Sealed electrical connector assembly

A connector assembly comprises front and rear connector bodies, a wire grommet with wire passages, and a nut. Tightening the nut forces a rearward portion of the grommet into a tapered segment of a passage through the rear connector body, thereby radially compressing the grommet and sealing the wires passing therethrough.

FIELD OF THE INVENTION

The field of the present invention relates to electrical connector assemblies. In particular, a sealed electrical connector assembly including a radially compressed wire grommet is disclosed herein.

BACKGROUND

In certain circumstances it is desirable to isolate from a use environment the electrical contacts and wires within an electrical connector assembly. One such circumstance arises when electrical connectors are employed in aviation. Exposure to extremes of temperature, pressure, or humidity, and frequent cycling between those extremes (e.g., with each takeoff, climb, cruise, descent, and landing) can lead to corrosion or other degradation of the electrically conductive parts of the connector. In certain conventional electrical connector assemblies a resiliently deformable wire grommet is employed to seal around one or more wires that enter the connector assembly. It may be desirable to provide improved or enhanced sealing around the wires by a wire grommet.

SUMMARY

An inventive connector assembly comprises a substantially rigid front connector body, a substantially rigid rear connector body, a resiliently deformable wire grommet, and a threaded nut. The resiliently deformable wire grommet has a substantially cylindrical outer surface and one or more axial wire passages therethrough. Each wire passage includes two or more wire-sealing segments; each wire-sealing segment is sized and shaped so as to (i) enable a corresponding wire to be inserted through the corresponding wire passage and (ii) form a seal around the corresponding inserted wire. The rear connector body has a rear axial passage therethrough. A front end of the rear axial passage is large enough to receive therein a rearward portion of the grommet without substantial radial compression of the grommet. A rearward-tapered segment of the rear axial passage is structurally arranged so as to receive therein the rearward portion of the grommet, engage the outer surface of the rearward portion of the grommet, and compress radially the rearward portion of the grommet and two or more of the wire-sealing segments of each wire passage therein.

The front connector body has a front axial passage. A rearward portion of the front connector body includes external threads. A forward portion of the front connector body is structurally arranged so as to hold one or more electrical contacts that are each connected to a corresponding wire passing through the rear axial passage and the corresponding wire passage of the grommet. At least portions, including a rearward portion, of the front axial passage are structurally arranged so as to receive therein the grommet without substantial radial compression of the grommet. The nut has a central opening and internal threads. The nut is structurally arranged so as to (i) receive through the central opening a rearward portion of the rear connector body, (ii) obstruct rearward movement of the forward portion of the rear connector body through the central opening, and (iii) engage with the internal threads the external threads of the front connector body. The connector assembly is structurally arranged so that tightening of the nut threadedly engaged on the rearward portion of the front connector body results in forward movement of the nut and the rear connector body toward the front connector body, rearward movement of the rearward portion of the grommet into the tapered segment of the rear axial passage, and radial compression, by the tapered segment of the rear axial passage, of the rearward portion of the grommet and two or more of the wire-sealing segments of each wire passage therein.

A method employing the inventive connector assembly comprises: (a) inserting each one of a set of one or more wires through the wire grommet through a corresponding one of the one or more wire passages; (b) securing one or more corresponding electrical contacts, connected to the forward ends of the wires, to be held by the forward portion of the front connector body; (c) inserting the grommet into the front axial passage; (d) engaging the front and rear connector bodies; (e) threadedly engaging the nut and the front connector body; and (f) tightening of the nut threadedly engaged on the rearward portion of the front connector body, thereby resulting in forward movement of the nut and the rear connector body toward the front connector body, rearward movement of the rearward portion of the grommet into the tapered segment of the rear axial passage, and radial compression, by the tapered segment of the rear axial passage, of the rearward portion of the grommet and two or more of the wire-sealing segments of each wire passage therein.

Objects and advantages pertaining to sealed electrical connector assemblies may become apparent upon referring to the example embodiments illustrated in the drawings and disclosed in the following written description or appended claims.

The embodiments depicted are shown only schematically: all features may not be shown in full detail or in proper proportion, certain features or structures may be exaggerated relative to others for clarity, and the drawings should not be regarded as being to scale. InFIGS. 3-7 and 12-16, cross hatching has been omitted to reduce clutter in the drawings. The embodiments shown are only examples: they should not be construed as limiting the scope of the present disclosure or appended claims.

DETAILED DESCRIPTION OF EMBODIMENTS

A connector assembly (FIGS. 1-7) comprises a substantially rigid front connector body300(FIG. 8); a substantially rigid rear connector body200(FIG. 9); a resiliently deformable wire grommet100(FIG. 10); and a threaded nut400(FIG. 11). The front connector body300, the rear connector body200, and the nut400can each comprise any one or more suitably rigid solid materials, including but not limited to: one or more metals or metal alloys; one or more plastics, resins, or polymers; one or more natural or synthetic fibrous materials; one or more other electrically conductive materials; or one or more other electrical insulating materials.

