A microminiature, multi-pin electrical connector for high voltage applications. The connector includes a plug portion including a resilient body member having a plurality of cavities therein, and a receptacle portion having a plurality of extended members. When the plug and receptacle portions are connected, the extended members extend into the cavities to mate terminal means within the cavities and extended portions. The receptacle portion includes means for supporting the extended members while permitting them to move independently relative to one another. Radial and axial compression seals, preferably formed integral with the resilient body member, are provided to seal between the peripheral surface of each cavity and the outer peripheral surface of each extended member, and the base surface of each cavity and the extended end surface of each extended member, respectively. The seals permit the extended members to float and automatically align themselves within their associated cavities to ensure the establishment and maintenance of an effective seal between the walls of the cavities and the extended members. The connector portions include outer metal housings, and the resilient body member includes an integral annular flange for sealing between the housings when the connector portions are connected to provide a substantially fully shielded connector capable of carrying 6 KVDC within a temperature range of about -55.degree. C. to about +125.degree. C. and over a broad range of pressure.

BACKGROUND OF THE INVENTION 
The present invention relates generally to multi-pin electrical connectors 
and, in particular, to microminiature multi-pin connectors for use in 
high-voltage applications. 
Multi-pin electrical connectors are often used in applications which 
require extreme reliability of performance under severe environmental 
conditions. For example, such connectors are frequently incorporated into 
high-voltage electronic circuits within aircraft and must operate reliably 
at up to 6 KVDC or more within a broad temperature and pressure range. In 
addition, because of space and weight limitations, the connectors must be 
as compact and lightweight as possible consistent with maintaining the 
pins electrically isolated from one another. If the pins are not separated 
from one another by a sufficient distance, or otherwise electrically 
isolated from one another, arcing and other losses can occur. 
Commonly assigned U.S. Pat. No. 3,842,393, issued on Oct. 15, 1974, 
discloses a high-voltage microminiature multi-pin connector which can be 
assembled in a package of about one-half inch by one inch. the connector 
includes a receptacle portion and a socket plug portion adapted to be 
connected together to complete electrical circuits through the connector. 
The receptacle portion includes a relatively rigid, plastic body defining 
an outer shroud and a plurality of integral, inner, cylindrical members 
each of which contain a socket terminal. The plug portion includes a hard, 
plastic, outer body having a non-conductive, resilient insert bonded 
thereto. The insert contains a plurality of cylindrical cavities each of 
which contain a pin terminal. 
When the plug and receptacle portions are connected, the cylindrical 
members extend into the cylindrical cavities causing the pin and socket 
terminals to mate to complete electrical connections through the 
connector. 
In the connector disclosed in U.S. Pat. No. 3,842,393, the cavities in the 
resilient insert are formed with peripheral walls of undulating shape to 
define a plurality of integral, resilient O-rings which extend around the 
peripheral walls of the cavities. When the cylindrical members of the 
receptacle portion are extended into the cavities upon connection of the 
connector portions, the O-rings are caused to deform and spread out to 
form spaced, annular, insulating seals between the peripheral walls of the 
cavities and the outer peripheral surfaces of the cylindrical members to 
electrically isolate adjacent terminals from one another and to 
mechanically prevent debris from entering between the cylindrical members 
and the walls of their associated cavities. 
Because the cylindrical members in the connector disclosed in U.S. Pat. No. 
3,842,393 are rigidly connected together, the connector must be 
manufactured within fairly narrow tolerances. Specifically, if one or more 
of the cylindrical members is not accurately aligned with its associated 
cavity, an incomplete seal can result therebetween, preventing effective 
electrical isolation between adjacent terminals. Also, even slight 
misalignment can cause substantial rubbing between a cylindrical member 
and the walls of its associated cavity each time that the connector is 
connected or pulled apart. The resulting friction can rapidly deteriorate 
the resilient walls of the cavities, greatly reducing the life span of the 
connector. 
Also, the connector of U.S. Pat. No. 3,842,393 is unshielded; and there are 
many applications in which a shielded connector is necessary or preferred 
for added strength and reliability. 
SUMMARY OF THE INVENTION 
In accordance with the present invention, a multi-pin electrical connector 
is disclosed which comprises a first connector portion or plug and a 
second connector portion or receptacle. Each connector portion comprises a 
sub-assembly including electrical terminals attached to electrical 
conductor means sealingly positioned within dielectric means, the 
subassembly being disposed in housing means. 
