Electrical connector with locking clip

An electrical connector assembly includes first male and second female connectors having respectively a generally annular locking spring with inwardly directed flexible tines and an outer cylindrical coupling member. The tines are deflected outwardly by the outer coupling member when the second connector is inserted into the first connector for coupling the connectors. A locking clip having a pair of identical, semi-cylindrical mating sections adapted for mutual engagement and manual assembly about the coupled first and second connectors locks the two connectors together to prevent inadvertent disconnection. An uncoupling tool adapted for insertion in respective opposed slots in the two connected mating sections of the lock clip engages and axially displaces a release sleeve in one of the connectors, which, in turn, engages and outwardly deflects the locking clip's tines permitting the non-destructive separation of the two connectors.

FIELD OF THE INVENTION

The invention relates to an electrical connector assembly comprising male and female mating connectors. A first connector (male or female) includes a generally annular locking spring having centrally projecting flexible tines which are inclined slightly in the direction of insertion of the mating connector. The tines define an opening for receiving and coupling to the outer surface of a cylindrical coupling member of a second, mating connector. As the mating connector is assembled to the first connector, the cylindrical coupling member of the mating connector engages and deflects the tines of the locking spring in the direction of insertion, thereby enlarging the receiving opening formed by the tines and admitting the mating connector while locking onto its outer surface, thereafter preventing separation.

The first connector has an axially slidable actuator sleeve having a circumferential rib and an annular engagement portion sized and arranged to slide along the cylindrical member of the second connector when the connectors are engaged. This motion displaces and pivots the tines of the annular locking spring, to increase the size of the receiving opening defined by the inner edges of the tines of the locking spring, thereby releasing the mating connector for removal.

A locking clip in the general form of a band comprised of identical mating sections each in the general form of a semi-cylinder may be assembled by hand over the first connector (in which the locking spring is mounted). The locking clip cannot be removed without destroying it. The locking clip, when assembled to the exterior of the first connector, covers the release sleeve and prevents manual manipulation of it, thereby preventing inadvertent manual disconnection of the two mating connectors by requiring application of an uncoupling tool to effect release.

The uncoupling tool has spaced-apart legs tapered to their respective insertion or distal ends which may be inserted respectively into narrow, aligned, opposing slots, one in each half of the locking clip. When urged along a plane perpendicular to the axis of connection, the legs of the uncoupling tool engage the circumferential rib on the release sleeve and force the release sleeve in an axial direction to deflect the tines of the locking clip and move them to form a larger circumference, releasing the coupling member of the mating connector into a release position, thereby freeing the connectors for separation.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

The present invention relates to a connector assembly—that is, it relates to a male and female mating electrical connectors. The improvement disclosed herein relates to the incorporation of a locking clip which may be applied to one of the two mating connectors in order to prevent them from being disconnected once they have been connected except by the use of an uncoupling tool.

The locking structure and associated locking clip may be incorporated into either the male or female connector. In the illustrated embodiment, the locking clip and associated locking spring are incorporated into the female connector. However, they could equally well be applied to or incorporated in the male connector. Therefore, reference is made herein to a “first” connector (which contains the locking spring and the locking clip, as will be understood from the following description) which may be either female or male, and a “mating” connector which is the other.

In particular, the present invention relates to a type of quick-disconnect connector including mating male and female connectors of a “plug” type. That is, the connectors are connected together by forcing the connecting elements (typically pins) of the male connector into associated connector elements (sockets) in the female connector.

The type of connector assembly with which the present invention is concerned typically is used in an industrial environment, such as in the manufacturing automation industries. In this type of environment, the conditions of use are typically harsh and quick disconnectors are used throughout a typical facility. It is not unusual for these quick disconnect connectors to be disassembled. This may have the effect of shutting down a machine or an assembly line, or interrupting a computer-based controller system.