For purposes of the present disclosure and appended claims, directional terms such a front, forward, rear, rearward, and so forth are defined relative to the connector assembly, with “front” and the like being the direction from the connector assembly toward a mating connector assembly, and “rear” and the like being the opposite direction, i.e., toward one or more wires or a cable connected to the connector assembly. Any motion or movement recited in the disclosure, examples, or claims are relative motions or movements, e.g., forward movement of the rear connector body200toward the front connector body300is equivalent to rearward movement of the front connector body300toward the rear connector body200.

The substantially rigid rear connector body200(also referred to as a connector accessory or as a connector backshell) has a rear axial passage202therethrough; the substantially rigid front connector body300(also referred to as a plug connector body in a plug-type connector assembly, or as a receptacle connector body in a receptacle-type connector assembly) has a front axial passage302. When the connector assembly is connected to one or more wires90(seven wires90in the examples shown; any suitable number of one or more wires can be employed) and assembled, a resiliently deformable wire grommet100is positioned within the front axial passage302and the wires90pass through the rear axial passage202and through corresponding wire passages102of the grommet100. A forward portion of the front connector body300is structurally arranged so as to hold one or more electrical contacts92that are each connected to a corresponding wire90. In the examples shown the electrical contacts92are pin contacts of a bulkhead-mounted receptacle-type connector; in other examples the contacts are socket contacts. Any suitable number (one through 128 or more), type (e.g., pin or socket), or arrangement (e.g., square, rectangular, polygonal, or circular array or arrangement) of the one or more electrical contacts92can be employed in any type of connector assembly (e.g., plug, receptacle, bulkhead-mounted, wall-mounted, or cable-mounted). The wire grommet100serves to isolate the electrical contacts92and the conductive cores of the wires90from a use environment.

Any suitably rigid material can be employed for the front connector body300and the rear connector body200, as noted above. In many example embodiments, the rear connector body200comprises a metal or metal alloy, so that the rear connector body200is electrically conducting and can serve to at least partly electromagnetically shield the one or more wires90passing through the rear axial passage202. If the wires90are contained within a sheath (not shown) rearward of the connector assembly, that sheath can continue around a rearward portion of the rear connector body, if needed or desired. In some examples such a sheath can include conductive sheathing that serves as electromagnetic shielding for the wires90, and electrical continuity can be established between such conductive sheathing and a conductive rear connector body200(e.g., by banding or crimping the conductive sheath onto the rear connector body200). In some examples the sheath can include an outer insulating layer that continues around a rearward portion of the rear connector body200(e.g., plastic or elastomeric shrink tubing applied around the wires90and the rear connector body200).

In many example embodiments, the front connector body300includes one or more metals or metal alloys, which can serve as electrical shielding in a manner similar to that described for the rear connector body200, particularly if both front and rear connector bodies300and200include one or more metals or metal alloys and are in electrical contact with one another. The front connector body typically also includes one or more insulating materials arranged for holding the electrical contacts92in place without introducing unwanted electrical contact between them (i.e., without shorting them). In the example embodiment shown, the front connector body300includes an insulating body308(comprising, e.g., thermoplastic or other suitable insulating material) with wire channels310therethrough. Each wire channel310accommodates a corresponding one of the wires90and has a corresponding one of the electrical contacts92held at its front end. Additional structural members312can be employed to hold the electrical contacts92in place if needed or desired. A front end of the front connector body300can be structurally adapted in any suitable way to engage a mating connector assembly. In the example embodiment shown, the front connector body300includes threads314for engaging a threaded portion of a mating connector (not shown).

When the front and rear connector bodies300and200are assembled, a forward portion of the front connector body200is received in a rearward portion of the front axial passage302. An outer surface of the forward portion of the rear connector body200and the inner surface of the rearward portion of the front axial passage302are structurally adapted so as to effect non-rotatable and longitudinally movable engagement of the front and rear connector bodies300and200. In some examples, the outer surface of the forward portion of the rear connector body200can include a set of one or more longitudinal splines, keys, or grooves, the inner surface of the rearward portion of the front axial passage302can include a set of one or more longitudinal splines, keys, or grooves, and engagement of the splines, keys, or grooves of the front and rear connector bodies300and200effects the non-rotatable and longitudinally movable engagement. In the example embodiment shown, the outer surface of the forward portion of the rear connector body200includes a set of multiple radially outward-extending longitudinal splines206, the inner surface of the rearward portion of the front axial passage302includes a set of multiple radially inward-extending longitudinal splines306, and engagement of the splines306and206of the front and rear connector bodies300and200, respectively, effects the non-rotatable and longitudinally movable engagement. Longitudinal movement enables fully engaged assembly of the connector bodies300and200(discussed further below); non-rotatable engagement prevents twisting of the wire grommet100or wires90by relative rotation of the connector bodies300and200(e.g., induced by tightening the threaded nut400; discussed further below).

