Abstract:
Integrated electrical connectors ( 14 ) and electrical cable assemblies ( 10 ) constructed therewith are provided. Connectors ( 14 ) permit termination of braided electrical cables ( 12 ) without the use of backshell adapters and without requiring undue stretching of the braided sheath ( 84 ) over a relatively large cable sheath termination nipple ( 46 ) which could lead to undesirable EMI. Connectors ( 14 ) comprise a plurality of hinged petals ( 40 ) that are shiftable between an open position, which permits access to the connector insert ( 18 ) carried by the connector ( 14 ) and a closed position in which the petals ( 40 ) cooperate to define an appropriately-sized cable sheath termination nipple ( 46 ).

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention is directed toward an integrated electrical connector for terminating an electrical cable and electrical cable assemblies constructed therewith. Particularly, the electrical connector is configured so as to be used without a backshell adapter. In order to accomplish this function, the connector includes a plurality of hinged petals having structures that when drawn toward each other define a cable sheath termination nipple. The petals open up to provide access to the connector insert for facilitating termination of wires carried by the cable. The present electrical connector permits use of relatively small diameter cables with integrated electrical connectors thereby eliminating the need for a backshell adapter. 
     2. Description of the Prior Art 
     Electrical connectors of varying configurations are used to terminate an electrical cable so as to permit interfacing between the wires of the cable and another electronic device. Certain electrical connectors comprise plug connectors, which present pins or other similar “male” structure, and other electrical connectors comprise receptacle connectors, which present one or more “female” structures into which corresponding pins can be inserted. Wires carried by an electrical cable are inserted into the connector and coupled with a connector insert that carries the pins or receptacles as the case may be. 
     In order to insert the wires into the connector and then the connector insert, the opening at the cable-receiving end of the connector must be at least as large as the connector insert itself so as to facilitate access to all receptacles of the connector insert. However, in certain applications, the electrical connector has the capability of accommodating more wires than the electrical cable to be coupled therewith carries. This presents a problem, particularly when trying to directly secure a cable having an outer braided sheath to the connector. 
     The braided sheath shields and protects the wiring from the effects of electromagnetic interference (EMI). EMI is a disturbance that affects an electrical circuit due to either electromagnetic induction or electromagnetic radiation emitted from an external source. The disturbance may interrupt, obstruct, or otherwise degrade or limit the performance of the circuit. The braided sheath operates to limit the effects of EMI on the signals being carried by the cable&#39;s wires. 
     If a smaller diameter cable having a braided sheath is to be coupled with an electrical connector having the capability of handling more wires than carried by the cable, the braided sheath would need to be stretched over a sheath termination nipple forming a part of the connector. This stretching operation may open up windows in the braiding which could lead to undesirable EMI. In order to avoid this problem, electrical connector backshell adapters have been used to anchor the electrical cable and sheath. As the backshell adapter does not terminate the wires carried by the cable, access to the interior of the backshell adapter is less of an issue and a smaller diameter sheath termination nipple may be used compared to the sheath termination nipple on an integrated electrical connector. The backshell adapter is then coupled with an appropriately dimensioned electrical connector that does not include any mounting structure for the cable or sheath. 
     The use of separate connectors and backshells for terminating an electrical cable has been a traditional solution to the aforementioned problem. However, drawbacks to this approach are apparent in that two separate pieces of equipment are required which increases the expense and labor involved in terminating the cable. Therefore, there is a need in the art for a single piece, integrated connector that is capable of terminating an electrical cable bearing fewer wires than the connector itself is designed to accommodate, while avoiding over-stretching of the braided sheath that could lead to degradation or interference with the signals carried by the cable&#39;s wires. 
     SUMMARY OF THE INVENTION 
     The present invention overcomes the aforementioned problems by providing, according to one embodiment, an electrical connector comprising a connector housing having a first port and a second port, a connector insert located within the housing, and a plurality of hinged petals secured to the housing. The connector insert is configured to receive one or more wires that are introduced into the connector housing through the first port. The plurality of hinged petals are secured to the connector housing adjacent the first port and are shiftable between a closed position at least partially covering the first port and an open position exposing the first port. Shifting of the petals to the open position provides substantially unobstructed access to the connector insert located within the housing. The petals, when in the closed position, cooperate to define a cable sheath termination nipple providing structure for coupling of the connector with an electrical cable. The cable sheath termination nipple has a central through opening with a diameter that is less than the diameter of the connector insert. 
     According to another embodiment of the present invention, there is provided an electrical connector comprising a connector housing, a connector insert located within the housing, and a plurality of hinged petals. The connector housing comprises a first port and a second port, with the plurality of petals being secured to the housing adjacent the first port. The connector insert is configured to receive one or more wires that have been inserted into the connector through the first port. The plurality of hinged petals are shiftable between a closed position at least partially covering the first port and an open position exposing the first port. Each of the hinged petals comprises a substantially planar section configured to cover at least a portion of the first port when in the petal is in the closed position and a nipple segment extending transversely from the planar section. The nipple segments cooperate to define a cable sheath termination nipple. 