Therefore, a connector was developed, which is disclosed in PCT Application WO2004DE00793 20040414, published Dec. 16, 2004, which is incorporated herein in its entirety. In this connector, a retaining spring in the form of an annular ring having flexible tines extending inwardly is incorporated into one of the connectors. The tines are located so as to receive a cylindrical coupling member of the associated mating connector. When the cylindrical coupling member of the associated mating connector is forced into the first connector (having the annular locking element), the tines of the locking element are moved rearwardly (that is, in the direction of insertion of the mating connector). This action displaces the tines rearwardly and forces them such that the innermost free edges of the individual tines define an opening of larger circumference than when they were at rest (i.e. before the mating connector is inserted). Typically, the coupling member of the mating connector has an annular recess positioned such that when the mating connector is fully connected to the first connector the innermost edges of the tines of the retaining ring move into the annular ring thereby locking the mating connector into assembled relation with the first connector. As used herein, the “axial” direction or direction of connection (or disconnect) is along the chain line C/L inFIG. 6.

A sliding actuator sleeve is provided in the first connector which may be manually actuated by moving it rearwardly (that is, away from the mating connector). The sliding actuator sleeve is provided with an actuating portion which forces all of the tines of the retention ring into an expanded diameter so that the inner most edges of the tines are moved out of the annular recess on the coupling member of the mating connector, and the mating connector is free to be removed simply by pulling it in an opposing axial direction.

This type of connector has become popular and lends itself to applications involving hazardous locations, such as oil refineries and chemical plants which require special precautions against inadvertent disconnection which might generate a spark.

Referring first toFIG. 1, reference numeral10generally designates a first electrical connector, and reference numeral11generally designates a mating electrical connector. In the illustrated embodiment, the first connector10is a female connector and the mating connector11is a male connector.

In the illustrated embodiment, a locking clip12, to be discussed in further detail within, is assembled to the first connector10. However, as persons skilled in the art will readily appreciate, a similar locking clip12could equally well be placed on a male connector if the release mechanism to be described were instead incorporated into the mating connector11.

Turning now toFIG. 2as well asFIG. 1, and referring particularly to the elements of the first connector10, the connector10is coupled to the wires of a cable15which typically might include 2-12 insulated wires, the stripped ends of which are connected to the connector elements (which would be sockets in the illustrated embodiment since the connector10is a female connector). The connector elements, whether male or female, are typically embedded and supported by an insulating member called an insert, designated16inFIG. 2. The rear (left) end of the insert10and the associated connecting wires are covered by an overmold structure18which may be a synthetic material such as rubber to provide strain relief for the connection between the cable wires and their associated connector elements mounted in the insert16. The remaining portion of the connecting wires (not shown inFIG. 2) are enclosed within the cable15, as is commonly known.

The male connector or receptacle11is conventional, having its own insert for securing the corresponding connector elements which are typically pins in a male connector of this type. Although not seen inFIG. 1, the connecting elements of the male connector terminate in sockets such as that designated26inFIG. 6which in turn are connected to wires in another cable or directly to a printed circuit board as a fixed component in a system, in the case where the male connector is, for example, mounted to a panel. In the illustrated embodiment, the male or mating connector11is a panel-mounted version.

Turning now toFIG. 3, it can be seen that the first connector10is integrally connected to the overmold18and cable15. As seen inFIG. 1, the mating connector11includes a cylindrical coupling member22which surrounds and protects the male connecting elements. An annular groove75is formed on the outer wall of the cylindrical coupling member22.

Turning now toFIG. 6, there is shown an enlarged cross section of the first connector10. It includes an insert25in which are embedded the female connecting elements26, in the form of sockets. The sockets26, of course, are electrically connected to the wires of the cable15. Still referring toFIG. 6, the insert25includes a receiving sleeve29which is spaced outwardly from the cylindrical side surface25A of the insert forming an annular space generally designated31into which the cylindrical coupling member22of the mating connector11is placed during connection. An O ring23engages the outer surface of the cylindrical coupling member22when the two connectors are assembled to form a seal.

Mounted on the receiving sleeve29is a spring retainer33. The spring retainer33is annular in shape and fixed to the receiving sleeve29by two barbs34formed on the inner surface of the spring retainer. The spring retainer33cooperates with an annular cut-out portion of the receiving sleeve29to form an annular recess39for receiving the O ring23.

Referring toFIGS. 6 and 7, mounted to the forward portion (i.e. in the direction of connection, to the right inFIGS. 6 and 7) of the spring retainer33is a retaining or locking spring36. The spring36includes an outer circumferential ring38in the form of a circular, generally flat washer which is integrally formed with a plurality of tines, designated40, which extend inwardly toward the center of the ring38and are inclined slightly toward the rear—i.e. the direction of insertion of the mating connector. The tines40are spaced about the entire ring38with equal angular space between adjacent tines.

