Abstract:
A combination of a wet mate electrical connector and a gigabit miniature transceiver in a pressure resistant cable plug connector assembly. The cable plug connector assembly includes a wet mate connector, a miniature gigabit transceiver, and electrical and optical connections necessary to convert transmitted electrical data signals to optical data signals and vice versa.

Description:
REFERENCE TO RELATED APPLICATION 
       [0001]    This patent application claims priority to U.S. provisional patent application entitled “Gigabit Wet Mate Active Cable,” having Ser. No. 61/474,131, filed on Apr. 11, 2011, the entirety of which is hereby incorporated by reference into the present patent application. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to connectors for under water environments, and more particularly, to deep water fiber optic or electro optical hybrid connectors. 
         [0004]    2. Description of Related Art 
         [0005]    Current wet mate electrical connector and cable technology utilizes ruggedized CAT5 or 6 cables and electrical wet mate connectors of proven design. Unfortunately, CAT 5 or 6 cables are limited in there effective signal communication length to about 100 meters. Additionally, electrical twisted pair cables used in CAT 5 and 6 cables are heavy and bulky and transmitted signals are susceptible to electrical interference. Conversely, fiber optic cables that can be used as an alternative to electrical cables for better signal transmission integrity and for longer transmission distances do not have comparatively low cost fiber optic connector interfaces for reliable low loss and repeatable wet mate connection in adverse submerged environments. All of these attributes are undesirable for a wet mate environment, especially at deep water depths for the reliable low cost transmission of high data rate signals over long distances where repeated mating and unmating of connectors subsea may occur. 
         [0006]    Accordingly, there is a need for a deep water connector system that provides the benefits of fiber optic cables for increased transmission distances via the attached cables. Additionally, there exists a need for deep water connector cables which are lighter, less bulky, and more flexible. There also exists a need to combine the benefits of fiber optic subsea cable transmission with the benefits of proven electrical subsea wet mate connector interfaces. 
       ASPECTS AND SUMMARY OF THE PRESENT INVENTION 
       [0007]    In order to overcome these deficiencies in the prior art, the present invention provides a novel combination of wet mate electrical connectors and a gigabit miniature transceiver in a pressure resistant cable plug connector assembly. The cable plug connector assembly includes a wet mate connector, a miniature gigabit transceiver, and electrical and optical connections necessary to convert transmitted electrical data signals to optical data signals and vice versa. 
         [0008]    In accordance with one aspect of the present invention, an active cable is provided by incorporating a gigabit transceiver necessary to convert transmitted electrical data signals into optical data signals and vice versa. 
         [0009]    An additional aspect of the present invention locates optical connections either de-mountable or permanent inside a pressure resistant fiber cable end of the wet mate connector assembly. 
         [0010]    Another aspect of the present invention enables the wet mate gigabit optical cable connector assembly to be protected from and operate at water depths having water pressure levels approaching 10,000 pounds per square inch (psi). 
         [0011]    A further aspect of the present invention is to provide data transmission distances in deep water environments exceeding 10 kilometers by using optical gigabit transmission lines made possible by the connector assembly of the present invention. 
         [0012]    By providing the higher speed serializer/deserializer (SerDes) data and power for the transceiver (DC low voltage) rather than the lower speed 4 pair 1000 Base-T electrical data (the signals that are typically used) through the wet mate connector assembly, the electronics in the active cable can be limited to just the transceiver. The rest of the electronics, such as the RJ-connector, electrical transformers, power regulation, and physical layer (PHY) switch chipset, which are required to connect standard RJ electrical Ethernet cable signals to the SerDes signal used by the transceiver, all reside inside the bulkhead of the wet mate connector assembly within the water proof and pressure proof chamber behind the connector interface. This configuration allows the size of the active cable heads to be minimized and easily packaged in space typically used by wet mate electrical connector systems. Furthermore, numerous variations are provided for connecting the active cable plug end to the connecting bulkhead connector or another free connector plug end via a threaded mate or a bayonet mate. 