The nut400includes a central opening402and internal threads404. The nut400is structurally arranged so as to receive through the central opening402a rearward portion of the rear connector body200and to obstruct rearward movement of the forward portion of the rear connector body200through the central opening402. In the example embodiment shown, an outward circumferential flange208of the rear connector body200is too large to pass an inward circumferential flange406of the nut400; other suitable structural arrangements can be employed. A rearward portion of the front connector body300includes external threads304that engage the internal threads404of the nut400. Tightening of the nut400threadedly engaged on the rearward portion of the front connector body300(via threads304/404) results in forward movement of the nut400and the rear connector body200toward the front connector body300and concomitant forward movement of the non-rotatably engaged forward portion of the rear connector body200into the rearward portion of the front axial passage302. Fully tightening the nut400results in fully engaged assembly of the connector bodies300and200at the forward limit of forward movement of the rear connector body200and the nut400. In some examples, contact between the flange208of the rear connector body200and a rear end of the front connector body300limits the forward movement. In some examples, the connector assembly is structurally arranged so as to enable the non-rotatable and longitudinally movable engagement of the front and rear connector bodies300and200without threaded engagement of the nut400and the front connector body300; once the connector bodies300and200are engaged, the rear connector body200can be moved forward until the threads404of the nut400can engage the threads304of the front connector body300.

The resiliently deformable (i.e., elastically deformable) wire grommet100has a substantially cylindrical outer surface and one or more axial wire passages102therethrough. Each wire passage102includes two or more wire-sealing segments102a(also referred to as glands). Each wire passage102typically also includes an intervening, transversely enlarged, internal chamber102bbetween each adjacent pair of wire-sealing segments102aalong each wire passage102; such enlarged chambers102bcan facilitate insertion of the wires90through the corresponding passages102(e.g., by providing space to accommodate displacement of compressed grommet material from adjacent wire-sealing segments102a) without unduly compromising the sealing of each wire90by the corresponding passage102. Each wire-sealing segment102ais sized and shaped so as to (i) enable a corresponding wire90to be inserted through the corresponding wire passage102and (ii) form a seal around the corresponding inserted wire90. Typically this is achieved by making the wire-sealing segments102aslightly smaller than the thickness of the wire90. Resilient stretching of each wire-sealing segment102aenables the slightly over-sized wire90(and in some examples a wire-containing tube of an insertion/removal tool) to be inserted through the passage102; resilient rebound of each wire-sealing segment102acreates a seal around the corresponding wire90. Exactly how much smaller than the wire thickness are the wire-sealing segments can vary and typically is determined by the properties of the resilient grommet material, the surface characteristics of the wire insulation, the cross-sectional shapes of the wires90and the wire-sealing segments102a(see below), the size of a wire-containing tube of an insertion/removal tool (if employed), the amount of radial compression of the wire grommet by the rear connector body (discussed further below), and the tightness of the seal needed or desired in a given use environment (i.e., to achieve operationally acceptable sealing). Any suitable size differential can be employed that enables insertion of the wires90through the wire passages102and also results in an operationally acceptable seal around the wires90.

Typical resiliently deformable materials for wire grommet100include, but are not limited to: synthetic or natural rubber; silicone or fluorosilicone elastomer; fluorocarbon elastomer (e.g., Viton®); ethylene propylene diene monomer (EPDM) elastomer; neoprene; other resiliently deformable polymer or resin; or other suitable resiliently deformable material. In some example embodiments the grommet100or the front axial passage302can further include a rotational indexing structure (e.g., one or more mating longitudinal grooves, keys, or splines) arranged to permit insertion of the grommet100into the front axial passage302in only one relative orientation about a longitudinal axis; in the example shown the grommet100includes a key104. In some examples, the grommet100can be attached or secured to the front connector body300within the front axial passage302, e.g., by adhesive or a mechanical retaining member such as a snap ring or threaded retaining ring. In other examples, the grommet100is not secured or attached to the front connector body300, but is held in place by the engagement of the front and rear connector bodies300and200with each other.

Any suitable cross-sectional shape can be employed for the wire-sealing segments102a. In some example embodiments each wire-sealing segment102ahas a substantially circular cross section to accommodate a corresponding wire also having a circular cross section. A circular cross section for the wire-sealing segments102acan be employed in some example embodiments with non-circular wires90(e.g., oval or elliptical cross sections), so as to eliminate the need to rotationally orient the non-circular wire90before inserting it into the corresponding wire passage102. In still other example embodiments, non-circular wire-sealing segments102acan be employed having a shape corresponding to a non-circular shape of the wires90, with the wires90being properly oriented before insertion through the wire passages102.