The inner or center most edges of all of the tines40define a circular opening for receiving the outer surface of the cylindrical coupling member22of the mating connector. When the coupling member22is placed on the insert25of the first connector and slid axially into connecting relation (that is to the left inFIG. 6), each of the tines40is forced inwardly (to the left inFIG. 6). Because the ring38is fixed, the opening formed by the tines which originally is only slightly less than the outer circumference of the cylindrical coupling member22of the mating connector) is enlarged so that during insertion, the tines slide along the outer surface of the coupling member until the mating connector is fully seated. At that time, the tines are located in the circumferential groove75(FIG. 1) of the cylindrical coupling member22of the mating connector11, and the two are locked together since any attempt to pull the first connector10away from the mating connector11would cause the tines to jam against the cylindrical coupling member22and prevent its withdrawal.

Thus, the two connectors cannot be disconnected through any accidental action or through vibration or the like or anything else that might happen in typical use.

In order to release the mating connector, a sliding actuator sleeve44is located adjacent the spring retainer33. The sliding actuator sleeve includes an actuator section44A in the form of an annular surface which is curved in the lateral direction of motion as seen inFIG. 6, and which engages the tines40adjacent the base or mounting ring38. It will be observed that when the sliding actuator sleeve44is moved to the left inFIG. 6, the curved actuator section44A displaces the tines40of the spring retainer33toward the insertion direction (that is to the left inFIG. 6) thereby forcing the tines40to assume a position such that their innermost edges form an opening of increased circumference. This disengages the innermost ends of the tines40from the annular groove75of the mating connector, thereby freeing the mating connector which may then be manually removed and disconnected from cylindrical coupling member22the first connector10.

However, as noted above, for safety or other reasons, it may be desirable to restrict the manual release of the two connectors to only those authorized to do so.

Turning now to the locking clip12, it is intended to be permanently secured to a connector body with removal prevented. The illustrated locking clip12may be applied manually, without the need for special tools, as will be further described, simply by assembling two mating parts together about the exterior of a connector. As indicated, the locking clip is intended for use in those areas, such as an area containing hazardous material, in which it is desired to prevent inadvertent, accidental or unauthorized disconnection of an electrical connector assembly.

Turning now toFIG. 3, the locking clip12includes first and second half sections48,49. The half sections48,49may be identical in structure so that only one need be described in detail for a complete understanding of the invention. Because the two half sections48,49are shown identical in structure, the same element numbers are used in both half sections to identify common elements, with those elements in half section48having the letter designation “A” added to the element number. Turning then to the half section48ofFIG. 4B, it includes a semi-cylindrical wall51A, terminating in two axially extending edges53A,54A. Formed on the edge54A of the wall51A is a barbed tongue55A which extends along the axial length of the edge54A. A receptacle57A is formed in the edge53A of the side wall51A, and has an interior shape corresponding to the exterior shape of the barbed tongue55on a mating half section49.

Thus, if a correspondingly shaped half of a clip is rotated about its axis 180 degrees from the position of the clip shown inFIG. 4B, the tongue55which extends along the axial length of the edge54of locking half clip49would be positioned to be received in the receptacle57A of the edge53A of locking half clip48, and it would have a receptacle57corresponding to receptacle57A adapted to couple to the tongue55A of the mating clip half48, as seen inFIG. 3. When the two clip halves are thus assembled together, they form a protective cylindrical cover which, when assembled as shown inFIG. 4Asurrounding a connector as disclosed above, cannot be disassembled without destroying the clip. Again, the clip halves48,49may be identical in structure.

Clip half49(FIG. 3) includes at one axial end, a retainer flange60which is semi-circular in form, and has an axial thickness (seeFIG. 6) which permits it to be inserted into the annular space50formed by the forward edge66of the overmold18and the rear radial surface32of the receiving sleeve29(FIG. 6). In this manner, when the two clip halves are coupled together, the two corresponding flanges60,60A, one of each clip half, form a complete, encircling retainer flange, securing the locking clip12, in its entirety to the first connector10.

