Connecting conductor

A connecting-conductor is disclosed. The connecting-conductor may have a first conductor-element and a second conductor-element. Each conductor-element has a first end that is mechanically-connected and electrically-conductively connected to a resistor-element. The resistor-element has an electrical-insulating substrate, and a resistive material annularly disposed on at least part of the electrical-insulating substrate. The first end of each conductor-element is electrically-conductively connected to the resistive material. The first conductor does not touch the second conductor, and an electrical pathway is created via the resistive material from one of the conductor-elements to the other of the conductor-elements.

FIELD OF THE INVENTION

The present invention generally relates to devices, systems, and methods of transmitting electricity. More specifically, the present invention may relate to devices, systems, and methods of placing a resistor between two electricity conductors.

BACKGROUND OF THE INVENTION

In the prior art, electromagnetic energy conductors (“EE Conductors”), such as those that carry electricity, are used to carry electromagnetic energy from one device to another. For example, a signal may be sent in the form of electricity from one circuit board via an EE Conductor to another circuit board. Or, a signal may be sent in the form of electromagnetic energy from a controller to an actuator that activates a motor.

Such EE Conductors are often joined together using a prefabricated plug and socket that mate together. There are a number of commonly used mechanisms used to hold the plug and socket in their mated positions (that is to say held relative to each other). One such mechanism is a threaded connection wherein a housing associated with the plug and a housing associated with the socket each have a threaded surface, and by turning one of the housings relative to the other, these threaded surfaces may be mated together such that the housings, and therefore the plug and socket, are held together.

Another such mechanism utilizes one or more screws, each of which extends through the housing of the socket and the housing of the plug. In such a mechanism, one or both of housings may have a threaded surface to which the threads of the screw are mated, or it is possible that the screw may be held in place by a threaded nut.

A third such mechanism relies on the plug and socket housing being mated together, and then one or both of the housings is deformed (a.k.a. crimped) such that the socket housing is unable to be separated from the plug housing, except by reversing the effect of the deformation.

Other mechanisms for holding the plug and socket in their mated positions are possible. Regardless of the type of mechanism, the plug housing and the socket housing have a predetermined structure and the dimensions are carefully planned so that the features of the plug and socket that carry the electromagnetic energy from one EE Conductor to the other EE Conductor are brought into contact when the plug and socket housings are mated. Such features of the plug and socket that carry the electromagnetic energy are often mating pins and sockets that are brought together in a conductive relationship, so as to conduct the electromagnetic energy, when the plug housing is mated with the socket housing. It is often the case that the predetermined structure and planned dimensions of the plug and socket housings are such that there is very little available space within the housings once they are mated. Consequently, additional components cannot be included within the housings without redesigning the housings.

In addition, the EE Conductors along with the mating plug and sockets that join them are often part of a larger system that mandates and restricts the size and placement of the EE Conductors, plugs, and sockets. For example, when such EE Conductors are used in vehicles, such as cars or airplanes, the location of a particular plug and socket is normally planned somewhat precisely so as not to interfere with other systems on the vehicle, or interfere with a desired use of the vehicle, or to facilitate manufacturing of the vehicle. As such, redesigning the plug and socket housings may necessitate the redesign of other systems and/or components. Consequently, redesigning plugs and sockets is to be avoided.

Vehicles, such as cars or airplanes, utilizing EE Conductors may need to be modified to meet changing safety standards or to bring a system that is on the vehicle into compliance with existing safety standards in ways that were previously not anticipated. For example, the manufacturer of an airplane may decide that additional protection of its electromagnetic systems is needed in order that the electromagnetic systems are better protected from lightning strikes. In order to provide that protection it would be desirable to quickly and cheaply add a resistor to the electromagnetic systems of the airplane. An ideal location for adding such a resistor would be at the junction between two EE Conductors. However, given the restrictions discussed above, currently it would be neither quick nor cheap to add a resistor to the features contained within the plug and socket housings.

SUMMARY OF THE INVENTION

The invention may be embodied as a connecting-conductor having a first conductor-element and a second conductor-element. Each conductor-element has a first end that is mechanically-connected and electrically-conductively connected to a resistor-element. The resistor-element has an electrical-insulating substrate, and a resistive material annularly disposed on at least part of the electrical-insulating substrate. The first end of each conductor-element is electrically-conductively connected to the resistive material. The first conductor does not touch the second conductor, and an electrical pathway is created via the resistive material from one of the conductor-elements to the other of the conductor-elements.

The resistor-element may include a conductive material that is:(a) annularly disposed on at least part of the electrical-insulating substrate; and(b) electrically-conductively and mechanically-connected to one of the conductor-elements and to the resistive material.

The resistor-element may include a conductive material that is:(a) annularly disposed on at least part of the electrical-insulating substrate; and(b) electrically-conductively and mechanically-connected to one of the conductor-elements and to the resistive material.