The plug portion includes means defining a plurality of cavities in the 
dielectric means, each of the plurality of cavities containing an 
electrical terminal. The receptacle portion which is adapted to be 
connected to the plug portion includes a plurality of extended members 
positioned to extend into the plurality of cavities when the first and 
second connector portions are connected. Each of the plurality of extended 
members contain a terminal to be mated with the terminals in the cavities 
when the extended members extend into the cavities. The receptacle portion 
further includes means for supporting the plurality of extended members 
while permitting the extended members to move independently relative to 
one another, and sealing means for sealing between each extended member 
and its associated cavity when the extended members extend into the 
cavities. 
With the present invention, each extended member is capable of moving 
independently of every other extended member in the receptacle portion. 
Accordingly, when the plug and receptacle portions are connected, each 
extended member will automatically move to properly align itself within 
its associated cavity to ensure that a complete and effective seal will be 
established between each extended member and the walls of its associated 
cavity. This will ensure that all adjacent terminals will be properly 
electrically isolated from one another and that the space between each 
extended member and the walls of its associated cavity will be properly 
mechanically sealed at all times to prevent voltage breakdown and also 
prevent dust or other debris from entering therebetween. 
Also, because the extended members are movable within their respective 
cavities, friction between each extended member and the walls of its 
associated cavity when the connector portions are connected or pulled 
apart will be minimized, thus reducing wear of the resilient walls of the 
cavities and extending the useful life of the connector. 
In addition, because the extended portions automatically align themselves 
within their respective cavities, the connector can be manufactured within 
somewhat reduced tolerance requirements, resulting in fewer rejects and 
lower manufacturing costs. 
In accordance with a presently preferred embodiment, each extended member 
comprises a separate cylindrical member adapted to extend into cylindrical 
cavities in the plug connector portion. The receptacle portion further 
includes a retaining member having a plurality of slots for receiving and 
retaining a plurality of flexible conductor wires which extend into the 
receptacle portion and are electrically connected to the terminals 
contained in the cylindrical members. By retaining the conductor wires, 
the cylindrical members are prevented from moving longitudinally within 
the receptacle portion, but are otherwise free to move independently 
relative to one another to establish and maintain proper alignment within 
its associated cavity. 
In accordance with a further aspect of the invention, the sealing means 
between each extended member and the walls of its associated cavity 
includes both a radial seal to seal between the peripheral walls of the 
cavities and the outer peripheral surfaces of the extended members and an 
axial compression seal to seal between the base surfaces of the cavities 
and the extended end surfaces of the extended members. The use of both 
radial seals and axial compression seals between each extended member and 
the walls of its associated cavity permits the extended members to 
essentially float within their respective cavities surrounded by the 
resilient sealing structure, resulting in a connector that is safe and 
reliable under even severe environmental conditions. 
According to a presently preferred embodiment of the invention, the 
cavities are formed within a resilient dielectric body membere which is 
insert molded around the pin terminals. The radial seal comprises a 
plurality of resilient sealing portions that function as O-rings formed 
integral with the body member and extending around the periphery of each 
cavity at spaced locations thereon. The axial compression seal comprises 
an annular seal also formed integral with the first dielectric body member 
and extending from the base surface of each cavity and surrounding a 
portion of the pin terminal. 
According to a further aspect of the invention, both the first and second 
housing portions of the two subassemblies include a metal housing which 
surrounds the dielectric body means portions and which substantially 
encloses the connector when the plug and receptacle portions are connected 
to provide shielding and increased strength to the connector. The 
resilient first dielectric body member includes an integral, annular, 
sealing flange positioned to seal between the housings of the two 
connector portions when they are connected together. 
In general, the present invention provides a microminiature multi-pin 
electrical connector suitable for use in high-voltage applications of 6 
KVDC or more and capable of operating reliably and safety throughout a 
temperature range of from -55.degree. C. to 125.degree. C. and over a 
broad range of pressure. The connector maintains effective isolation 
between adjacent terminals at all times, prevents voltage breakdown, and 
does not require the use of potting materials, as commonly required in 
such connectors. In addition, the connector is substantially fully 
shielded by an outer metal housing without any increase in the size of the 
connector as compared to the unshielded connector disclosed in U.S. Pat. 
