Abstract:
The present invention is directed to a connector housing for high voltage wires, either single ended or double ended with an integrated connector. Other features of the present invention include integration of a deep recessed high voltage connector contact for an arc and leakage resistant high voltage connection point, use of a female socket pin embedded at the base of the connector. The socket pin is co-molded into the connection end of the body, or it is co-molded or press fitted into a hole at the end of the connector housing.

Description:
[0001]    This US Non-provisional patent application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/922,168 filed on Apr. 6, 2007. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention generally relates to the field of high voltage connectors for the purpose of connecting high voltage electricity from a power supply source device to a load. More specifically, this patent deals with cost effective high voltage connectors for this purpose, and relates to a convenient and expedient means to join or repair high voltage wires post installation in a cost effective manner. 
       BACKGROUND OF THE INVENTION 
       [0003]    An accepted definition of the term “high voltage” is any voltage over 42 volts (V). This level has been established by worldwide safety agencies as the level at above which normal dry human skin contact may result in injury. Typical “high voltage” power supplies in the electronics realm operate in the thousands of volts area; especially in the electrostatics industries, where voltages may be in the tens of thousands, but the current is very low, in micro-amps or milli-amps. 
         [0004]    Connecting high voltage electricity from a power supply source device to a load has long been problematic, as voltages above about 300V may cause air surrounding the conductor to break down, or ionize, into damage-causing corona and arcing. 
         [0005]    Many styles of high voltage connectors for this purpose have been developed. They typically consist of a long “male” connector part and a deeply recessed female counterpart. They may include O rings or other devices to effectively seal the air around the contact point. By their nature, these connectors consist of many individual parts, requiring many manufacturing steps. They are as such relatively expensive, pricing them out of range of the typical low cost high voltage electrostatic or other high voltage product application. 
         [0006]    Currently, high voltage connections require long tracking distances with insulating material to prevent corona and electron leakage from the point of connection. This is most often done by deeply recessing a contact point at the base of a long tunnel of insulating material to form the “female” contact, with the male contact being a long conductor point insulated by an appropriate material, except at the point of connection at the bottom of the tunnel. These connectors tend to be expensive and space consuming. Therefore, it would be highly desirable to have a connection tunnel that is integrated into the power source or encapsulated within over-molding material. 
       SUMMARY OF THE INVENTION 
       [0007]    It is the primary object of the present invention to provide a high voltage connector arrangement having improved performance and reduced cost for connecting high voltage wires in a simple and cost effective manner. 
         [0008]    Another object of this invention is to create a method that will simplify the manufacturing of said high voltage connector units, with appropriate process and material, resulting in a low cost high voltage wire connector unit. 
         [0009]    Another object of this invention is to create a resultant high voltage wire connector unit in which the wire connection is fully protected from the environment, and also, by the use of the proper techniques, the high voltage wires inside are fully encapsulated and insulated from each other, preventing internal arcing that would damage the parts. 
         [0010]    The present low cost gas and liquid tight high voltage electrical connector invention is novel in that it has no dedicated male portion of the connector. Therefore it is desirable to integrate the high voltage wire itself as it becomes the male portion of the connector, saving significant parts cost. The wire may or may not have an added “pin” on the end of the wire to contact the female portion of the connector. 
         [0011]    In this respect, before explaining at least one embodiment of the invention in detail it is to be understood that the invention is not limited in its application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. 
         [0012]    In a preferred high voltage wire splice embodiment, the system provides an inexpensive and expedient means to join or repair high voltage wires post installation. Generic watertight cord grips are used on the outside of the connector body as an environmental seal around a variety of high voltage wire diameters. 
         [0013]    A first alternate embodiment of the novel low cost gas and liquid tight high voltage electrical connectors includes a connector designed for non-encapsulated operation. 
         [0014]    A second alternate embodiment of the novel low cost gas and liquid tight high voltage electrical connectors has the wire pre-attached to the female socket pin and co-molded into the connector body, so the connector may be considered a “stand alone” and unpotted device. 
