High-density electrical connector

Disclosed herein is an electrical connector, comprising a plug and a receptacle. The plug comprises first electrical contacts electrically isolated from each other and arranged into a first outer contact annulus and a first inner contact annulus concentric with and radially spaced apart from each other. The receptacle comprises second electrical contacts electrically isolated from each other and arranged into a second outer contact annulus and a second inner contact annulus concentric with and radially spaced apart from each other. The plug is selectively connectable with the receptacle. When the plug is selectively connected with the receptacle, each of the first electrical contacts of the first outer contact annulus is in physical contact with a corresponding one of the second electrical contacts of the second outer contact annulus and each of the first electrical contacts of the first inner contact annulus is in physical contact with a corresponding one of the second electrical contacts of the second inner contact annulus.

FIELD

This application relates generally to electrical components, and more specifically to an electrical connector having a plug and a receptacle.

BACKGROUND

Conventional high-density electrical connectors include rows of stacked electrical contact boards. Because any one of the boards may unpredictably act as a primary datum, as a plug of the connector is inserted into a receptacle of the connector, misalignment of or unreliable connections between the other of the boards may occur. Accordingly, predictably aligning multiple groupings of electrical contacts in a high-density electrical connector can be difficult.

SUMMARY

The subject matter of the present application has been developed in response to the present state of the art, and in particular, in response to the problems and needs of conventional devices or products for providing a high-density electrical connection between a tool and a tool control system that have not yet been fully solved. The subject matter of the present application has been developed to provide an electrical connector that facilitates a high-density electrical connection that overcomes many of the shortcomings of the prior art.

Disclosed herein is an electrical connector, comprising a plug and a receptacle. The plug comprises first electrical contacts electrically isolated from each other and arranged into a first outer contact annulus and a first inner contact annulus concentric with and radially spaced apart from each other. The receptacle comprises second electrical contacts electrically isolated from each other and arranged into a second outer contact annulus and a second inner contact annulus concentric with and radially spaced apart from each other. The plug is selectively connectable with the receptacle. When the plug is selectively connected with the receptacle, each of the first electrical contacts of the first outer contact annulus is in physical contact with a corresponding one of the second electrical contacts of the second outer contact annulus and each of the first electrical contacts of the first inner contact annulus is in physical contact with a corresponding one of the second electrical contacts of the second inner contact annulus. The preceding subject matter of this paragraph characterizes example 1 of the present disclosure.

The plug comprises a central axis. The first electrical contacts of the first outer contact annulus are resiliently flexible away from the central axis of the plug. The first electrical contacts of the first inner contact annulus are resiliently flexible toward the central axis of the plug. The preceding subject matter of this paragraph characterizes example 2 of the present disclosure, wherein example 2 also includes the subject matter according to example 1, above.

The plug further comprises an outer contact retention annulus comprising first ribs, spaced apart from each other in a circular arrangement, and first slots each between adjacent ones of the first ribs. The plug further comprises an inner contact retention annulus comprising second ribs, spaced apart from each other in a circular arrangement, and second slots each between adjacent ones of the second ribs. Each one of the first electrical contacts of the first outer contact annulus is movably positioned within a corresponding one of the first slots of the outer contact retention annulus. Each one of the first electrical contacts of the first inner contact annulus is movably positioned within a corresponding one of the second slots of the inner contact retention annulus. The preceding subject matter of this paragraph characterizes example 3 of the present disclosure, wherein example 3 also includes the subject matter according to example 2, above.

The receptacle comprises a central axis. The second electrical contacts of the second outer contact annulus are radially fixed relative to the central axis. The second electrical contacts of the second inner contact annulus are radially fixed relative to the central axis. The preceding subject matter of this paragraph characterizes example 4 of the present disclosure, wherein example 4 also includes the subject matter according to any one of examples 2 or 3, above.

An annular space is defined between the first outer contact annulus and the first inner contact annulus of the plug. The receptacle comprises a support ring interposed between and radially supporting the second outer contact annulus and the second inner contact annulus of the receptacle. When the plug is selectively connected with the receptacle, the support ring of the receptacle is inserted into the annular space of the plug. The preceding subject matter of this paragraph characterizes example 5 of the present disclosure, wherein example 5 also includes the subject matter according to any one of examples 1-4, above.