No. 3,842,393. The connector of the present invention is also fully 
interchangeable with the connector in U.S. Pat. No. 3,842,393. 
Further advantages and specific features of the invention will become 
apparent hereinafter in the following detailed description of a presently 
preferred embodiment taken in conjunction with the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
FIGS. 1 to 8 illustrate a high-voltage, microminiature, multi-pin, 
electrical connector according to a presently preferred embodiment of the 
invention. The connector is generally designated by reference numeral 10 
and, as best shown in FIG. 1, comprises a first connector or plug portion 
11 and a second connector or receptacle portion 12 adapted to be connected 
together to complete electrical circuits through the connector. 
Plug portion 11 is illustrated in greater detail in FIGS. 2, 4 and 6, and 
comprises a rigid outer housing or shell 16 surrounding a relatively 
resilient, subassembly 17. Subassembly 17 is comprised of a dielectric 
body member 17a having a plurality of cavities 18 therein, which extend 
rearwardly from front face 19. Subassembly 17 further has a like plurality 
of electrical pin terminals 23 terminated to electrical conductor wires 22 
sealingly positioned within body member 17a with one end 23c of each 
terminal 23 extending into an associated cavity 18 as shown in FIG. 4. 
Conductor wires 22 preferably comprise Teflon- or silicone-insulated 
wires. As will be explained more fully hereinafter, cavities 18 are 
substantially cylindrical in shape and are sized to receive a plurality of 
cylindrical members 52a of the receptacle portion 12 of the connector upon 
connection of the plug and receptacle portions. 
Connector body 17a comprises a resilient, readily deformable body member of 
plastic or rubber; and a presently preferred material for connector body 
17a comprises a silicone. Rigid housing 16 comprises a metal housing to 
provide shielding and strength to the connector 10. Anyone of a number of 
metals as known in the art may be used for the housing depending, inter 
alia, upon the environmental conditions to which the connector will be 
subjected and cost factors. 
Subassembly 17a, the terminals 23, and their associated conductors are 
assembled as an integral unit to form subassembly 17. A presently 
preferred method for manufacturing plug portion 11 comprises first 
crimping, soldering or otherwise attaching the terminals 23 having wire 
barrel portions 23a to the ends of the conductor wires 22 and placing the 
conductor wires 22 and attached pin terminals 23 into a mold. The material 
to form connector body 17a is then introduced into the mold; and connector 
body 17a is insert molded around the ends of conductor wires 22, and a 
portion of terminals 23, to seal and bond body member 17a to the wire and 
terminal portions contained therein. Subassembly 17 is then placed into 
metal housing 16 and bonded to the inside surface of the housing by a 
suitable bonding material that is compatable with the dielectric mold 
material and metal. Ferrules 23a preferably have an enlarged portion 23b 
which provides both retention means and strain relief means for the 
connector. The conductor wires 22 extend rearwardly from rear face 21 of 
subassembly 17 and through opening 16a in the end of housing 16, as shown 
in FIGS. 6 and 8. 
Receptacle portion 12 of connector 10 is illustrated in greater detail in 
FIGS. 3, 5 and 7, and comprises a rigid outer housing or shell 51 having a 
plurality of separate, cylindrical-shaped subassembly members 52 extending 
longitudinally and supported within housing 51. Each cylindrical 
subassembly member 52 further has a socket terminal 58 terminated to an 
end of electrical conductor wire 57, said terminal 58 and end of wire 57 
being sealingly positioned within cylindrical member 52. Conductor wire 57 
extends rearwardly from rear face 56 of cylindrical member 52. Socket 
terminals 58 are adapted to receive pin terminals 23 on the plug portion 
11 to complete electrical circuits through the connector when plug and 
receptacle portions 11 and 12 are connected together. 
As indicated in FIG. 3, cylindrical subassembly members 52 are supported 
for independent movement within receptacle portion 12 by a retaining 
fixture 59 which comprises a rectangular-shaped member having a plurality 
of slots 61 formed therein. Slots 61 preferably include chamfered portions 
61a, as best shown in FIG. 3; and conductor wires 57 are adapted to be 
inserted into and to be retained within slot portions 61, as shown in 
FIGS. 5 and 7. 