         [0015]    A third alternate embodiment of the novel low cost gas and liquid tight high voltage electrical connectors utilizes silicone dielectric grease that may be applied at the contact area and the seal area to enhance corona free operation at very high voltages. This use of dielectric grease at the contact point is highly advantageous with extremely high voltages. 
         [0016]    It must be clearly understood at this time although the preferred embodiment of the invention consists of the over-molded female socket pin with poke-home style connector, that many other configurations exist, including any number of high voltage connectors, requiring a safe and efficient high voltage delivery to numerous configurations of contacts, or other combinations thereof, that will achieve the a similar operation, and they will also be fully covered within the scope of this patent. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of this invention. 
           [0018]      FIG. 1  depicts a side elevational view of a double ended high voltage connector device, constructed in accordance with the present invention; 
           [0019]      FIG. 2  depicts a cross-sectional view of the high voltage connector illustrating the component parts, constructed in accordance with the present invention; 
           [0020]      FIG. 3  is a side elevational view of a panel mount high voltage connector device with a section of the female socket pin exposed so a wire may be attached to the female socket pin prior to potting the connector with the power supply unit or other device, constructed in accordance with the present invention; 
           [0021]      FIG. 4  illustrates a cross sectional elevational view of a panel mount high voltage connector device with a section of the female socket pin exposed so a wire may be attached to the female socket pin prior to potting the connector with the power supply unit or other device, constructed in accordance with the present invention; 
           [0022]      FIG. 5  depicts an exploded perspective view of the panel mount high voltage connector device, illustrating the connector body as it would be connected to the watertight cord grip, constructed in accordance with the present invention; 
           [0023]      FIG. 6  shows a side elevational view of a high voltage connector device illustrating the connector body, single ended and over-molded, an insulated wire, compression nut, and gland body, constructed in accordance with the present invention; 
           [0024]      FIG. 7  depicts a cross sectional view of the connector body, single ended, illustrating the insulated wire, a female socket pin which is over-molded and is introduced into the single ended connector body, constructed in accordance with the present invention; 
           [0025]      FIG. 8  is a perspective view of a single ended over-molded high voltage connector device body, with insulated wire, an embodiment of the single ended over-molded connector body with an integrated compression nut connector, constructed in accordance with the present invention; and 
           [0026]      FIG. 9  is a cross sectional view of a high voltage connector splice device housing, double ended, with compression nuts, and illustrating the application location of dielectric grease with in said housing, constructed in accordance with the present invention. 
       
    
    
       [0027]    For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawings which are incorporated in and form a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of this invention. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0028]    Referring now to  FIG. 1 ,  FIG. 1  depicts a side elevational view of a double ended high voltage splice connector device  10 A. The connector housing  12  is attached to a gland  18  and  22 , at each end. A compression nut  14  and  16  is mounted at the distal portions of the connector housing  12  by the glands  18  and  22 . This unit is designed for non-encapsulated operation. Also, this double-ended high voltage splice connector device  10 A is optimally suited for repair applications. 
         [0029]      FIG. 2  depicts a cross-sectional view of the high voltage connector  10 A illustrating the compression nuts  14  and  16  and the double ended connector housing  12  with gland bodies  18  and  22 , in greater detail, constructed in accordance with the present invention. The threaded portions of the connector housing  12  accept the threaded portions of each of the glands  18  and  22 . 
         [0030]      FIG. 3  is a side elevational view of a panel mount high voltage connector device  10 B that has the female socket pin  30  encapsulated or press fit into the single ended connector body  32 . The female connector pin  30  may be exposed externally to allow connection to a high voltage power source. This connection may be made by means of crimping or soldering, or any other likewise means for connecting. The connector may be considered a “built in” or internally incorporated as  10 B may be fully encapsulated. As shown,  10 B is fully encapsulated within a power source and the external portion of the watertight cord grip  36  passes through a panel  38 . Therefore, device  10 B is designed for full encapsulation and in operation is utilized by panel mounting (or chassis box mounting) through a panel  38 . 