In some instances, resiliency of the grommet100and the size or shape differential between the wire-sealing segments102aand the wires90may not result in a sufficiently good seal around the wires90. Such instances can arise more frequently when non-circular wires90are employed with a grommet100having substantially circular wire-sealing segments102aof the wire passages102. Oval or elliptical wire cross sections arising from current wire manufacturing processes are increasingly common. Poor sealing can also arise with wires having insulation in the form of a spiral-wound tape, which results in a spiral ridge on the outer surface of the wire where each turn of the insulating tape overlaps an adjacent turn. That ridge can provide a path for moisture or other contaminants to enter the connector. It therefore would be desirable to provide enhanced sealing of the wires90by the grommet100.

In the inventive connector assemblies disclosed herein, the front and rear connector bodies300and200are structurally adapted so as to provide, upon fully engaged assembly of the connector assembly, radial compression of the wire grommet100over a substantial fraction of its length, including radial compression of two or more of the wire-sealing segments102a. That radial compression, particularly of two or more of the wire-sealing segments102aof each wire passage102, provides the desired enhanced sealing of the wires90by the grommet100, even when non-circular wires90and circular wire-sealing segments102aare employed, or even when wires90having spiral-wound insulation are employed.

To achieve the inventive arrangement, the front end of the rear axial passage202is large enough to receive therein a rearward portion of the grommet100without substantial radial compression of the grommet100, and the rear axial passage202includes a rearward-tapered segment204(referred to hereafter as the tapered segment204). The tapered segment204of the rear axial passage202is structurally arranged so as to receive therein the rearward portion of the grommet100, engage its outer surface, and compress it radially along with radially compressing two or more of the wire-sealing segments102aof each wire passage102within the grommet100. At least portions, including a rearward portion, of the front axial passage302are structurally arranged so as to receive therein at least the forward portion of the grommet100without substantial radial compression of the grommet100. In some examples (e.g., the embodiment ofFIGS. 1-14), the rearward portion of the front axial passage302is structurally arranged to receive therein a forward portion of the rear connector body200, including the tapered segment204of the rear axial passage202, interposed between the rearward portion of the grommet100and an inner surface of the rearward portion of the front axial passage302. The connector assembly is thus structurally arranged so that tightening the nut400drives the tapered segment204of the axial passage202forward into the rearward portion of the front axial passage302wedged between inner surface of the front axial passage302and the outer surface of the grommet100. The wedge action of the tapered segment204on the outer surface of the grommet100results in radial compression of the rearward portion of the grommet100and two or more of the wire-sealing segments102aof each wire passage102therein. In some examples, three or more wire-sealing segments can be radially compressed by the wedge action, on the outer surface of the grommet100, of the tapered segment204of the rear axial passage202. The non-rotatable engagement of the front and rear connector bodies300and200prevents torsional strain or twisting of the wire grommet100by the engaged tapered segment204as the rear connector body200is driven forward by tightening the nut400. Such twisting or torsional strain can result in various undesirable effects, such as excessive resistance to tightening the nut400, disruption of the sealing of the wire-sealing segments102aaround the wires90, twisting or breakage of the wires90, or structural failure of the wire grommet100.

The grommet100comprises a resiliently deformable material to enable radial compression by the tapered segment204of the rear axial passage202. However, such resilient materials are not necessarily particularly compressible; radial compression of the rearward portion of the grommet100typically causes a portion of the grommet100forward of the compressed portion to bulge outward, i.e., to expand radially. In some examples, a forward portion of the tapered segment204of the rear axial passage202can be structurally arranged so as to accommodate that radial expansion, e.g., by having a radius at its forward end that is larger than the radius of the grommet100in its uncompressed state. In some examples, at the forward limit of the forward movement of the rear connector body200toward the front connector body300, a gap remains at a front end of the rear connector body200that can accommodate the radial expansion of that portion of the grommet100forward of the radially compressed rearward portion of the grommet100. In some of those latter examples, a resilient sealant330can partly fill the gap.

In some examples, the connector assembly further comprises a resilient O-ring340(as inFIGS. 12-14). At the forward limit of the forward movement of the rear connector assembly200, engagement of the O-ring340between the outer surface of the forward portion of the rear connector body200(e.g., just forward of the flange208) and the inner surface of the rear portion of the front axial passage302serves to establish a seal to substantially isolate from the use environment the rear portion of the front axial passage302. The additional seal provided by the O-ring304is in addition to that provided by the grommet100and its radial compression by the tapered segment204of the rear axial passage202. In examples that include splines206/306, the splines typically are arranged or positioned so as not to interfere with sealing provided by the O-ring340.