     In still other embodiments according to the present invention, there is provided an electrical cable assembly comprising an electrical cable carrying one or more wires and an electrical connector, such as described herein, secured to an end of the electrical cable. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an electrical connector assembly in accordance with one embodiment of the present invention; 
         FIG. 2  is a perspective view of the electrical connector assembly of  FIG. 1  and an exemplary plug connector to which it may be mated; 
         FIG. 3  is a cross-sectional view of an electrical connector assembly in accordance with one embodiment of the present invention; 
         FIG. 4  is an elevation view of an electrical connector looking toward the connector&#39;s cable sheath termination nipple; 
         FIG. 5  is a perspective view of the electrical connector of  FIG. 4  with the connector petals in the closed, port-blocking configuration; 
         FIG. 6  is a perspective view of the electrical connector of  FIG. 4  with the connector petals shown in the open configuration exposing the connector insert; and 
         FIG. 7  is a perspective view of an electrical connector having a plurality of wires coupled therewith. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Turning now to  FIG. 1 , an electrical cable assembly  10  is shown comprising an electric cable  12  and an electrical connector  14  made in accordance with one embodiment of the present invention. Connector  14  comprises a connector housing  16  and a connector insert  18  disposed therein. In certain embodiments, housing  16  is made from a radiopaque material, such as metal, and insert  18  comprises primarily a non-conductive material such as a synthetic resin material (i.e., plastic) or ceramic. Connector  14  also includes a threaded outer nut  20  that can be used to fasten connector  14  to a companion connector  22  (as shown in  FIG. 2 ). 
     Housing  16  is generally cylindrical in shape, but it is within the scope of the present invention for housing  16  to be substantially any tubular configuration, including square or rectangular. Housing  16  comprises a first port  24  that is configured to receive one or more wires  26  carried by cable  12  and a second port  28  that is configured to mate with, for example, a complemental port  30  of connector  22 . As can be seen in the Figures, connector insert  18  is a receptacle-type, or “female,” insert comprising a plurality of receptacles  32  disposed therein. Note, however, it is within the scope of the present invention for insert  18  to comprise a plug-type or “male” insert as is known in the art and shown, for example, in companion connector  22 . As best seen in  FIG. 3 , receptacles  32  comprise a wire-receiving portion  34  located proximate the first port  24 , and a plug-receiving portion  36  located proximate the second port  28 . In certain embodiments, wire-receiving portion  34  is sized to receive both wire  26  and its insulating covering  38 , whereas plug-receiving portion  36  generally is sized to accommodate only wire  26 . As illustrated, connector insert  18  comprises 100 receptacles. However, it is within the scope of the invention for insert  18  to comprise any number of receptacles  32  in any configuration or pattern. 
     A plurality of hinged petals  40  are secured to housing  16  adjacent to first port  24 . In certain embodiments, connector  14  comprises at least three petals  40 , and more preferably, four petals  40 . Petals  40  are independently shiftable between a closed position as illustrated in  FIG. 5 , and an open position as illustrated in  FIG. 6 . Each of petals  40  comprises a substantially planar section  42  configured to cover at least a portion of first port  24  when in the closed position, and a nipple segment  44  extending transversely from planar section  42 . When shifted to the open position, petals  40  swing outwardly thereby exposing and providing unfettered access to connector insert  18 . 
     Planar section  42  comprises an inboard margin  56  and an outboard margin  58 . Nipple segments  44  extend transversely from inboard margin  56  and in a direction away from first port  24 , when petals  40  are oriented in the closed position. Nipple segments  44  cooperate to define a cable sheath termination nipple  46  when petals  40  are oriented in the closed position. Nipple  46  presents a central through opening  47  that communicates with first port  24 . In certain embodiments, opening  47  has a diameter that is less than the diameter of connector insert  18 . In particular embodiments, opening  47  has a diameter that is less than 75%, less than 65%, or less than 50% of the diameter of connector insert  18 . Each of nipple segments  44  comprises an outboard rib  48  positioned proximal to the outboard end margin of the nipple segment and an inboard rib  50 , with ribs  48 ,  50  defining a channel portion  52  therebetween. When petals  40  are in the closed position, channel portions  52  cooperating to define a continuous band-receiving channel  54  that circumscribes nipple  46 . 
     Each of petals  40  further comprise a sidewall segment  60  extending transversely from outboard margin  58  and in a direction toward first port  24  when the petals or oriented in the closed position. In certain embodiments, connector housing  16  includes an offset shoulder  62  located proximate first port  24  that has a slightly reduced outer diameter as compared with other portions of housing  16 . The amount of offset for shoulder  62  is approximately equal to the thickness of sidewall segment  60  so that when petals  40  are in the closed position, sidewall segment  60  lies substantially flush with an adjacent outer surface  64  of connector housing  16 . 
