accordingly, when a sealant (95) is poured into the chamber the sealant is prevented from escaping the chamber due to the sealing engagement between the gasket (16) and the surround components. The wires (22) may be secured on the extension (50) provided on the cover (14) using a cable tie (54) as shown in FIGs. 2, 4 and 5.
15
Further, after installation of the sub-assembly (96) into the housing (12), there are three spaces defined inside the housing (12) marked as a top space (98), the middle space (34) and a bottom space (99) in FIG. 5. After the sub-assembly (96) is installed in the housing (12) the bottom space (99) and the middle space (34) inside
20 the USB assembly (10) may be filled with a sealant material from the back end (52) of the housing (12). The top space (98) may be kept empty to save the sealant material as there is no component in the top space that requires protection from moisture or water, as almost all the electronic or electrical components of the PCB (20), other than the connector receptacle (18), are located in the middle space (34)
25 or the bottom space (99).
The sealant material (95) may be any suitable material known in the art which can poured into the housing (12) in liquid state and then the sealant solidifies for sealing of the USB assembly (10). When the sealant is poured in, the sealant may fill in 30 the middle space (34) and the bottom space (99) and surround the components of the PCB (20). After solidification, the sealant ensures that any electrical and
14

electronic components of the USB assembly (10) are prevented from contact with moisture or water. The sealant may be filled in a quantity such that the sealant reaches upto the extension (50) of the cover (14). Alternatively, sealant can be poured from the back end (52) to reach a height slightly less than the height of the 5 housing (12). No exact measurement of sealant height or volume is required.
Furthermore, PCB manufacturers demand more tolerance on thickness and overall length due to manufacturing limitations. Accordingly, in the embodiment as shown, the PCB (20) is not used to locate the connector receptacle (18) in the
10 housing (12). Instead, the cover (14) is used to locate the connector receptacle (18) inside the housing (12). Since the cover (14) can be made of a material such as engineering plastic, better dimensional control may be achieved. Accordingly, minimum acceptable clearance is provided between the cover (14) and housing for fitment of the elongated ribs (66) of the cover (14) in the corresponding guide
15 channels (64) of the housing (12). Whereas, sufficient clearance may be provided for the elongated ribs (66) of the PCB (20) and the corresponding guide channels (64) to avoid fouling. The minimum clearance between the elongated ribs (66) and the corresponding guide channels (64) of the housing (12) is also essential to prevent sealant flow in top space (98) of the housing (12).
20
Further, the method and assembly for sealing as disclosed herein prevents sealant material to flow inside USB connector shell which has gaps or slits over its surface, etc. Also, sealant material is prevented from flowing into undesirable areas of housing within which connector receptacle (18) is located thus reducing total
25 weight of Assembly. The USB assembly (10) and the method of sealing as disclosed herein also helps in precisely locating the connector receptacle (18) mounted on the PCB (20) with respect to window (68) in the housing (12) through which a mating plug enters into the connector receptacle (18). The disclosure herein provides for eliminating secondary operations to cover the entire assembly
30 in order to prevent entry of water, dust and other contamination in the USB assembly (10). These secondary operations include plastics welding, heat sealing,
15

fastening, snap locking, etc. The disclosure further provides for an alternate method of sealing the USB assembly (10) by pouring sealant (95) from back end (52) of the housing (12) which is less complex. This helps in reducing rejection rates during mass production. Thus, making the USB assembly (10) compact and 5 production of USB assembly (10) economical.
Accordingly, a USB assembly (10) and a method for producing a sealed USB assembly (10) for vehicles such as two-wheeler is provided. As described above, the connector receptacle (18) and other electronic parts are soldered on to the PCB
10 (20) which allows the USB devices to charge or interact safely with vehicle battery or electronics. The USB assembly (10) may have the wires (22) with a suitable connector at the end of the wires (22) so that it can be connected to the vehicle wiring harness. The cover (14) is rigidly fixed to the PCB (20) from top and the gasket (16) is assembled on to the connector receptacle (18) from front side as
15 described above. The sub-assembly (96) thus formed, is push guided inside the housing (12) so that the connector receptacle (18) is clearly visible at the fore end (70) of the housing (12) and the cover (14) sits inside the housing (12) with help of snap locks (58) provided at back end (52) of the housing (12) as explained earlier. The wires (22) can be tied with tie cable or a cord clamp on the extension
20 (50). The complete USB assembly (10) can then be potted with suitable sealant (95) from back end (52) of the housing (12). To seal the USB assembly (10) from front side, a pad (76) is fitted with the cap (26) using suitable means. A torsion spring (74) and a spring dowel (97) sleeve is used to fit the cap (26) on to the housing (12) to make the USB assembly (10). The protective cap (26) is self-
25 returning and returns back as soon as USB plug cable is removed.
Further, in an embodiment of the present disclosure, illumination to the connector
receptacle (18) may be provided so that it is visible from a distance in dark or
poorly lit environment. Such illumination can be provided by adding a LED to the
30 PCB (20) and selecting a transparent material for the gasket (16) and/or the sealant.
16

The geometry and other configuration of the gasket (16) can be modified in such a way that it provides uniform illumination around the USB receptacle.
The present disclosure provides for a USB socket for any off-road or on-road vehicles. The USB socket may be used as a USB charging port in two wheeled vehicles. Generally, USB chargers are manufactured to operate in an enclosed environment such as office, residence or vehicle environment. Such USB chargers are not completely sealed for potting purpose which is the prime requirement in 2 wheelers. Further, potting from front side is difficult in terms of maintaining quality. An alternate arrangement is herein in which it is described how potting can be done from back side overcoming all bottlenecks as discussed above or other associated problems in the art.