The support ring of the plug comprises an outer contact retention annulus comprising first ribs, spaced apart from each other in a circular arrangement, and first slots each between adjacent ones of the first ribs. The support ring of the plug further comprises an inner contact retention annulus comprising second ribs, spaced apart from each other in a circular arrangement, and second slots each between adjacent ones of the second ribs. Each one of the second electrical contacts of the second outer contact annulus is fixedly positioned within a corresponding one of the first slots of the outer contact retention annulus. Each one of the second electrical contacts of the second inner contact annulus is fixedly positioned within a corresponding one of the second slots of the inner contact retention annulus. The preceding subject matter of this paragraph characterizes example 6 of the present disclosure, wherein example 6 also includes the subject matter according to example 5, above.

The plug further comprises a housing comprising an interior cavity and a contact carrier housed within the housing. The first electrical contacts are non-translationally fixed to the contact carrier and the contact carrier is translationally movable relative to the housing. The preceding subject matter of this paragraph characterizes example 7 of the present disclosure, wherein example 7 also includes the subject matter according to any one of examples 1-6, above.

The housing further comprises an alignment aperture. The contact carrier comprises an alignment tab that extends through and is translationally movable within the alignment aperture. The receptacle comprises an alignment slot. When the plug is selectively connected with the receptacle, the alignment tab of the contact carrier is inserted into the alignment slot of the receptacle. The preceding subject matter of this paragraph characterizes example 8 of the present disclosure, wherein example 8 also includes the subject matter according to example 7, above.

The housing further comprises a retention aperture. The contact carrier further comprises a retention tab that is resiliently flexible and biased to extend through the retention aperture of the housing. The receptacle comprises a recess. When the plug is selectively connected with the receptacle, the retention tab of the contact carrier engages the recess of the receptacle. The preceding subject matter of this paragraph characterizes example 9 of the present disclosure, wherein example 9 also includes the subject matter according to any one of examples 7 or 8, above.

When the plug is selectively connected with the receptacle, translational movement of the housing of the plug relative to the contact carrier of the plug in a direction away from the receptacle, causes the housing to engage and resiliently and radially inwardly deform the retention tab to release the retention tab from the recess. The preceding subject matter of this paragraph characterizes example 10 of the present disclosure, wherein example 10 also includes the subject matter according to example 9, above.

The contact carrier further comprises a central receptacle interface radially inward of the first inner contact annulus. The plug further comprises one of electrical pin receptacles or electrical pins coupled to the central receptacle interface. The receptacle further comprises a central pin interface that comprises another one of the electrical pin receptacles or the electrical pins. When the plug is selectively connected with the receptacle, the electrical pin receptacles are electrically coupled with the electrical pins. The preceding subject matter of this paragraph characterizes example 11 of the present disclosure, wherein example 11 also includes the subject matter according to any one of examples 7-10, above.

The plug further comprises a radio-frequency (RF) shield non-movably fixed to the contact carrier and interposed between the first electrical contacts and the one of the electrical pin receptacles or the electrical pins of the plug. The preceding subject matter of this paragraph characterizes example 12 of the present disclosure, wherein example 12 also includes the subject matter according to example 11, above.

The RF shield comprises two concentric parts that are radially offset from each other and at least partially overlap each other. The preceding subject matter of this paragraph characterizes example 13 of the present disclosure, wherein example 13 also includes the subject matter according to example 12, above.

The receptacle further comprises a radio-frequency (RF) shield non-movably fixed to the receptacle and interposed between the second electrical contacts and the other of the electrical pin receptacles or the electrical pins of the receptacle. The preceding subject matter of this paragraph characterizes example 14 of the present disclosure, wherein example 14 also includes the subject matter according to any one of examples 11-13, above.

The RF shield comprises two concentric parts that are radially offset from each other and at least partially overlap each other. The preceding subject matter of this paragraph characterizes example 15 of the present disclosure, wherein example 15 also includes the subject matter according to example 14, above.