The resistor-element may include a conductive material that is annularly disposed on at least part of the electrical-insulating substrate to provide a conductive pathway between the first conductor-element and the resistive material.

The resistor-element may include:(a) a conductive material at a first location that is electrically-conductively and mechanically-connected to the first conductor-element and to the resistive material; and(b) a conductive material at a second location that is electrically-conductively and mechanically-connected to the second conductor-element and to the resistive material.

The resistor-element may have a first surface defining a receiving-hole, and the first end of the first conductor-element or the first end of the second conductor-element may reside in the receiving-hole.

The resistor-element may have a first surface defining a receiving-hole, and the first end of the first conductor-element or the first end of the second conductor-element may reside in the receiving-hole. In such an embodiment:(a) the first conductor-element may reside in the receiving-hole, and the resistor-element may further have a second surface defining another receiving-hole in which the first end of the second conductor-element resides; or(b) the receiving-hole may extend through the resistor-element, and the first end of the first conductor-element may reside in a first part of the receiving-hole, and the first end of the second conductor-element may reside in a second part of the receiving-hole; or(c) the first end of the first conductor-element may reside in the receiving-hole, and the first end of the second conductor-element may have a surface defining a hole in which part of the resistor-element resides.

The first end of the first conductor-element may have a surface defining a hole in which a first part of the resistor-element resides, and the first end of the second conductor-element may have a surface defining a hole in which a second part of the resistor-element resides.

The electrical-insulating substrate may be a ceramic material, a plastic material, or a polymer material.

The electrical-insulating substrate may be material selected from the group consisting of: porcelain, alumina, steatite, titanate, and glass.

The resistive material may be selected from the group consisting of: carbon and a carbon composition.

At least one of the conductor-elements may be a material selected from the group consisting of: copper, copper alloy, steel, aluminum, and aluminum alloy.

The first conductor-element and/or the second conductor-element may be solid.

The first conductor-element and/or the second conductor-element may have a tubular portion or may be tubular from end to end.

The conductive material may be selected from the group consisting of: copper, copper alloy (such as bronze or brass), tin, tin alloy, aluminum, aluminum alloy, gold, nickel, and silver.

FURTHER DESCRIPTION OF THE INVENTION

FIG. 1andFIG. 2depict a connecting-conductor10that may be used within the housings of a plug and socket to place a resistor between two EE Conductors. InFIG. 1andFIG. 2there is a shown a first conductor-element100in the shape of a pin, a second conductor-element300in the shape of a socket, and these conductor-elements100,300are joined together by a resistor-element200. The overall length L and diameter D of the connecting-conductor10may be selected to be the same or very similar to the length and diameter of the existing pin or socket that is brought together in a conductive relationship when the plug housing is mated with the socket housing.

The resistor-element200depicted inFIG. 1as having an electrical-insulating substrate210and a resistive material230that is annularly disposed on at least part of the electrical-insulating substrate210. A first end110of the first conductor-element100is mechanically-connected to the resistor-element200, and electrically-conductively connected to the resistive material230via a first conductive material250A that is annularly disposed on at least part of the electrical-insulting substrate210. In a similar manner, a first end310of the second conductor-element300is mechanically-connected to the resistor-element200, and electrically-conductively connected to the resistive material230via a second conductive material250B that is annularly disposed on at least part of the electrical-insulting substrate210. In this manner, the first conductor-element100does not touch the second conductor-element300, and an electrical pathway is created via the resistive material230from one of the conductor-elements100,300to the other of the conductor-elements300,100. And, the second ends120,320of the conductor-elements100,300are depicted as being available for joining to other components. For example, the second end320of conductor-element300may be joined to an EE Conductor, and the second end120of the conductor-element100may be mated with a socket conductor that resides within one of the plug or socket housings. For clarity, if the connecting-conductor10shown inFIGS. 1 and 2is associated with a plug housing, then the corresponding socket housing would contain a socket that mates with the second end120of conductor-element100when the plug housing and the socket housing are mated. Alternatively, if the connecting-conductor10shown inFIGS. 1 and 2is associated instead with a socket housing, then the corresponding plug housing would contain a socket that mates with the second end120of conductor-element100when the plug housing and the socket housing are mated.

The conductive material250A,250B is shown inFIGS. 1 and 2annularly disposed on at least part of the electrical-insulating substrate210. Each of the conductive materials250A,250B is also shown inFIGS. 1 and 2electrically-conductively and mechanically-connected to one of the conductor-elements100,300as well as to the resistive material230. In this manner, an electrical pathway is created via the resistive material230from one of the conductor-elements100,300to the other of the conductor-elements300,100.