A method employing an inventive connector assembly, e.g., such as the examples shown inFIGS. 1-14, comprises: (a) inserting each one of a set of one or more wires90through the wire grommet100through a corresponding one of the one or more wire passages102; (b) securing one or more corresponding electrical contacts92, connected to the forward ends of the wires90, to be held by the forward portion of the front connector body300; (c) inserting the grommet100into the front axial passage302; (d) engaging the front and rear connector bodies300and200; (e) threadedly engaging the nut400and the front connector body300; (f) tightening of the nut400threadedly engaged on the rearward portion of the front connector body300, thereby resulting in forward movement of the nut400and the rear connector body200toward the front connector body300, forward movement of the non-rotatably engaged forward portion of the rear connector body200into the rearward portion of the front axial passage302, rearward movement of the rearward portion of the grommet100into the tapered segment204of the rear axial passage202, and radial compression, by the tapered segment204of the rear axial passage202, of the rearward portion of the grommet100and two or more of the wire-sealing segments102aof each wire passage102therein. Typically, but not necessarily, the contacts92are connected to the wires90before the wires90are inserted through the wire grommet100; typically, but not necessarily, the contacts92are connected to the wires90before the contacts92are secured to be held by the front connector body300.

In some examples of such a method, the one or more wires90are inserted through the wire grommet100before inserting the wire grommet100into the front axial passage302. In those instances, the wires90serve to align the wire passages102with corresponding wire passages in the front connector body300. In other examples of such methods, the one or more wires90are inserted through the wire grommet100after inserting the wire grommet100into the front axial passage302. In those instances, an insertion/removal tool is used that comprises a tube arranged (i) to receive therein one of the one or more wires90, (ii) to be inserted along with the wire90through the corresponding one of the one or more wire passages102, and (iii) to be withdrawn from the corresponding wire passage102leaving the wire90within the corresponding wire passage102.

Another example embodiment is shown inFIGS. 15 and 16wherein a rearward portion of the grommet100, including at least two of the wire-sealing segments102aof each wire passage102, protrudes rearward from the front axial passage302. The tapered segment204engages the outer surface of the protruding portion of the grommet100and, as the rear connector body200is driven forward by tightening the nut400, compresses the grommet100radially, including two or more of the wire-sealing segments102aof each wire passage102therein. The connector assembly can be structurally arranged so that the tapered segment204of the rear axial passage202does not enter the front axial passage302as the nut400is tightened and the nut400and the rear connector body200move forward. Alternatively, the connector assembly can be structurally arranged so that the forward movement of the nut400and the rear connector body200toward the front connector body300results in at least partial entry of a forward portion of the rear connector body200and the tapered segment204of the rear axial passage202into the front axial passage302.

A method employing an inventive connector assembly, e.g., such as the examples shown inFIGS. 15 and 16, comprises: (a) inserting each one of a set of one or more wires90through the wire grommet100through a corresponding one of the one or more wire passages102; (b) securing one or more corresponding electrical contacts92, connected to the forward ends of the wires90, to be held by the forward portion of the front connector body300; (c) inserting the grommet100into the front axial passage302, leaving a portion of the grommet100protruding from the front axial passage302rearward beyond a rear end of the front connector body300; (d) threadedly engaging the nut400and the front connector body300; and (e) tightening of the nut400threadedly engaged on the rearward portion of the front connector body300, thereby resulting in forward movement of the nut400and the rear connector body200toward the front connector body300, rearward movement of the protruding portion of the grommet100into the tapered segment204of the rear axial passage202, and radial compression, by the tapered segment204of the rear axial passage202, of at least the protruding portion of the grommet100and two or more of the wire-sealing segments102aof each wire passage102therein. Typically, but not necessarily, the protruding portion of the grommet100is inserted into the tapered segment204of the rear axial passage202, and the rear connector body advanced somewhat toward the front connector body300, before the threads304/404are engaged. As described above, the wires90can be inserted through the grommet100before insertion of the grommet100into the front axial passage302, or, using an insertion/removal tool, after insertion of the grommet100into the front axial passage302.