         [0013]    The foregoing has outlined, rather broadly, the preferred features of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiments as a basis for designing or modifying other structures for carrying out the same purposes of the present invention, and that such other structures do not depart from the spirit and scope of the invention in its broadest form. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  is a perspective view of a wet mateable connector assembly configured in accordance with the present invention, wherein a grip ring of a screw ring connector is in an extended position; 
           [0015]      FIG. 2  is a side view of the wet mateable connector assembly shown in  FIG. 1 ; 
           [0016]      FIG. 3  is a side view of the wet mateable connector shown in  FIGS. 1 and 2  disconnected from an electrical bulkhead mount; 
           [0017]      FIG. 4  is an exploded view of the wet mateable connector assembly shown in  FIGS. 1 and 2 ; 
           [0018]      FIG. 5  is a cross-sectional view of the wet mateable connector assembly shown in  FIGS. 1 and 2 ; 
           [0019]      FIG. 6  is a cross-sectional view of the wet mateable connector shown in  FIG. 3 ; 
           [0020]      FIG. 7  is a cross-sectional view of the wet mateable connector assembly shown in  FIG. 6  without several elements; 
           [0021]      FIG. 8  is an enlarged cross-sectional view of the electrical connector end of the wet mateable connector shown in  FIG. 6 ; 
           [0022]      FIG. 9  is an enlarged cross-sectional view of the optical connector end of the wet mateable connector shown in  FIG. 6 ; 
           [0023]      FIG. 10  is an enlarged cross-sectional top view of the optical connector end of the wet mateable connector shown in  FIG. 6 ; 
           [0024]      FIGS. 11   a - 11   e  are different views of a mount for a gigabit transceiver and attached electrical connector. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0025]    Referring now to the drawings,  FIGS. 1 and 2  illustrates a perspective view and a side view, respectively, of a wet mateable connector assembly  10  configured in accordance with the present invention. The wet mateable connector assembly  10  includes a bulkhead mount  12  and a wet mateable connector  14 . In this illustrated embodiment, the bulkhead mount  12  includes a circular base  16  having mounting holes  17 . The rear of the circular base  16  includes a wire tube enclosure  18  for enclosing power wire  20  and Ethernet connection wire  23 . The wire tube enclosure  18  is preferably rubber molded over wires  20 , 23 . An O-ring gasket  19  receptacle is located on the rear of the circular base  16  to form a hermetic seal when the circular base  16  is mounted to an appropriated structure. The front of the circular base  16  includes a circular post  22  to be mated with the wet mateable connector  14 . The bulkhead mount  12  is preferably constructed of metal, such as stainless steel, and the post  22  and the circular base  16  are preferably formed as a unitary member. Screw threads  11  are located on the outer periphery of the post  22  for securing the bulkhead mount  12  to the grip ring  28 . 
         [0026]    The wet mateable connector  14  is comprised of a flexible optical fiber strain relief boot  24 , a plug shell  26 , a grip ring assembly or grip ring  28 , and a non-slip grip  30  covering the grip ring  28 . The plug shell  26  and the grip ring  28  are preferably constructed of stainless steel. The flexible fiber strain relief boot  24  and the non-slip grip  30  covering the grip ring  28  are preferably constructed of rubber or urethane. 
         [0027]      FIGS. 1 and 2  illustrate the wet mateable connector assembly  10  before being fully connected or completely screwed onto the bulkhead mount  12 . These views expose the post  22  having bulkhead male insert key  32  having mating threads  11  to form a screw locking mechanism. Also illustrated is a female plug receptacle key  36  for receiving and mating with the bulkhead male insert key  32 . 
         [0028]      FIG. 3  is an electrical end perspective view of the wet mateable connector  14  shown in  FIGS. 1 and 2 . A clear view is provided of the male connector plug  38  having multiple pins  39 . Also illustrated are the flexible optical fiber strain relief boot  24 , the plug shell  26 , the grip ring  28 , and the non-slip grip  30 . Also illustrated is the female plug receptacle key  36  for receiving and mating with the bulkhead male insert key  32 . 
         [0029]      FIG. 4  is an exploded view of the wet mateable connector assembly  10  shown in  FIGS. 1 and 2 . The bulkhead mount  12  is shown including the circular base  16  having holes  17 , wire tube  12 , and post  22 . The post  22  includes a male insert key  32  having mating threads  11  to form a keyed screw locking mechanism. Also illustrated is a female plug receptacle  40  having a female plug receptacle key  36  for receiving and mating with the bulkhead male insert key  32 . The female plug receptacle key  36  includes coupling thread  42  and an O-ring receptacle or circular ridge  44 . 