No portion of the first electrical contacts is elastically deformed. The preceding subject matter of this paragraph characterizes example 16 of the present disclosure, wherein example 16 also includes the subject matter according to any one of examples 1-15, above.

Each of the first electrical contacts of the plug comprises a curved contact surface. When the plug is selectively connected with the receptacle, the curved contact surface of each of the first electrical contacts is in electrical contact with a corresponding one of the second electrical contacts of the receptacle. The preceding subject matter of this paragraph characterizes example 17 of the present disclosure, wherein example 17 also includes the subject matter according to any one of examples 1-16, above.

The receptacle further comprises a housing comprising an interior cavity and a contact carrier housed within the housing. The second electrical contacts are non-movably fixed to the contact carrier and the contact carrier is non-movably fixed to the housing. The preceding subject matter of this paragraph characterizes example 18 of the present disclosure, wherein example 18 also includes the subject matter according to any one of examples 1-17, above.

Additionally disclosed herein is a plug of an electrical connector. The plug comprises a first set of electrical contacts electrically isolated from each other and arranged into an outer contact annulus about a central axis of the plug. The plug also comprises a second set of electrical contacts electrically isolated from each other and arranged into an inner contact annulus about the central axis of the plug. The inner contact annulus is concentric with and radially spaced apart from the outer contact annulus. The first set of electrical contacts of the outer contact annulus are resiliently flexible away from the central axis of the plug. The second set of electrical contacts of the first inner contact annulus are resiliently flexible toward the central axis of the plug. The preceding subject matter of this paragraph characterizes example 19 of the present disclosure.

Also disclosed herein is a receptacle of an electrical connector. The receptacle comprises a support ring concentric with a central axis of the receptacle and comprising a radially outward surface and a radially inward surface. The receptacle also comprises a first set of electrical contacts supported on the radially outward surface of the support ring, electrically isolated from each other, and arranged into an outer contact annulus about the central axis of the receptacle. The receptacle further comprises a second set of electrical contacts supported on the radially inward surface of the support ring, electrically isolated from each other, and arranged into an inner contact annulus about the central axis. The inner contact annulus is concentric with the outer contact annulus. The support ring is interposed between the inner contact annulus and the outer contact annulus. The first set of electrical contacts of the outer contact annulus are radially fixed relative to the central axis. The second set of electrical contacts of the inner contact annulus are radially fixed relative to the central axis. The preceding subject matter of this paragraph characterizes example 20 of the present disclosure.

DETAILED DESCRIPTION

Referring toFIG. 1, one embodiment of an electrical connector100includes a plug102and a receptacle104. The electrical connector100is considered a high-density electrical connector because the electrical connector100has a high density of electrical contacts or terminals each configured to transmit electrical signals between the plug102and the receptacle104when connected. Generally, the majority of the electrical contacts of the electrical connector100are arranged circumferentially or annularly about a common axis (e.g., central axis195ofFIGS. 3 and 7). Coaxial and rotational alignment of the plug102and the receptacle104ensures proper alignment of corresponding electrical contacts of the plug102and the receptacle104. Moreover, coaxial and rotational alignment of the plug102and the receptacle104is based on initial alignment of a single, predictable primary datum independent of the electrical contacts. Such a configuration is advantageous over conventional high-density electrical connectors with rows of stacked electrical contact boards because any one of the boards may unpredictably act as the primary datum, which may result in a misalignment of or unreliable connections between the other of the boards.

The plug102includes a housing110and circuit boards106extending from the housing110. The circuit boards106may include electrical traces imprinted on an electrically-insulating substrate. Moreover, in some implementations, the circuit boards106can be flexible circuit boards. Each circuit board106is electrically coupled to one or more electrical contacts of the plug102at one end and other electrical connections (not shown), such as those of a medical tool, at an opposite end. As shown inFIGS. 2-5, the housing110includes an engagement end portion116with a reduced outer peripheral diameter relative to the rest of the housing110. The engagement end portion116includes alignment apertures118and retention apertures126spaced apart about the periphery of the engagement end portion116. As shown inFIG. 3, the housing110defines an interior cavity138accessible through the alignment apertures118and the retention apertures126.