In addition to the preceding, the following examples fall within the scope of the present disclosure or appended claims:

A connector assembly comprising: (a) a resiliently deformable wire grommet having a substantially cylindrical outer surface and one or more axial wire passages therethrough, wherein each wire passage includes two or more wire-sealing segments and each wire-sealing segment is sized and shaped so as to (i) enable a corresponding wire to be inserted through the corresponding wire passage and (ii) form a seal around the corresponding inserted wire; (b) a substantially rigid rear connector body having a rear axial passage therethrough, wherein (i) a front end of the rear axial passage is large enough to receive therein a rearward portion of the grommet without substantial radial compression of the grommet and (ii) a rearward-tapered segment of the rear axial passage is structurally arranged so as to receive therein the rearward portion of the grommet, engage the outer surface of the rearward portion of the grommet, and compress radially the rearward portion of the grommet and two or more of the wire-sealing segments of each wire passage; (c) a substantially rigid front connector body having a front axial passage, wherein (i) a rearward portion of the front connector body includes external threads; (ii) a forward portion of the front connector body is structurally arranged so as to hold one or more electrical contacts that are each connected to a corresponding wire passing through the rear axial passage and the corresponding wire passage of the grommet, (iii) at least portions, including a rearward portion, of the front axial passage are structurally arranged so as to receive therein the grommet without substantial radial compression of the grommet, and (iv) the rearward portion of the front axial passage is structurally arranged to receive therein a forward portion of the rear connector body, including at least a portion of the tapered segment of the rear axial passage, interposed between the rearward portion of the grommet and an inner surface of the rearward portion of the front axial passage; (d) a nut with a central opening and internal threads, wherein the nut is structurally arranged so as to (i) receive through the central opening a rearward portion of the rear connector body, (ii) obstruct rearward movement of the forward portion of the rear connector body through the central opening, and (iii) engage with the internal threads the external threads of the front connector body, wherein: (e) an outer surface of the forward portion of the rear connector body and the inner surface of the rearward portion of the front axial passage are structurally adapted so as to effect non-rotatable and longitudinally movable engagement of the front and rear connector bodies; (f) the connector assembly is structurally arranged so that tightening of the nut threadedly engaged on the rearward portion of the front connector body results in forward movement of the nut and the rear connector body toward the front connector body, forward movement of the non-rotatably engaged forward portion of the rear connector body into the rearward portion of the front axial passage, rearward movement of the rearward portion of the grommet into the tapered segment of the rear axial passage, and radial compression, by the tapered segment of the rear axial passage, of the rearward portion of the grommet and two or more of the wire-sealing segments of each wire passage therein.

The connector assembly of Example 1 wherein the grommet extends rearward beyond a rear end of the front connector body.

The connector assembly of Example 1 wherein a rear end of the front connector body extends rearward beyond a rear end of the grommet.

Example 4. The connector assembly of any one of Examples 1 through 3 wherein: (i) the outer surface of the forward portion of the rear connector body includes a set of one or more longitudinal splines or grooves, (ii) the inner surface of the rearward portion of the front axial passage includes a set of one or more longitudinal splines or grooves, and (iii) engagement of the splines or grooves of the front and rear connector bodies effects the non-rotatable and longitudinally movable engagement thereof.

The connector assembly of any one of Examples 1 through 4 wherein: (i) the outer surface of the forward portion of the rear connector body includes a set of multiple radially outward-extending longitudinal splines, (ii) the inner surface of the rearward portion of the front axial passage includes a set of multiple radially inward-extending longitudinal splines, and (iii) engagement of the splines of the front and rear connector bodies effects the non-rotatable and longitudinally movable engagement thereof.

The connector assembly of any one of Examples 1 through 5 wherein the connector assembly is structurally arranged so as to enable the non-rotatable and longitudinally movable engagement of the front and rear connector bodies without threaded engagement of the nut and the front connector body.

A connector assembly comprising: (a) a resiliently deformable wire grommet having a substantially cylindrical outer surface and one or more axial wire passages therethrough, wherein each wire passage includes two or more wire-sealing segments and each wire-sealing segment is sized and shaped so as to (i) enable a corresponding wire to be inserted through the corresponding wire passage and (ii) form a seal around the corresponding inserted wire; (b) a substantially rigid rear connector body having a rear axial passage therethrough, wherein (i) a front end of the rear axial passage is large enough to receive therein a rearward portion of the grommet without substantial radial compression of the grommet and (ii) a rearward-tapered segment of the rear axial passage is structurally arranged so as to receive therein the rearward portion of the grommet, engage the outer surface of the rearward portion of the grommet, and compress radially the rearward portion of the grommet and two or more of the wire-sealing segments of each wire passage therein; (c) a substantially rigid front connector body having a front axial passage, wherein (i) a rearward portion of the front connector body includes external threads; (ii) a forward portion of the front connector body is structurally arranged so as to hold one or more electrical contacts that are each connected to a corresponding wire passing through the rear axial passage and the corresponding wire passage of the grommet, and (iii) a rearward portion of the front axial passage is structurally arranged so as to receive therein a forward portion of the grommet without substantial radial compression of the grommet, wherein a portion of the grommet protrudes from the front axial passage rearward beyond a rear end of the front connector body; and (d) a nut with a central opening and internal threads, wherein the nut is structurally arranged so as to (i) receive through the central opening a rearward portion of the rear connector body, (ii) obstruct rearward movement of the forward portion of the rear connector body through the central opening, and (iii) engage with the internal threads the external threads of the front connector body, (e) wherein the connector assembly is structurally arranged so that tightening of the nut threadedly engaged on the rearward portion of the front connector body results in forward movement of the nut and the rear connector body toward the front connector body, rearward movement of the protruding portion of the grommet into the tapered segment of the rear axial passage, and radial compression, by the tapered segment of the rear axial passage, of at least the protruding portion of the grommet and two or more of the wire-sealing segments of each wire passage therein.