Cylindrical subassembly members 52 are formed of a plastic material having 
substantially the same coefficient of expansion as the material of 
resilient body member 17a of plug portion 11; and a presently preferred 
material for members 52 comprises silicone. Housing 51 comprises a metal 
housing and is preferably formed of the same material as housing 16 of 
plug portion 11. As best shown in FIG. 5, housing 51 is formed to define a 
first portion 51a into which the ends of cylindrical members 52 extend and 
which is adapted to receive plug portion 11, a second portion 51b 
comprising an integrally formed transverse wall having a plurality of 
passageways 60 through which the cylindrical members 52 extend, and a 
third portion 51c for receiving retaining fixture 59 and a housing cover 
portion 63, as will be described hereinafter. Retaining fixture 59 may 
conveniently be formed of a suitable thermosetting plastic such as a 
flame-retardant, glass-reinforced, polyester material. Conductor wires 57 
preferably comprise Teflon- or silicone-insulated wires similar to 
conductor wires 22 in plug portion 11. 
To manufacture receptacle portion 12, the ends of conductor wires 57 are 
first crimped, soldered, or otherwise attached to socket terminals 58. 
Typically these terminals have a wire barrel section 58a with strain 
relief and retention means 58b. Each terminal 58 with its attached wire 57 
is placed into a mold cavity. The dielectric material to form cylindrical 
subassembly member 52 is introduced into the mold and individual 
cylindrical members 52 are insert molded around terminal 58 and wire 57 to 
seal and bind the dielectric material to the terminal and wire portion 
contained therein. The individual cylindrical subassembly members 52, 
containing terminals 58 with wire 57 attached, are then inserted into 
passageways 60 of second portion 51b (FIG. 5) in metal housing 51. The 
wires 57 are then positioned in the slot portions 61a of the retaining 
fixture 59, and the retaining fixture 59 is inserted through the back open 
end 62 of housing 51. A metal housing cover portion 63 is then pushed into 
the open end 62 of housing 51 and soldered or otherwise attached to the 
housing 51 to complete the receptacle portion 12. Alternatively wires 57 
with cylindrical members attached may be inserted into retaining member 59 
and the fixture containing the wires may be inserted into open end 62 of 
housing 51. 
As shown in FIG. 3, housing cover portion 63 defines an opening 63a on one 
side thereof through which the conductor wires 57 extend into the 
receptacle portion 12. Although in the embodiment illustrated, housing 
cover portion 63 is designed for right angle entry of the conductor wires 
57, housing cover portion 63 can be designed for axial wire entry if 
desired or required for the particular application in which the connector 
10 is to be used. 
Housing cover portion 63 also includes a portion 63b which is adapted to 
extend into housing 51 when the cover portion is mounted to the housing 
51. Portion 63b is adapted to contact retaining fixture 59 and push it 
forward against end surfaces 56 of cylindrical members 52 until fixture 59 
rests against shoulder 64 on housing 51 (FIG. 5). This causes the 
retaining fixture 59 to be firmly locked in position within housing 51. 
FIG. 8 illustrates the plug and receptacle portions 11 and 12 of connector 
10 connected together. Plug 11 is inserted into socket-receiving porion 
51a of receptacle portion 12 as shown. This causes cylindrical members 52 
to enter into aligned cylindrical cavities 18 in plug portion 11, which, 
in turn, causes pin terminals 23 to extend into socket terminals 58 to 
complete electrical circuits through the connector 10. 
As best shown in FIGS. 4 and 6, resilient connector body 17a of plug 
portion 11 is molded to define an undulating surface on the peripheral 
walls of each of the cylindrical cavities 18. More particularly, the 
peripheral walls defining each cavity comprise an undulating surface 
having three, spaced, rounded, sealing portions 31 that function as 
O-rings which extend around the peripheral walls of cavities 18 and are 
integral with resilient connector body 17a. In addition, connector body 
17a is molded to define annular raised portions 32 which are also integral 
with connector body 17a and extend upwardly from the base surface 33 of 
each cavity 18 and surround a portion of each of the terminals 23. 
Sealing portions 31 function as radial seals when the cylindrical 
subassembly members 52 are inserted into cylindrical cavities 18 to seal 
between the peripheral walls of the cavities and the outer peripheral 
surfaces 52a of the cylindrical members 52. Annular raised portions 32 
function as axial compression seals to seal between the base surfaces 33 
of the cavities and the extended end surfaces 54 of the cylindrical 
members 52. This is illustrated most clearly in FIG. 8. 