It should be noted that the word “annularly” is used herein to identify not only rings of material that are substantially circular, but other shapes as well. For example, if the electrical-insulating substrate210is triangular, or square, or oval shaped, then the annularly disposed conductive material250A,250B as well as the resistive material230may have a corresponding triangular, or square, or oval shape too. Thus, the word “annularly” is used herein in a manner that is broader than its tradition definition to refer to shapes other than circular rings.

The mechanical and electrical connection between the conductor-elements100,300and the conductive material250A,250B of the resistor-element200may be achieved by placing beads400A,400B (such as that shown inFIG. 1) of conductive solder or conductive epoxy where the conductor-elements100,300are close to their corresponding conductive-material250A,250B, and allowing that bead to harden. However, the mechanical connection between the conductor-elements100,300and the resistor-element200may be achieved or augmented in other ways. For example, a non-conductive epoxy may be used to join the conductor-elements100,300directly to the electrical-insulting substrate by applying the epoxy to those surfaces of the conductor-elements100,300and/or to the electrical-insulating substrate210that are placed in close proximity to each other during formation of the connecting-conductor10.

The mechanical connection between the conductor-elements100,300and the electrical-insulating substrate200may be strengthened by providing one or more legs that extend into a conductor-element. For example,FIG. 1shows such a leg220(see alsoFIGS. 3A and 3B) extending into the first end310of the second conductor-element300. The second conductor-element300has an internal surface330into which the leg220extends and resides.

The mechanical connection between the conductor-elements100,300and the electrical-insulating substrate200may be strengthened by providing one or more receiving holes in the electrical-insulating substrate200, such as the partial receiving hole270(seeFIG. 3B) that is shown inFIG. 1accepting the first end110of the first conductor-element100. Other arrangements are possible. For example,FIGS. 4A and 4Bdepict an embodiment of the invention in which the electrical-insulating substrate210has two receiving holes (each a partial hole), one receiving hole for receiving the first end110of the first conductor-element110, and another receiving hole for receiving the first end310of the second conductor-element310.

FIG. 4Cdepicts another embodiment of the invention in which the electrical-insulating substrate210has a receiving hole270that extends through the electrical-insulating substrate210. Annularly applied to the surface defining that receiving hole270is the resistive material230. When assembled, the shoulders140,340of the conductor-elements100,300touch and/or are electrically connected to the conductive material250A,250B.

FIGS. 5A and 5Bdepict another embodiment of the invention in which legs220A,220B of the electrical-insulating substrate210extend into the conductor-elements100,300. Note that the conductor-elements100,300shown inFIG. 5Bare different types. The conductor-element300is a tube from end310to end320, whereas the conductor-element100is not a full tube and instead has a portion that is tubular in the vicinity of end110. This need not be the case, for example, the connecting-conductor100shown inFIG. 5Bmay be replaced with a full-tube type so that the types of connecting-conductors are the same type. For emphasis of this idea, the conductor-elements100,300may be the same type (e.g. seeFIGS. 4B and 4C), or different types (e.g.FIGS. 1 and 5B). Throughout the figures, there are shown various types of conductor-elements, and it should be noted that such types are not necessarily limited to use in the particular embodiments depicted. For example, the partial-tube type shown inFIG. 5Bfor the conductor-element100could be used in the embodiment ofFIG. 1as the conductor300.

The resistor-element200may be formed by applying the conductive material250A,250B to the electrical-insulating substrate210, for example by spraying or dipping procedures, and the resistive material may be applied to the electrical-insulating substrate210by similar procedures. The effective resistance of the resistor-element200may be selected by varying the amount of conductive material250A,250B and resistive material230used, while maintaining a desired thicknesses of those materials.

It is worth noting that the particular arrangement shown in the figures are not the only viable arrangements. For example, the locations of the conductive materials and the resistive material may be reversed. That is to say for example that the area identified inFIG. 1by “230” may be a conductive material, and the areas identified inFIG. 1by “250A” and “250B” may be the resistive material.

The electrical-insulating substrate210may be a ceramic material, a plastic material, a polymer material having the ability to electrically insulate one electrically conductive substance from another. For example, the electrical-insulating substrate210may be porcelain, alumina, steatite, titanate, and/or glass. The resistive material230may be carbon, a composition of carbon, or other materials that resist but do not prevent the transmission of electricity. The conductor-elements100,300may be copper, copper alloy (such as bronze or brass), steel, aluminum, aluminum alloy, as well as other conductive substances. The conductive material250A,250B may be copper, copper alloy (such as bronze or brass), tin, tin alloy, aluminum, aluminum alloy, gold, nickel, and/or silver, as well as other conductive substances.

Although the present invention has been described with respect to one or more particular embodiments, it will be understood that other embodiments of the present invention may be made without departing from the spirit and scope of the present invention. Hence, the present invention is deemed limited only by the appended claims and the reasonable interpretation thereof.