         [0031]      FIG. 4  shows a cross sectional view of a high voltage connector  10 B with a section of the female socket pin  30  exposed so a wire may be attached to the female socket pin  30  prior to potting the connector within the power supply unit or other device. It indicates the receptacle for the back section of the female socket pin  30 , single ended exposed, so a wire may be attached to the female socket pin  30  prior to potting the connector within the power supply unit or other device. A single ended connector body  32  with watertight cord grip  36 , and a portion of panel  38  is depicted. An insulated wire  40  with a stripped end  42  shows the manner in which a male portion of wire is introduced into the female socket end of said high voltage connector  10 B. Additionally, this connector  10 B may be used with dielectric grease added to the housing prior to insertion of the high voltage wire. The dielectric grease acts to exclude oxygen, and thereby, prevents corona and arcing when extremely high voltages are present. 
         [0032]      FIG. 5  depicts a perspective exploded view of the high voltage connector  10 B, illustrating the connector body  32  as it would be connected to the watertight cord grip  36  as it is passed through the panel  38 . The length of the connector body and the thickness of the wall may be adjusted to suit the voltage levels being utilized with the connector. Typical industry accepted figures are 10,000 volts per inch of interior length, and 200V per mil of wall thickness. A connector designed for 25,000V operation might be about three inches in length with a wall thickness of about 0.15 to 0.19 inches. The inner diameter of the connector needs to suit the typical high voltage wire diameter of approximately 0.2 inches, so it may have a dimension of about 0.25 inches inner diameter. The single ended high voltage connector  10 B may be used to safely and efficiently provide for a passage through a portion of panel  38  or other obstacle. The single ended connector body  32  on the interior side of the panel  38  will accommodate the watertight cord grip  36  on the external side of the panel  38 . 
         [0033]      FIG. 6  shows a side elevational view of a high voltage connector device  10 C, illustrating the connector body, single ended and over-molded, an insulated wire, compression nut, and gland body, constructed in accordance with the present invention.  FIG. 6  shows a connector body  50 , single ended with an over-molded female socket pin  56 , and an insulated wire  54 , compression nut  52 , gland body  55 . In operation, this single-ended high voltage connector  10 C may be a “stand alone” or a potted connector and may or may not employ dielectric grease internally to exclude oxygen from the connection point. 
         [0034]      FIG. 7  depicts a cross sectional view through the high voltage connector device  10 C shown in  FIG. 6 , illustrating single ended connector body  50 . The insulated wire  54  has a female socket pin  56  which is over-molded and is introduced into the single ended connector body  50 . The insulated wire  64  has a stripped end  66  and is inserted into the single ended connector body  50  by a compression nut  55  and gland body  55 . Prior to insertion, dielectric grease may be applied internally within connector body  50  at socket  56 . The dielectric grease excludes oxygen from the connection point and thereby prevents plasma, corona and arcing, which may act to damage the connection. 
         [0035]      FIG. 8  is a perspective view of a single ended over-molded connector body  50 , with insulated wire  54 . This is an embodiment of the single ended over-molded connector body  10 C with an integrated compression nut  52  connector, having the pin  56  and the wire  54  over-molded. 
         [0036]      FIG. 9  illustrates a high voltage splice connector device  10 D which comprises a double ended connector housing  70  with two compression nuts  72  and  74  and two gland bodies  76  and  78 . Gland bodies  76  and  78  and insulated wires  80  and  90  with stripped ends  82  and  92  are included in this cross-sectional view of the double ended connector housing  10 D. This illustration shows the wire splice connector  94  and the dielectric grease  96 , in greater detail, constructed in accordance with the present invention. In extremely high voltage connection applications, it is highly advantageous to use the dielectric grease to prevent arcing and damage to the connector during operation. The wire splice connector  94  may be a crimped butt splice or may be soldered, or any other likewise means of making a wire connection between two or more wires. 