The plug102further includes a contact carrier120housed within the interior cavity138of the housing110at the engagement end portion116. The engagement end portion116retains the contact carrier120, but allows the contact carrier120to translationally shift along the central axis195. For example, the contact carrier120includes retention tabs124that are resiliently flexible and biased to extend through and beyond corresponding retention apertures126in the engagement end portion116to releasably couple or retain the contact carrier120to the engagement end portion116. In this position, the retention tabs124are positioned to engage corresponding recesses160in the receptacle104(see, e.g.,FIG. 7), which releasably connects the plug102to the receptacle104. Translational movement of the housing110relative to the contact carrier120, in a direction away from the receptacle104, causes an edge of the retention apertures126to engage and resiliently flex corresponding retention tabs124inwardly toward the interior cavity138. Such flexing of the retention tabs124disengages the retention tabs124from corresponding recesses160in the receptacle104(see, e.g.,FIG. 7), which allows the plug102to be disconnected from the receptacle104.

Although in the illustrated example, the plug102is releasably connected to the receptacle104via a passive latch mechanism comprising the retention tabs124and the recesses160, as described above, in other examples, the plug102is releasably connected to the receptacle104via other coupling mechanisms, such as active latch mechanisms, friction latch mechanisms, and the like.

The contact carrier120also includes alignment tabs122that extend through and radially outwardly beyond the alignment apertures118in the engagement end portion116. The alignment tabs122are allowed to translationally move parallel with the central axis195within the alignment apertures118, but the alignment apertures118constrain movement of the alignment tabs122in directions perpendicular to the central axis195. The alignment tabs122are circumferentially spaced apart from each other about the engagement end portion116. The alignment tabs122are configured to engage corresponding alignment slots158of the plug102to ensure proper alignment between the plug102and the receptacle104. Because alignment between the plug102and the receptacle104is controlled by the alignment tabs122of the contact carrier120, rather than some feature of the housing110, alignment tolerances are reduced by effectively by-passing the housing110.

As shown inFIG. 5, one or more of the alignment tabs122can have a width that is different than the width of another one or more of the alignment tabs122. In the illustrated example, the width of the alignment tab122at the top of the plug102, as shown inFIG. 5, is wider than the two alignment tables122nearer the bottom of the plug102, as shown inFIG. 5. The alignment slots158in the receptacle104have the same pattern and sizing as the alignment tabs122. Accordingly, the wider alignment tab122can act as a key feature to ensure the plug102is properly rotationally oriented relative to the receptacle104when the two are mated together. Although the alignment tabs122of the illustrated example are arranged in a particular circumferential pattern (e.g., evenly spaced) and have a particular size (e.g., one wider than two others), in other examples, the alignment tabs122, and corresponding alignment slots158, can be arranged in any of various particular or unique circumferential patterns and have any of various particular or unique sizing to help facilitate connections only between plugs and receptacles that have matching patterns and sizing.

Referring toFIG. 4, the contact carrier120also includes an outer contact retention annulus146A and an inner contact retention annulus146B. Both the outer contact retention annulus146A and the inner contact retention annulus146B are concentric with the central axis195and thus are concentric with each other. Each of the outer contact retention annulus146A and the inner contact retention annulus146B includes a plurality of ribs144spaced apart from each other about a circumference of the corresponding outer contact retention annulus146A and inner contact retention annulus146B. In other words, the ribs144of each annulus are arranged in a circular or ring-like arrangement about the central axis195. Defined between adjacent ribs144of the outer contact retention annulus146A and the inner contact retention annulus146B are corresponding slots150. The spacing of the ribs144, and thus the width of the slots150, is selected to allow a corresponding electrical contact140to move, within a slot150, radially outward away from the central axis195and radially inward toward the central axis195(see, e.g., directional arrows inFIG. 4) and to prevent or restrict the corresponding electrical contact140from moving laterally in a circumferential direction. Accordingly, the electrical contacts140are allowed to flex radially while remaining within the slots150and constrained in a fixed angular position, which promotes electrical isolation between the electrical contacts140and proper positioning for contacting the electrical contacts166of the receptacle104.