The connector assembly of Example 7 wherein the connector assembly is structurally arranged so that the forward movement of the nut and the rear connector body toward the front connector body results in at least partial entry of a forward portion of the rear connector body and the tapered segment of the rear axial passage into the front axial passage.

The connector assembly of Example 7 wherein the connector assembly is structurally arranged so as to substantially prevent entry of any portion of the rear connector body into the front axial passage.

The connector assembly of any one of Examples 1 through 9 wherein each wire passage includes an intervening, transversely enlarged, internal chamber between each adjacent pair of wire-sealing segments along each wire passage.

The connector assembly of any one of Examples 1 through 10 wherein (i) the tapered segment of the rear axial passage is structurally arranged so as to compress radially the rearward portion of the grommet and three or more of the wire-sealing segments of each wire passage and (ii) the connector assembly is structurally arranged so that tightening of the nut results in radial compression of three or more of the wire-sealing segments of each wire passage.

The connector assembly of any one of Examples 1 through 11 wherein the grommet or the front axial passage includes a rotational indexing structure arranged to permit insertion of the grommet into the front axial passage in only one relative orientation about a longitudinal axis.

The connector assembly of any one of Examples 1 through 12 wherein: (i) the outer surface of the grommet includes a set of one or more longitudinal grooves or splines, (ii) the inner surface of the front axial passage includes a set of one or more longitudinal grooves or splines, and (iii) engagement of the grooves or splines of the grommet and the front axial passage are structurally arranged to permit insertion of the grommet into the front axial passage in only one relative orientation about a longitudinal axis.

The connector assembly of any one of Examples 1 through 13 wherein a forward portion of the tapered segment of the rear axial passage is structurally arranged so as to accommodate radial expansion of a portion of the grommet forward of the radially compressed rearward portion of the grommet.

The connector assembly of any one of Examples 1 through 14 wherein the front and rear connector bodies are structurally arranged so that, at a forward limit of the forward movement, a gap remains at a front end of the rear connector body that can accommodate radial expansion of a portion of the grommet forward of the radially compressed rearward portion of the grommet.

The connector assembly of Example 15 wherein a resilient sealant at least partly fills the gap.

The connector assembly of any one of Examples 1 through 16 wherein (i) the rear connector body includes a radially outward-extending circumferential flange and (ii) contact between the flange and a rear end of the front connector body limits the forward movement.

The connector assembly of any one of Examples 1 through 17 further comprising a resilient O-ring, wherein, at a forward limit of the forward movement, engagement of the O-ring between the outer surface of the forward portion of the rear connector body and the inner surface of the rear portion of the front axial passage serves to substantially isolate from a use environment the rear portion of the front axial passage.

A method employing the connector assembly of any one of Examples 1 through 6 or 10 through 18, the method comprising: (a) inserting each one of a set of one or more wires through the wire grommet through a corresponding one of the one or more wire passages; (b) securing one or more corresponding electrical contacts, connected to the forward ends of the one or more wires, to be held by the forward portion of the front connector body; (c) inserting the grommet into the front axial passage; (d) engaging the front and rear connector bodies; (e) threadedly engaging the nut and the front connector body; and (f) tightening of the nut threadedly engaged on the rearward portion of the front connector body, thereby resulting in forward movement of the nut and the rear connector body toward the front connector body, forward movement of the non-rotatably engaged forward portion of the rear connector body into the rearward portion of the front axial passage, rearward movement of the rearward portion of the grommet into the tapered segment of the rear axial passage, and radial compression, by the tapered segment of the rear axial passage, of the rearward portion of the grommet and two or more of the wire-sealing segments of each wire passage therein.

A method employing the connector assembly of any one of Examples 7 through 9, the method comprising: (a) inserting each one of a set of one or more wires through the wire grommet through a corresponding one of the one or more wire passages; (b) securing one or more corresponding electrical contacts, connected to the forward ends of the wires90, to be held by forward portion of the connector body; (c) inserting the grommet partly into the front axial passage, leaving a portion of the grommet protruding from the front axial passage rearward beyond a rear end of the front connector body; (d) threadedly engaging the nut and the front connector body; and (e) tightening of the nut threadedly engaged on the rearward portion of the front connector body, thereby resulting in forward movement of the nut and the rear connector body toward the front connector body, rearward movement of the protruding portion of the grommet into the tapered segment of the rear axial passage, and radial compression, by the tapered segment of the rear axial passage, of at least the protruding portion of the grommet and two or more of the wire-sealing segments of each wire passage therein.