         [0030]      FIG. 4  also illustrates a gigabit transceiver  50  mounted to a printed circuit board (PCB)  52 . The PCB  52  is mounted to an Ethernet plug  54  having the connector pins  39  of the male connector plug  38 . The Ethernet plug  54  is connected to an optical fiber crimp assembly  56  by crimp rods  57 , 58 . LC optical connectors  60  are shown connected to the gigabit transceiver  50 . An O-ring  61  functions to provide a hermetic seal between the Ethernet plug  54  and the female plug receptacle  40 . 
         [0031]    The optical fiber crimp assembly  56  includes a two piece crimp support and adjustment  62 , 63 . An O-ring  64  functions as a hermetic seal for optical fibers passing though the optical fiber crimp assembly  56 . Bolt nuts  66  are screwed onto the crimp rods  57 , 58  to secure and properly adjust the distance between the gigabit transceiver  50  and the optical fiber crimp assembly  56 . A six millimeter optical fiber pass through and seal  70  is located within and between the flexible optical fiber strain relief boot  24  and the plug shell  26 . The O-ring  64  is located adjacent to the optical fiber pass through and seal  70  within the plug shell  26 . The O-ring  76  provides centering for the grip ring  28  and the plug shell  26 . 
         [0032]    The plug shell  26  includes screw threads  71  on the rear for screwing into a threaded end  72  of female plug receptacle  40 . A circular indentation  79  within the plug shell  26  is sized for receiving an O-ring, and diametrically opposed flats  74  function to enable the tightening of plug shell  26  with a spanner. 
         [0033]      FIG. 5  shows a cross-sectional view of the wet mateable connector assembly  10  shown in  FIGS. 1 and 2 . The bulkhead mount  12  includes a circular base  16 , electrical wire tube  18 , O-ring receptacle  19 , and post  22 . Fixing grub screws  80  are located through the post  22 . Mating threads  11  are located on the post  22 , and corresponding mating threads  27  are located inside the grip ring  28 . An O-ring  21  is located between the inside circular base  16  and the female plug receptacle  40 . The electrical wire tube  18  extends from the female plug receptacle  40  and passes through an aperture  31  in the circular base  16 . The female plug receptacle  40  and the electrical wire tube  18  are preferably formed as a unitary member from brass over-molded with rubber. 
         [0034]    The Ethernet plug  54  is located within the plug shell  26 . The Ethernet plug  54  interconnects with female plug receptacle key  36  via mated electrical pins and receptacle contacts. A cross section of one such mated connector pair  41  is shown. The plurality of mated pair connectors  41  connects the SerDes and external power supply to the gigabit transceiver  50 . A pair of grub screws  43  is located on the outside perimeter of the grip ring  28  and functions to limit the range of travel of the grip ring  28  relative to the plug shell  26  to and from the mated condition. O-rings  79 , 83  provide centering and allow the grip ring  28  to move over plug shell  26  toward and away from the electrical connector end of the plug shell  26 . 
         [0035]    In accordance with the present invention, a miniature gigabit transceiver  50  is located on a PCB  52  which is mounted to an Ethernet wet mate electrical plug  54 . LC optical fiber connectors  60  are optically connected to the gigabit transceiver  50 . The gigabit transceiver  50  is located and hermetically sealed within the plug shell  26 . A crimp support rod  58  is connected to crimp clamp  90  and secured in place by the nuts  76  and  91 . The nuts  76 ,  91  can be adjusted to position the gigabit transceiver the desired distance from the optical fiber crimp assembly  56 . 
         [0036]    An O-ring  64  hermetically seals the optical fiber pass though and seal  70  to the plug shell  26 . Flange  75  on the optical fiber pass through and seal  70  properly positions the optical fiber pass through and seal  70  on the optical end of the plug shell  26 . Flange  87  on the optical fiber pass through and seal  70  properly positions and secured the flexible optical fiber strain relief boot  24  to the optical end of the plug shell  26 . 