The outer contact retention annulus146A is larger (e.g., has a larger diameter) than the inner contact retention annulus146B such that an annular gap is defined between the outer contact retention annulus146A and the inner contact retention annulus146B. The gap is configured to receive the annular-shaped contact support ring152of the receptacle104, as will be further defined below. The slots150of the outer contact retention annulus146A are open towards the central axis195and the slots150of the inner contact retention annulus146B are open away from the central axis195.

The electrical contacts140of the plug102form a group134of electrical contacts140. The group134of electrical contacts140are arranged into an outer contact annulus148A and an inner contact annulus148B each concentric with the central axis195. The electrical contacts140of the outer contact annulus148A are circumferentially spaced apart from each other and collectively define an annular-shaped grouping of contacts140. Accordingly, the electrical contacts140are electrically isolated from each other. Similarly, the electrical contacts140of the inner contact annulus148B are circumferentially spaced apart from each other and collectively define an annular-shaped grouping of electrical contacts140. The outer contact annulus148A is larger than the inner contact annulus148B. In other words, the electrical contacts140of the outer contact annulus148A are all positioned a first distance away from the central axis195and the electrical contacts140of the inner contact annulus148B are all positioned a second distance away from the central axis195, where the first distance is greater than the second distance. In some implementations, the outer contact annulus148A includes at least twenty-five electrical contacts140(e.g., at least seventy-four electrical contacts140). The inner contact annular148B includes fewer electrical contacts140than the outer contact annulus148A. For example, in some implementations, the inner contact annulus148B includes between forty and sixty (e.g., fifty-four) electrical contacts140.

Referring toFIG. 12, each electrical contact140includes a fixed end191and a free end190(e.g., cantilevered end). The electrical contact140is configured to facilitate resilient flexing of the free end190relative to the fixed end191. Accordingly, in some implementations, a thickness of the electrical contact140at a location between the fixed end191and the free end190is less to define a flex point at that location. The fixed end191is configured to be non-movably fixedly secured to contact carrier120(see, e.g.,FIG. 3) such that the free end190is partially positioned within a corresponding slot150. In other words, a portion of the free end190is within the slot150and another portion of the free end190is out of the slot150. In this manner, the free end190is properly aligned by the ribs144defining the slot150at the same time as being exposed for establishing electrical contact with an electrical contact166of the receptacle104. In some implementations, the free end190includes a concave or curved contact surface to promote electrical connectivity with and slidability along the electrical contact166. According to one example, as shown inFIG. 12, the free end190is substantially U-shaped.

The electrical contacts140are made from an electrically conducting material, such as copper. Moreover, in one implementation, the electrical contacts140are made using a metal stamping process. For example, each electrical contact140can be formed by stamping without a subsequent bending of the electrical contact140. In other words, no portion of the electrical contact140is plastically deformed. Because bending of the electrical contact140is not necessary, electrical contact140can be smaller and formed at a lower cost, with a more fine-tuned moment of inertia, and with more controlled tolerances compared to stamped and bent electrical contacts.

In one embodiment, the contact carrier120defines an annular slot187that is concentric with the central axis195. The annular slot187is located radially inwardly from the inner contact retention annulus146B. Moreover, the annular slot187encircles a central receptacle interface136. The central receptacle interface136is concentric with the central axis195and includes a plurality of spaced-apart electrical pin receptacles142. The electrical pin receptacles142are positioned within corresponding channels formed in the central receptacle interface136. Although not shown, the electrical pin receptacles142are electrically coupled to other electrical connections, such as those of a medical tool, commercial tool, or other device, at an opposite end. The central receptacle interface136can have any number of electrical pin receptacles142. For example, inFIGS. 2 and 5, the central receptacle interface136has eight electrical pin receptacles142. However, in other examples, the central receptacle interface136can have fewer than eight electrical pin receptacles142(e.g., one to seven electrical pin receptacles142) or more than eight electrical pin receptacles142(e.g., twelve, eighteen, or more electrical pin receptacles142). The electrical pin receptacles142are made of an electrically conductive material. In one implementation, the electrical pin receptacles142are configured to transmit electrical power and the electrical contacts140are configured to transmit electrical communication signals.