Cylindrical members 52 have a diameter which is slightly greater than the 
diameter of the cavities through sealing portions 31. Accordingly, when 
the relatively stiff, cylindrical members 52 are inserted into cavities 
18, resilient sealing portions 31 will deform and spread out and form a 
plurality of spaced, annular seals of insulating material between the 
peripheral walls of the cavities and outer peripheral surfaces 52a of 
cylindrical members 52. These seals function as non-conductive barriers 
between adjacent terminals and as mechanical seals to prevent voltage 
breakdown and also to prevent dirt, moisture and other contamination from 
entering into the spaces between the cylindrical members 52 and the walls 
of their associated cavities. The sealing portions 31 thus help prevent 
arcing or other current flow between adjacent terminals. The diameter of 
sealing portions 31 can be progressively smaller from the rearward one to 
the forward one to reduce the mating forces between sealing portions 31 
and cylindrical members 52, but still provide effective sealing 
therebetween. 
In addition, the extended end surfaces 54 of the cylindrical members 52 
will press against and deform the flexible, annular, raised portions 32 on 
the base surfaces 33 of cavities, causing raised portions 32 to also 
spread out to provide an effective seal between surfaces 33 and 52 to 
further prevent voltage breakdown at reduced pressure and the entry of 
dust, moisture or other debris. 
Resilient connector body 17a is formed to also include an integral, annular 
flange 36 extending outwardly from adjacent front face 19 thereof as best 
seen in FIGS. 2, 4 and 8. Flange 36 is adapted to extend between metal 
housings 16 and 51 of plug and receptacle portions 11 and 12, 
respectively, to effectively seal between housing members 16, 51 when the 
connector 10 is assembled and to prevent entry of contaminants into the 
connector. 
The metal housing will further completely surround the connector and 
provide effective shielding and strength to the connector. 
When plug and receptacle portions 11 and 12 are connected each cylindrical 
member 52 will extend into its associated cavity 18 to cause, in turn, 
terminals 23 and 58 to mate to complete electrical circuits through the 
connector. Because cylindrical members 52 are independently movable within 
receptacle portion 12, each member 52 will automatically align itself 
within its associated cavity 18 when the connector portions 11, 12 are 
connected. This self-aligning capability provides increased assurance that 
a complete and effective mechanical seal will be established and 
maintained between each cylindrical member 52 and the walls of its 
associated cavity, resulting in a more reliable connector. This 
self-aligning capability permits cylindrical members 52 to correct for any 
slight misalignment that might exist between one or more of the 
cylindrical members and its associated cavity. Thus, the connector can be 
made to somewhat less exacting tolerances than prior connectors, resulting 
in reduced manufacturing costs. 
In addition, because the cylindrical members 52 are movable within their 
respective cavities, there will be less friction between the cylindrical 
members 52 and the walls of the cavities when connector portions 11, 12 
are connected together or pulled apart. This results in reduced wear of 
the resilient walls of the cavities 18 and an increased useful life 
expectancy for the connector system. 
With the present invention, each cylindrical 52 member essentially floats 
within its associated cavity 18 substantially fully surrounded by the 
resilient radial and axial compression seals 31 and 32. Each mated 
terminal pair, therefore, can be more effectively and reliably 
electrically isolated from adjacent mated terminals. This isolation can be 
effectively maintained despite any slight relative movement of the 
connector portions as a result of thermal expansion that may be 
encountered during use of the connector. 
The shielded connector 10 of the present invention can be assembled in a 
package of about one-half inch by one inch, essentially the same size as 
the unshielded connector disclosed in U.S. Pat. No. 3,842,393, and is 
fully interchangeable with the unshielded connector. The sealing structure 
provided is effective in isolating the terminals from one another to 
prevent voltage breakdown, arcing or other losses therebetween and does 
not require the use of potting materials as in many prior connectors. The 
connector 10 is particularly designed for use in high-voltage applications 
and can reliably carry 6 KVDC throughout a temperature range of from about 
-55.degree. C. to about +125.degree. C. and over a broad range of 
pressure. 
While what has been described constitutes a presently preferred embodiment, 
it should be understood that the connector can be varied in numerous ways 
without departing from the invention. For example, although a six-pin 
connector is described and illustrated, connectors having different 
numbers of pins and different pin placements could also be provided if 
desired. Accordingly, it should be understood that the invention is to be 
limited only insofar as is required by the scope of the following claims.