The method of any one of Examples 19 or 20 wherein the one or more corresponding electrical contacts are connected to the one or more wires before the one or more wires are inserted through the wire grommet.

The method of any one of Examples 19 through 21 wherein the one or more wires are inserted through the wire grommet before inserting the wire grommet into the front axial passage.

The method of any one of Examples 19 through 21 wherein the one or more wires are inserted through the wire grommet after inserting the wire grommet into the front axial passage, using an insertion/removal tool that comprises a tube arranged (i) to receive therein one of the one or more wires, (ii) to be inserted along with the wire through the corresponding one of the one or more wire passages, and (iii) to be withdrawn from the corresponding wire passage leaving the wire within the corresponding wire passage.

The method of any one of Examples 19 through 23 wherein each one of the one or more wires has a non-circular transverse cross section.

The method of any one of Examples 19 through 24 wherein each one of the one or more wires has an oval or elliptical cross section.

The method of any one of Examples 19 through 25 wherein each one of the one or more wires includes spiral-wrapped insulation.

The method of any one of Examples 19 through 26 further comprising inserting into a sheath surrounding the set of one or more wires the rearward portion of the rear connector body.

The method of Example 27 wherein the sheath includes electrically conductive sheathing arranged to serve as electromagnetic shielding for the set of one or more wires, the rear connector body comprises an electrically conductive material, and the electrically conductive sheathing is in electrical contact with the rear connector body.

The method of any one of Examples 27 or 28 wherein the sheath includes electrically insulating sheathing.

It is intended that equivalents of the disclosed example embodiments and methods shall fall within the scope of the present disclosure or appended claims. It is intended that the disclosed example embodiments and methods, and equivalents thereof, may be modified while remaining within the scope of the present disclosure or appended claims.

In the foregoing Detailed Description, various features may be grouped together in several example embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that any claimed embodiment requires more features than are expressly recited in the corresponding claim. Rather, as the preceding numbered examples and the appended claims reflect, inventive subject matter may lie in less than all features of a single disclosed example embodiment. Thus, the appended claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate disclosed embodiment. However, the present disclosure shall also be construed as implicitly disclosing any embodiment having any suitable set of one or more disclosed or claimed features (i.e., a set of features that are neither incompatible nor mutually exclusive) that appear in the present disclosure (including the numbered examples) or the appended claims, including those sets that may not be explicitly disclosed herein. In addition, for purposes of disclosure, each of the appended dependent claims shall be construed as if written in multiple dependent form and dependent upon all preceding claims with which it is not inconsistent. It should be further noted that the scope of the appended claims does not necessarily encompass the whole of the subject matter disclosed herein.

For purposes of the present disclosure and appended claims, the conjunction “or” is to be construed inclusively (e.g., “a dog or a cat” would be interpreted as “a dog, or a cat, or both”; e.g., “a dog, a cat, or a mouse” would be interpreted as “a dog, or a cat, or a mouse, or any two, or all three”), unless: (i) it is explicitly stated otherwise, e.g., by use of “either . . . or,” “only one of,” or similar language; or (ii) two or more of the listed alternatives are mutually exclusive within the particular context, in which case “or” would encompass only those combinations involving non-mutually-exclusive alternatives. For purposes of the present disclosure and appended claims, the words “comprising,” “including,” “having,” and variants thereof, wherever they appear, shall be construed as open ended terminology, with the same meaning as if the phrase “at least” were appended after each instance thereof, unless explicitly stated otherwise.

In the appended claims, if the provisions of 35 USC §112(f) are desired to be invoked in an apparatus claim, then the word “means” will appear in that apparatus claim. If those provisions are desired to be invoked in a method claim, the words “a step for” will appear in that method claim. Conversely, if the words “means” or “a step for” do not appear in a claim, then the provisions of 35 USC §112(f) are not intended to be invoked for that claim.

If any one or more disclosures are incorporated herein by reference and such incorporated disclosures conflict in part or whole with, or differ in scope from, the present disclosure, then to the extent of conflict, broader disclosure, or broader definition of terms, the present disclosure controls. If such incorporated disclosures conflict in part or whole with one another, then to the extent of conflict, the later-dated disclosure controls.

The Abstract is provided as required as an aid to those searching for specific subject matter within the patent literature. However, the Abstract is not intended to imply that any elements, features, or limitations recited therein are necessarily encompassed by any particular claim. The scope of subject matter encompassed by each claim shall be determined by the recitation of only that claim.