Although the central receptacle interface136in the illustrated embodiment facilitates electrical connections, in other embodiments, the central receptacle interface136may be modified to facilitate connections of other types, such as fiber optic, fluidic, pneumatic, and the like. Accordingly, in some implementations, the central receptacle interface136can be interchangeable or reconfigurable to meet any of various interconnect capabilities, such as those demanded by a customer. Furthermore, in some implementations, the central receptacle interface136can be non-removably fixed to or selectively removably coupled to the contact carrier120. Interchangeability can be facilitated through the use of selectively releasable interlocking elements, such as clips, tabs, detents, etc., interference fit coupling, and/or any of various other like elements.

Additionally, in some implementations, the contact carrier120includes one or more radio-frequency (RF) interference shields configured to block RF interference or noise. For example, the shields can prevent RF interference generated by the transmission of electrical power through the electrical pin receptacles142from interfering with the electrical communication signals transmitted through the electrical contacts140. Referring toFIG. 3, the contact carrier120includes a first RF interference shield128and a second RF interference shield130that are concentric with and partially overlap each other. Although two RF interference shields are shown, in some implementations, the contact carrier120can include one or more than two RF interference shields. In one implementation, the RF interference shields are made of a Mu-metal (e.g., a nickel-iron alloy with high permeability).

Referring back toFIG. 1, the receptacle104of the electrical connector100includes a housing112and circuit boards108extending from the housing112. The circuit boards108may include electrical traces imprinted on an electrically-insulating substrate. Moreover, in some implementations, the circuit boards108can be flexible circuit boards. Each circuit board108is electrically coupled to one or more electrical contacts of the receptacle104at one end and other electrical connections (not shown), such as those of a control system for a medical tool, commercial tool, or other device, at an opposite end. As shown inFIGS. 6, 7, 9, and 10the receptacle104includes an engagement socket115sized and shaped to complement the engagement end portion116of the plug102. The engagement socket115is at least partially defined by the housing112. For example, the engagement socket115is configured to matingly receive the engagement end portion116of the plug102as shown inFIG. 11. The engagement socket115includes alignment slots158and retention recesses160spaced apart about the periphery of the engagement socket115. Each of the alignment slots158is configured to matingly engage a corresponding one of the alignment tabs122of the plug102and each of the retention recesses160is configured to matingly engage a corresponding one of the retention tabs124of the plug102.

The receptacle104further includes a contact carrier180housed within an interior cavity of the housing112. The contact carrier180can be non-removably fixed to or selectively removably coupled to the housing112. In some examples, the contact carrier180is non-movably fixed to the housing112. Moreover, the contact carrier180at least partially defines the engagement socket115of the receptacle104. In some implementations, the contact carrier180is substantially contiguous with the engagement socket115of the housing112and, in effect, is a continuation of the engagement socket115such that the housing112and the contact carrier180collectively form the engagement socket115. Alternatively, in certain implementations, the housing112and the contact carrier180are co-formed to have a one-piece, seamless, monolithic construction. The contact carrier180further includes cut-outs182that form part of the alignment slots158of the engagement socket115. The contact carrier180also includes apertures196that partially define the retention recesses160of the engagement socket115.

The contact carrier180of the receptacle104additionally includes a contact support ring152that is concentric with the central axis195of the electrical connector100. Formed into the outer circumference of the contact support ring152is an outer contact retention annulus168A. Additionally, formed into the inner circumference of the contact support ring152is an inner contact retention annulus168B. Both the outer contact retention annulus168A and the inner contact retention annulus168B of the receptacle103is concentric with the central axis195and with each other. Each of the outer contact retention annulus168A and the inner contact retention annulus168B includes a plurality of ribs170spaced apart from each other about a circumference of the corresponding outer contact retention annulus168A and inner contact retention annulus168B. In other words, the ribs170of each annulus are arranged in a circular or ring-like arrangement about the central axis195. Defined between adjacent ribs170of the outer contact retention annulus168A and the inner contact retention annulus168B are corresponding slots178. The spacing of the ribs170, and thus the width of the slots178, is selected to allow a corresponding electrical contact166to remain radially and laterally fixed relative to the central axis195. In other words, the outer contact retention annulus168A and the inner contact retention annulus168B prevent or restrict radial movement of the electrical contacts166toward or away from, respectively, the central axis195, and prevent or restrict the electrical contacts166from moving laterally in a circumferential direction. Accordingly, the electrical contacts166are constrained in a fixed radial and angular position, which promotes electrical isolation between the electrical contacts166and proper positioning for contacting the electrical contacts140of the plug102.