Turning now toFIG. 3, when the two clip halves48,49are assembled to the first connector10, the coupling is effected by placing the two clip halves so that the barbed tongue55or55A of one clip aligns with the receptacle57or57A of the other clip, and the semi-circular retainer flanges60,60A of the two clip halves are placed in the annular recess50(FIG. 6) which is located between the forward edge66of the overmold18, and the rear radial surface32of the receiving sleeve29.

Turning now toFIG. 3andFIGS. 4A and 4B, each clip half49,48includes a respective inner circumferential groove70,70A, which extends from one end of a side wall51,51A to the other end. At the center of each groove70,70A is a respective access opening72,72A which extends entirely through the associated wall. The circumferential access openings72,72A are aligned with each other when the clip halves are assembled, and each extends circumferentially about the locking clip, and they are both aligned circumferentially with the circumferential rib46formed on the exterior of the sliding actuator sleeve44(FIGS. 3 and 6). This relationship is seen inFIG. 6where it will be observed that the two clips48,49are in assembled relation, and the circumferential opening72of the clip half48provides radial access to the adjacent portion46A of the circumferential rib46of the sliding actuator sleeve44.

It will also be observed fromFIG. 6that a forward edge designated80inFIG. 1of the radial access opening72A, lies in spaced, opposing relation to a forwardly facing surface46A of the circumferential rib46of the sliding actuator sleeve44. It is in this space that the leg of an uncoupling tool (to be described) is placed to uncouple the connectors.

Briefly, when the uncoupling tool88is inserted, one leg (90or91) is interposed between the surface80and the surface46A, and further insertion of the tool downwardly as viewed inFIG. 6, wedges the two components (i.e. actuator sleeve44and locking clip12) apart, forcing the peripheral rim46to the left inFIG. 6, thereby forcing the sliding actuator sleeve44to the left inFIG. 6, and rotating the individual tines40of the retainer spring36to the left or release position inFIG. 6, and increasing the circumference of the opening defined by the interior edges of the tines, and disengaging the slot of a coupling member that may be in the annular coupling space31, thus freeing the mating connector to be released.

This is illustrated inFIG. 5B, the uncoupling, or release, tool being shown inFIG. 5Aand generally designated88. It includes a cross member89and first and second insertion legs90,91.

As seen in cross section inFIG. 5B, the legs of the uncoupling tool88are tapered, being narrower at the distal end and wider when proceeding toward the cross member89. InFIG. 5B(andFIG. 1), the male and female connectors are assembled, and the peripheral rim46of the actuating sleeve44can be seen through the opening72A in the near half of the locking clip12.

In summary, the locking clip, comprised of the two halves described, is a solitary structural member, and it is secured against axial movement relative to the connector on which it is received due to the placement of the retainer flange60in the annular recess50. The legs90,91of the uncoupling tool88(when received respectively in the two side openings72,72A of the clip halves) simultaneously engage the forward edge of the peripheral rim46, and, against the reaction of the fixed clip, cams or forces the sliding actuator sleeve44toward the rear (that is, to the left inFIG. 6), thus freeing the mating connector for removal.

FIGS. 8,9and10illustrate the structure described above and the release function.FIG. 8is an upper frontal perspective showing the uncoupling tool88in place for moving the actuator sleeve of the connector to the release position.

FIG. 9is an upper perspective view with the near half safety clip removed, showing the rear surface of the near leg of the uncoupling tool88engaging the forward surface of the circumferential rim46of the actuator sleeve44.

FIG. 10is a view similar toFIG. 9, but with both halves of the safety clip removed to show the actuator sleeve and uncoupling tool.

FIG. 11is an opposing view of the female connector ofFIG. 1with the uncoupling tool88applied to release the locking mechanism by being wedged between the front edge80of the radical access opening72of the clip half49and the forward surface of the peripheral ring46of the sliding actuator sleeve44.

FIG. 12is a longitudinal cross-section of the connector assembly ofFIG. 11taken along a plane perpendicular to the plane of the page and passing through the center line C/L showing the space62where the side legs of the decoupling tool are wedged between the fixed surface80of the locking clip and the front surface46A of the peripheral ring46on the actuator sleeve46.

Having thus disclosed in detail an embodiment of the invention, persons skilled in the art will be able to modify the structure illustrated and substitute equivalent elements for those disclosed; and it is, therefore, intended that all such substitutions and equivalents be covered as they are embraced within the scope of the appended claims.