         [0037]    The connector bodies pictured in  FIG. 3 ,  FIG. 4 ,  FIG. 5 ,  FIG. 6 ,  FIG. 7 , and  FIG. 8  all represent a high voltage connector device which has a connector body that is single ended and may be over-molded.  FIG. 1 ,  FIG. 2 , and  FIG. 9  are designed for unencapsulated wire joining operation or field repair applications. Embodiments  10 A and  10 D illustrate the double ended connector housing. Embodiment  10 B shows a single ended connector body with an externally exposed the female socket pin for fully encapsulated operation. Embodiment  10 C shows a single ended connector body with a wire pre-attached to the female socket pin and co-molded into the connector body, so the connector may be considered a “stand alone” and unpotted device.  FIG. 3 ,  FIG. 4  and  FIG. 5  shows the back section of the female socket pin exposed so a wire may be attached to the female socket pin prior to potting the connector with the power supply unit or other device. 
         [0038]    The length of the connector body and the thickness of the wall may be adjusted to suit the voltage levels being utilized with the connector. Typical industry accepted figures are 10,000 volts per inch of interior length, and 200V per mil of wall thickness. A connector designed for 25,000V operation might be three inches in length with a wall thickness of about 0.15 to about 0.19 inches. The inner diameter of the connector needs to suit the typical high voltage wire diameter of approximately 0.2 inches, so it may have a dimension of about 0.25 inches inner diameter. 
         [0039]    The female socket pin imbedded at the base of the connector is typically a Mill-Max 0370 style or equivalent part. The socket pin in embodiment  10 C is co-molded into the connection end of the body in the case of the single ended bodies, or it is press fit or co-molded into a hole at the end of the body such as in embodiment  10 B. 
         [0040]    The exterior liquid tight bushing utilized at the opening of the connector body is typically a Heyco Liquid Tight Strain Relief Gland, style M3444 or equivalent part. The open end of the connector body is fashioned with an interior thread to match and mate with the bushing&#39;s threads. The connector may be mounted into a chassis or box by means of placing the barrel part of the connector on the inside of the box or panel, and inserting and threading the bushing part of the connector through the chassis wall onto the barrel, thus mounting the connector to the panel as illustrated in  FIG. 3 ,  FIG. 4  and  FIG. 5 . Likewise the co-molded connector  10 C as shown in  FIG. 6 ,  FIG. 7  and  FIG. 8  may be panel mounted as well. 
         [0041]    High voltage wire for tens of thousands of volts operation is typically 0.15 to 0.22 inches, outside diameter, and is relatively stiff. This stiffness allows the wire to be pushed into the connector from the outside with relative ease. The wire insulation is first stripped back from the end about 0.2 inches, and a small contact pin of approximately 0.04 inches diameter is attached by crimping or soldering it to the stripped end. Or, if the wire&#39;s conductor is approximately the same diameter as the pin, the stripped portion of the wire itself can be tinned with solder to form a stiff “pin” without using an added contact pin. 
         [0042]    Optionally, to improve corona resistance of the connection point, a small amount of silicone dielectric grease (such as Loctite Dielectric Grease 30536 or equivalent, approximately 0.1 to 0.2 oz.) may be squirted deep into the connector well. The wire is then inserted through the loosened outer wire gland, and fully inserted into the barrel so the pin engages the socket deep into the connector. The wire gland is then tightened, producing a gas and liquid tight connection. 
         [0043]    This device is utilized for splicing two high voltage wires together.  FIG. 1 ,  FIG. 2  and  FIG. 9  depict a dual ended type connector, consisting of an insulating barrel with a wire gland at each end. The length and wall thickness of the device are selected depending on the voltage to be conducted as before. 
         [0044]    One of two the wires is first inserted into a wire gland and the barrel. The other wire gland is slipped over the other wire for later threading into the barrel. The mating ends of each wire are then stripped back approximately 0.25 inch, and are connected together with a crimp butt splice type of crimp connector (3M BSV18 or similar), or other equivalent means (they could be twisted and soldered for instance). Optionally, the splice and the ends of the wires near the splice may be coated liberally and completely with silicone dielectric grease to prevent air contact. The wire in the barrel portion is pulled back so that the splice is centered into the barrel. Then the other wire gland is slid into place and threaded on the barrel, and then both wire glands are tightened. This produces a gas and moisture tight high voltage wire splice. 
         [0045]    With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. Therefore, the foregoing is considered as illustrative only of the principles of the invention. 
         [0046]    Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.