The outer contact retention annulus168A is larger (e.g., has a larger diameter) than the inner contact retention annulus168B such that a thickness of the contact support ring152is interposed between the outer contact retention annulus168A and the inner contact retention annulus168B. The thickness of the contact support ring152between the outer contact retention annulus168A and the inner contact retention annulus168B is sized to fit within the gap between the outer contact retention annulus146A and the inner contact retention annulus146B of the plug102. The slots178of the outer contact retention annulus168A are open away from the central axis195and the slots178of the inner contact retention annulus168B are open toward from the central axis195.

The electrical contacts166of the receptacle104form a group of electrical contacts166. The group of electrical contacts166are arranged into an outer contact annulus156A and an inner contact annulus156B each concentric with the central axis195. The electrical contacts166of the outer contact annulus156A are circumferentially spaced apart from each other and collectively define an annular-shaped grouping of contacts166. Accordingly, the electrical contacts166are electrically isolated from each other. Similarly, the electrical contacts166of the inner contact annulus156B are circumferentially spaced apart from each other and collectively define an annular-shaped grouping of electrical contacts166. The outer contact annulus156A is larger than the inner contact annulus156B. In other words, the electrical contacts166of the outer contact annulus156A are all positioned a third distance away from the central axis195and the electrical contacts166of the inner contact annulus156B are all positioned a fourth distance away from the central axis195, where the third distance is greater than the fourth distance. The third distance corresponds with (e.g., is the same as) the first distance between the electrical contacts140of the outer contact annulus148A and the central axis195, and the fourth distance corresponds with (e.g., is the same as) the second distance between the electrical contacts140of the inner contact annulus148B and the central axis195.

In some implementations, the outer contact annulus156A includes at least twenty-five electrical contacts166(e.g., at least seventy-four electrical contacts166). The inner contact annular156B includes fewer electrical contacts166than the outer contact annulus156A. For example, in some implementations, the inner contact annulus156B includes between forty and sixty (e.g., fifty-four) electrical contacts166.

Referring toFIGS. 7 and 13, each electrical contact166includes an unexposed fixed end, electrically coupled to one of the circuit boards108, and an exposed fixed end. The exposed fixed end of each electrical contact166can be beveled or tapered to facilitate smooth physically coupling of a corresponding electrical contact140of the plug102. Moreover, adjacent the exposed fixed end is a substantially flat portion along which a corresponding electrical contact140slides as the plug102is inserted into the receptacle104(see, e.g.,FIG. 13).

The electrical contacts166are made from an electrically conducting material, such as copper. Moreover, in one implementation, the electrical contact140is made using a metal stamping process.

In one embodiment, the contact carrier180defines an annular tube189that is concentric with the central axis195. The annular tube189is located radially inwardly from the inner contact retention annulus156B. Moreover, the annular tube189encircles a central pin interface162. However, in other embodiments, instead of an annular tube189, the contact carrier180may have a central engagement element that is configured to engage a corresponding engagement element formed in the contact carrier120of the plug102.

The central pin interface162is concentric with the central axis195and includes a plurality of spaced-apart electrical pins164. The electrical pins164are positioned within corresponding channels formed in the central pin interface162. Although not shown, the electrical pins164are electrically coupled to other electrical connections (not shown), such as those of a medical tool control system. The central pin interface162can have any number of electrical pins164. For example, inFIG. 10, the central pin interface162has eight electrical pins164. However, in other examples, the central pin interface162can have fewer than eight electrical pins164(e.g., one to seven electrical pins164) or more than eight electrical pins164(e.g., twelve, eighteen, or more electrical pins164). The electrical pins164are made of an electrically conductive material. In one implementation, the electrical pins164are configured to transmit electrical power and the electrical contacts166are configured to transmit electrical communication signals. It is recognized that, in alternative examples, the plug102includes the electrical pins164and the receptacle104includes the electrical pin receptacles142.