     As shown in the Figures, petals  40  each comprise a hinge tab  66  located on sidewall segment  60 . Tab  66  is configured to be received in a clevis  68 , which is secured to outer surface  64  of housing  16 . Tab  66  and clevis  68  include aligned apertures configured to receive a wire ring  70 . Alternatively, a clevis pin inserted into each tab and clevis may be used instead of ring  70 . However, it is noted that the illustrated hinge structure is exemplary and that other types and configurations of hinges may be employed. 
     Petals  40 , as depicted in the Figures, are isometric. However, it is within the scope of the present invention for petals  40  to have differing dimensions and configurations. Also, connector  14  is depicted as a “straight” connector in which the cable sheath termination nipple  46  is coaxial with connector housing  16 . It is noted, though, that the connector may be configured as an “angled” connector wherein these features are offset at a relative angle of 45° or 90°, for example. In the case of such angled connectors, petals  40 , and their respective sub-parts, would need to be of different dimensions and configurations. 
     Connector housing  16  also comprises an upstanding ridge  72  that circumscribes outer surface  64 . Outer surface  64  further includes a plurality of raised tabs  74  proximate second port  28 . As illustrated, tabs  74  are of different sizes and shapes, and are spaced non-uniformly relative to each other. Tabs  74  are configured to be received in slots  76  disposed about an inner surface  78  of connector  22 . The placement of tabs  74  and slots  76  assist a user in mating connectors  14  and  22  by providing proper alignment therebetween. Once mated, nut  20  may be rotated so as to engage threads  80  of connector  22 . An inwardly extending collar  82  of nut  20  engages ridge  72  as nut is threaded onto connector  22  so as to draw the two connectors together and ensure that a solid electrical connection is made and maintained. 
     As previously noted, petals  40  are shiftable between closed and open positions. As seen in  FIG. 4 , when petals  40  are in the closed position, only a portion of the connector insert receptacles  32  are visible. The receptacles  32  located toward the outer periphery of connector insert  18  are covered and are not accessible for insertion of a wire  26 . However, as illustrated in  FIG. 7 , shifting of petals  40  to the open position exposes or completely uncovers first port  24  thereby permitting access to all receptacles  32  through port  24 . When petals  40  are in the open position, wires  26  carried by cable  12  may be inserted into respective receptacles  32 , particularly those that would otherwise be inaccessible when petals  40  are in the closed position. Upon installation of wires  26 , petals  40  can be returned to the closed position for securing cable sheath  84  to nipple  46  to complete electrical cable assembly  10 . 
     As illustrated in  FIGS. 1 ,  2 , and  7 , cable  12  comprises  31  individual wires  26 . Note, it is within the scope of the present invention for cable  12  to include more or fewer wires as the particular application requires. However, in certain embodiments, the electrical cable  12  comprises fewer wires than connector insert  18  is capable of accommodating. In particular embodiments, cable  12  comprises a number of wires that is less than 75%, less than 60%, or less than 40% of the number of receptacles  32  of insert  18 . 
     In certain embodiments, sheath  84  comprises a braided material that is capable of shielding the underlying wires from EMI. In particular embodiments, the braided material comprises a metal such as copper, iron, or stainless steel, and may be plated with a second metal such as tin or nickel. In still other embodiments, the braided shielding material may be a composite or thermoplastic material. 
     Given the difference in diameter between insert  18  and nipple  46 , following insertion of wires  26  into respective receptacles  32 , wires located toward the outer periphery of insert  18  may need to be bent or tapered toward the center of first port  24  so that petals  40  may be shifted to the closed position and the wires  26  directed through opening  47  of nipple  46 . At that point, a portion of sheath  84  is slipped over nipple  46  and up to or, more preferably, just past inboard rib  50 . Because nipple  46  may be sized according to the cable dimensions as opposed to having its size based upon that of the connector insert, over-stretching of sheath  84  and the formation of windows therein leading to undesirable EMI is avoided. Optionally, a rubber boot  86 , made from a heat shrink material, can also be fitted over sheath  84  to provide added protection to the connection between cable  12  and connector  14 . Once sheath  84  and boot  86  are in place in covering relationship to nipple  46 , a band  88 , such as a metallic spring band, may be placed there over and on top of channel  54  to securely anchor sheath  84  to connector  14 . In addition, band  88  assists with maintaining petals  40  in the closed position. The necked-down configuration that petals  40  impart also provides additional securement of wires  26  within housing  16 . Planar sections  42  offer resistance to removal of wires  26  from receptacles  32  as such would require deflection of wires  26  toward the center of first port  24 . 
     Accordingly, connector  14  permits creation of electrical cable assemblies  10  using cables  12  having significantly fewer wires than connector insert  18  can accommodate without the use of a backshell adapter. Connector  14 , through the use of hinged petals  40 , provides the necessary access to the connector insert for installation of wires  26  while avoiding problems attendant with having to mount a small diameter cable sheath over a much larger cable sheath termination nipple. Thus, connector  14  permits direct termination of cables that in certain applications would otherwise require the use a backshell adapter. 
     The above described embodiments are exemplary of the principles of the present invention and are provided by way of illustration. Nothing therein should be taken as a limitation upon the overall scope of the invention.