WE CLAIM:

An electrical connector assembly (10) comprising:
a PCB (20);
a connector receptacle (18) mounted on a PCB (20);
a plurality of electronic components mounted on the PCB (20);
a housing (12) supporting the PCB (20) in the housing (12), the housing (12) defining a cavity having a fore end (70) configured for positioning of the connector receptacle (18) and allowing access to the connector receptacle (18) from outside the housing (12); and
a sealing means (14,16) positioned in the housing (12), the sealing means (14,16) adapted to isolate the fore end (70) from the back end (52) for restricting a sealant from contacting the connector receptacle (18) placed at the fore end (70), when the sealant is poured in from the back end (52).
The electrical connector assembly (10) as claimed in claim 1, wherein the sealing means (14,16) comprises:
a cover (14) placed on the PCB (20), the cover (14) configured to isolate the connector receptacle (18) from the electrical components of the PCB (20).
The electrical connector as claimed in claim 2, wherein the sealing means (14,16) comprises:
a gasket (16) placed at the fore end (70) of the housing (12), the gasket (16) defining an opening (82) to receive the connector receptacle (18) and a periphery of the opening (82) adapted to abut the PCB (20) and the cover (14) to isolate the connector receptacle (18) from the electrical components of the PCB (20).

The electrical connector assembly (10) as claimed in any one of claims 1 to 3, wherein the housing (12) defines a window (68) at the fore end (70) for allowing access to the connector receptacle (18) from outside the housing (12).
The electrical connector assembly (10) as claimed in claim 4, further comprising a cap (26) pivotally coupled to the housing (12), the cap (26) adapted to cover the window (68).
The electrical connector assembly (10) as claimed in claim 2, wherein the cover (14) comprises:
a top plate (28) adapted for positioning over the PCB (20);
a separator wall (40) extending from the top plate (28);
wherein a front end (32) of the top plate (28), the separator wall (40) and the PCB (20) cover the connector receptacle (18) from top, sides, back and bottom to isolate the connector receptacle (18) from the electrical components.
The electrical connector assembly (10) as claimed any one of claims 2 or 6, wherein the cover (14) comprises male guides (42) adapted to be received in female guides (44) defined in the PCB (20) for positioning and supporting the cover (14) on the PCB (20).
The electrical connector assembly (10) as claimed in any one of claims 6 or 7, wherein the cover (14) comprises lugs (56) to engage the housing (12) for retaining the cover (14) in the housing (12).
The electrical connector assembly (10) as claimed in any one of claims 6 or 7, wherein the cover (14) comprises an extended portion (50) extending from a rear end (30) of the top plate (28) for harnessing wires (22) coupled with the PCB (20).

The electrical connector assembly (10) as claimed in claim 3, wherein the gasket (16) comprises:
a front face (88) adapted to abut the housing (12);
a back face (92) adapted to abut the cover (14) and the PCB (20); and
an inner wall (84) defining the opening (82).
The electrical connector assembly (10) as claimed in claim 3, wherein the gasket (16) comprises semi-circular ribs (94) on an outer peripheral wall of the gasket (16), the semi-circular ribs (94) adapted to abut the housing (12) for sealing a gap between the housing (12) and the gasket (16).
The electrical connector assembly (10) as claimed in claim 10, wherein the gasket (16) defines a PCB groove (90) on the back face (92) of the gasket (16) for abutting an end of the PCB (20) for sealing a gap between the PCB (20) and the gasket (16).
The electrical connector assembly (10) as claimed in claim 3, wherein the gasket (16) defines connector grooves (86) on the inner wall (84) for supporting flanges of the connector receptacle (18).
The electrical connector assembly (10) as claimed in claim 3, wherein the gasket (16) is rectangular in shape.
The electrical connector assembly (10) as claimed in claim 3, wherein the housing (12) defines a seat (80) for placing the gasket (16).
The electrical connector assembly (10) as claimed in any one of claims 1 to 15, wherein the housing (12) defines guide channels (64) for guiding the

insertion of the PCB (20) into the housing (12) and supporting the PCB (20) inside the housing (12).
The electrical connector assembly (10) as claimed in any one of claims 1 to 16, wherein the housing (12) defines guide channels (64) for guiding the insertion of the cover (14) into the housing (12) and supporting the cover (14) inside the housing (12).
The electrical connector assembly (10) as claimed in any one of claims 1 to 17, wherein the electrical connector assembly (10) is adapted for mounting on a motorcycle.
The electrical connector assembly (10) as claimed in claim 8, wherein the housing (12) has snap locks (58) for engaging with the lugs (56) for retaining the cover (14) in the housing (12).