Although the central pin interface162in the illustrated embodiment facilitates electrical connections, in other embodiments, the central pin interface162may be modified to facilitate connections of other types, such as fiber optic, fluidic, pneumatic, and the like. Accordingly, in some implementations, the central pin interface162can be interchangeable or reconfigurable to meet any of various interconnect capabilities, such as those demanded by a customer. Furthermore, in some implementations, the central pin interface162can be non-removably fixed to or selectively removably coupled to the housing112or the contact carrier180.

Additionally, in some implementations, the contact carrier180includes one or more radio-frequency (RF) interference shields configured to block RF interference or noise. For example, the shields can prevent RF interference generated by the transmission of electrical power through the electrical pins164from interfering with the electrical communication signals transmitted through the electrical contacts166. Referring toFIGS. 7 and 9, the contact carrier120includes a first RF interference shield114and a second RF interference shield117that are concentric with and partially overlap each other. Although two RF interference shields are shown, in some implementations, the contact carrier180can include one or more than two RF interference shields. In one implementation, the RF interference shields are made of a Mu-metal.

The housing110, contact carrier120, housing112, and contact carrier180can be made from electrically non-conductive materials, such as plastics.

Referring toFIG. 11, the plug102is shown inserted into the receptacle104to establish electrical connectivity between the plug102and the receptacle104. The process of inserting the plug102into the receptacle104and establishing electrical connectivity between the plug102and the receptacle104is initiated by bringing the plug102into at least approximate coaxial alignment with the receptacle104, such as shown inFIG. 8. Additionally, the plug102and the receptacle104rotationally oriented relative to each other until the alignment tabs122of the plug102are aligned with the alignment slots158. When aligned, the plug102and the receptacle104can be moved toward each other, as indicated by directional arrows inFIG. 8, until the alignment tabs122are inserted into the alignment slots158. Engagement between the alignment tabs122of the plug102and the alignment slots158ensures proper alignment between the plug102and the receptacle104by establishing an orientation datum with the contact carrier120, thus reducing tolerance stack between the plug102and the receptacle104.

Further insertion of the plug102into the receptacle104causes the annular tube189of the receptacle103to engage and the annular slot187of the plug102. Yet further insertion of the plug102into the receptacle results in the electrical contacts140contacting the electrical contacts166. Such contact causes the electrical contracts140to radially flex, which ensures proper contact between the electrical contacts140and the electrical contacts166. As the plug102is further inserted into the receptacle104, the electrical contacts140slide along corresponding electrical contacts166, which helps to decontaminate the electrical contacts and ensures a reliable stable connection between the electrical contacts. Such a slidable arrangement also promotes a lower insertion force for connection between the contacts to be established. After the annular tube189engages the annular slot187, further insertion of the plug102into the receptacle104results in the electrical pins164being inserted into corresponding electrical pin receptacles142.

Full insertion of the plug102into the receptacle104allows the retention tabs124of the plug102to recoil into corresponding ones of the retention recesses160of the receptacle104, thus releasably fixing the plug102in interconnecting engagement with the receptacle104. When disconnection of the plug102from the receptacle104is desired, the housing110is slid relative to the contact carrier120in a direction away from the receptacle104until the housing110engages the retention tabs124and resiliently flexes the retention tabs124out of engagement with the retention recesses160. With the retention tabs124disengaged from the retention recesses160, the plug102can be moved away from the receptacle104to disconnect the plug102from the receptacle104.

Although the plug102includes the electrical contacts140, the annular alignment slot187, and the electrical pin receptacles142, and the receptacle104includes the electrical contacts166, the annular tube189, and the electrical pins164, in some embodiments, the plug102includes the electrical contacts166, the annular tube189, and the electrical pins164, and the receptacle104includes the electrical contacts140, the annular slot187, and the electrical pin receptacles142without departing from the essence of the present disclosure.