         [0037]      FIG. 6  illustrates a cross-sectional view of the wet mateable connector  14  shown in  FIG. 3 . Illustrated are the flexible optical fiber strain relief boot  24 , the optical fiber pass through and seal  70 , the plug shell  26 , non-slip grip  30 , the Ethernet plug  54 , and the male connector plug  38  having multiple connector pins  39 . The optical fiber crimp assembly  56  and the two piece crimp support and adjustment  92 , 92  also are illustrated. The nuts  76 ,  91  connected to the crimp support rod  57  properly positions the optical fiber crimp assembly  56  relative to the gigabit transceiver  50 . The gigabit transceiver  50  is shown soldered to a printed circuit board (PCB)  52 . The PCB  52  is attached to the Ethernet plug  54  by nuts  95  ( FIG. 10 ). 
         [0038]      FIG. 7  is an enlarged view of the wet mateable connector  14  shown in  FIG. 6  without the optical fiber relief boot  24 , the optical fiber pass through and seal  70 , grip ring  28 , and non-slip grip  30 . The plug shell  26  and O-ring  64  are illustrated. Also illustrated are the Ethernet plug  54 , female plug receptacle  40  and female plug receptacle key  36 , gigabit transceiver  50 , and LC connector  70 .  FIG. 7  further provides a clearer view of the optical fiber crimp assembly  56  having interlocking elements  96 , 98 . The two-piece stacking elements  96 , 98 , wherein element  96  fits inside element  98  to secure and hold an optical fiber in place and provide strain relief by locking the fiber Kevlar® strength elements without damaging the optical fiber. 
         [0039]      FIG. 8  is an enlarged cross-sectional view of the electrical end of the wet mateable connector  14  shown in  FIG. 6 . Shown is the gigabit transceiver  50  mounted to PCB  52 . The PCB  52  is mounted to the Ethernet wet mate electrical plug  54  by nuts  95  ( FIG. 10 ). The Ethernet wet mate electrical plug  54  is enclosed within the plug shell  26 , the grip ring  28 , and non-slip grip  30 . The male connector plug  38  having multiple connector pins  39  also is shown in an enlarged view. 
         [0040]      FIG. 9  is an enlarged cross-sectional view and  FIG. 10  is an enlarged top cross-sectional view optical end of the wet mateable connector  14  shown in  FIG. 6 . Illustrated are the flexible optical fiber strain relief boot  24 , the optical fiber pass through and seal  70 , the plug shell  26 , grip ring  28 , and non-slip grip  30 . Also illustrated are the gigabit transceiver  50  mounted to the PCB  52 . An enlarged view of the optical fiber crimp assembly  56 , which include two-piece stacking elements  96 , 98  wherein element  96  fits inside element  98  to secure and hold an optical fiber in place and provide strain relief by locking the fiber Kevlar® strength elements without damaging the optical fiber. 
         [0041]      FIGS. 11   a - 11   e  show multiple enlarged views of the Ethernet wet mate electrical plug  54 .  FIG. 11   a  is a perspective view of the Ethernet wet mate electrical plug  54  with a mounting trough  102  for the PCB  52 . Mounting holes  104  are included in the trough  102  to secure the PCB  52  to the Ethernet wet mate electrical plug  54 . Male connector pins  39  are shown extending from the rear of the Ethernet wet mate electrical plug  54 . Wires from the male pins exit the Ethernet plug  54  to connect power and SerDes data to the PCB  52  by soldering the wires to the PCB  52 . 
         [0042]      FIG. 11   b  is a side view of the Ethernet plug  54  shown in  FIG. 11   a , which also illustrates the male connector pins  39 , mounting trough  102 , and mounting holes  104 . A flange  106  extends around the periphery of the Ethernet wet mate electrical plug  54  which provides a sealing surface when used in the complete assembly. 
         [0043]      FIG. 11   c  is a top view of the Ethernet wet mate electrical plug  54  showing the male connector pins  39 , flange  106 , mounting trough  102 , and mounting holes  104 .  FIG. 11   d  is a bottom view of the Ethernet wet mate electrical plug  54 . 
         [0044]      FIG. 11   e  is an end view of the Ethernet plug  54  showing the mounting trough  102  and flange  106 . Also shown are mounting holes  108  used to secure the crimp support rods or adjustment rods  57 , 58  shown in  FIG. 4 .