PRESSURIZED ELECTRICAL CONNECTOR AND METHOD OF ASSEMBLY

Abstract: An electrical connector capable of withstanding a predetermined pressure differential without leakage and a predetermined axial load without dislocation of insert assemblies from their normal position in the connector shell is disclosed. The connector includes one insert assembly which may be a pin or socket insert assembly and an other insert assembly which is a socket insert assembly. The one and the other insert assemblies include contacts arranged in "piggy-back" relation. The one insert assembly is ring staked to the connector shell and the socket insert assembly is bonded to a grommet and sealed in the shell.

Description: This invention relates to pressurized electrical connectors of the type including pin and socket insert assemblies having captivated "piggy-back" contacts. Electrical connectors are used in applications where they must withstand, for example, a pressure differential of 350 N/m² (fifty p.s.i). Moreover, these connectors must be capable of withstanding significant axial loads without their pin and socket inserts being dislocated from their normal position in the connector shell. The present invention accomplishes the above by providing a bonded and sealed connector with crimp removable contacts. A front insert assembly and contacts are fully staked and bonded in place. A rear insert assembly is retained and bonded in place with crimp removable contacts. Appropriate static loading and leak testing have shown that connectors so constructed meet the aforenoted pressure and loading requirements. SUMMARY OF THE INVENTION This invention contemplates a pressurized electrical connector and method of assembly, including a first pin or socket insert assembly and a second socket insert assembly having captivated internal contacts disposed in "piggy-back" relation, i.e. the contacts of the first insert assembly disposed above the contacts of the second insert assembly. The first insert assembly is ring-staked to the connector shell and the second insert assembly is bonded to a connector grommet and then sealed in the shell. Accordingly, the invention describes and claims an electrical connector and method of assembly comprising a first insert assembly having captivated internal contacts; a second insert assembly having captivated internal contacts; the contacts of the first insert assembly disposed above the contacts of the second insert assembly; a connector shell; an internal ring stake undercut carried by the shell; a ring arranged with the first and second insert assemblies; said ring being in cooperative arrangement with said shell undercut for enabling the first insert assembly to be ring-staked to the shell; a connector grommet; means for bonding the second insert assembly to the grommet; and means for staking and sealing the second insert assembly to the shell. BRIEF DESCRIPTION OF THE DRAWING Figure 1 is a diagrammatic, partially sectioned plan view showing first and second insert assemblies according to the invention. Figure 2 is a diagrammatic, partially sectioned plan view showing a connector shell according to the invention. Figure 3 is an enlarged diagrammatic representation showing a section of Figure 2. Figure 4 is a diagrammatic, partially sectioned plan view showing the structural relationship of the first insert assembly, the second insert assembly and the shell according to the invention. Figure 5 is a diagrammatic, partially sectioned, cut-away plan view of the connector of the invention. DETAILED DESCRIPTION OF THE INVENTION With reference to the drawing, and with particular reference first to Figure 1, a pin insert assembly 2 has contacts 2A and a socket insert assembly 4 has contacts 4A. It will be understood that although insert assembly 2 is shown and described for purposes of illustration as a pin insert assembly, it could be a socket insert assembly and would satisfy the intent of the invention as well. Contacts 2A are disposed above contacts 4A in "piggy-back" fashion as will be discerned from the drawing and the description to follow. Pin insert assembly 2 includes a key 6 and socket insert assembly 4 includes a key 8. A rubber grommet 10 is disposed near the tail end of the insert assemblies. A metal ring 12 having a split 14 is disposed ahead of grommet 10. With reference to Figures 2 and 3, a connector shell is designated by the numeral 16. As best shown in Figure 3 shell 16 has an internal ring stake undercut 18, whereby pin insert assembly 2 is ring-staked to shell 16 via ring 12. With further reference to Figure 3, shell 16 has an internal circumferential surface 20 to which a suitable sealant adhesive is applied to provide a seal between pin insert assembly 2 and shell 16. Alternately, the sealant adhesive may be applied to an external circumferential area 22 of pin insert assembly 2 shown in Figure 1. With reference again to Figure 1, pin and socket contacts 2A and 4A are assemblied to pin insert assembly 2 and socket insert assembly 4, respectively, so as to be captivated therein, as will be understood by those skilled in the art. Contacts 2A are unremovable and contacts 4A are removable. Care must be taken during this assembly not to contaminate any adhesive coated surfaces. Further no lubricant is required, nor is a lubricant to be used. Any adhesive that is to be used must not enter metal ring stake undercut 18 (Figure 3), as will be appreciated by those skilled in the art. Ring 12 is assembled to insert assembly 2 (Figure 1). The position of split 14 of ring 12 must not be positioned behind either of the insert keys 6 and 8. The assembly so provided is assembled into shell 16 (see Figure 4), making sure that the assembly is seated and retained against a shoulder 24 of shell 16 and that insert keys 6 and 8 are aligned with corresponding shell keyways 6A and 8A, respectively. Pressure is applied to ring 12 to insure that the assembly is fully seated, and for this purpose ring 12 may be of a sufficiently deformable grade of aluminum or some other like metal so as to be deformed as shown in Figure 4 to accomplish said seating and retention. With reference to Figure 5, socket insert assembly 4 is positioned on grommet 10 to create the aforenoted "piggy-back" relation. A retaining ring 26 holds insert assembly 4 in place. A sufficient sealant adhesive 28 is applied between shell 16 and insert assembly 4 to provide a seal between the shell and the insert assembly. Care must be exercised to ensure that the adhesive sealant does not interfere with the assembly of accessories, as might otherwise be the case. With the connector of the invention configured and assembled as described, a connector is provided which will withstand predetermined axial loads without insert assemblies 2 and 4 being dislocated from their normal positions within shell 16, and the connector will be leak tight while sustaining a predetermined pressure differential. It will be understood that in assembling the disclosed connector, conventional procedures well known in the art should be followed. That is to say, prior to assembly all components should be cleaned in the vapor phase of a suitable solvent, with excess solvent blown dry with air from an oil-free air source. The insert assemblies should be properly treated and the adhesive sealant must be applied within a prescribed interval after said treatment. Excess adhesive sealant must be removed with a suitable solvent, and appropriate curing procedures should be followed. With the aforegoing description of the invention in mind reference is made to the claims appended hereto for a definition of the scope of the invention.

Claims: An electrical connector,characterized by: a first insert assembly (2) having unremovable captivated internal contacts (24); a second insert assembly (4) having removable captivated internal contacts (4A); the contacts (2A) of the first insert assembly disposed above the contacts (4A) of the second insert assembly; a connector shell (16); an internal ring stake undercut (18) carried by the shell; a ring (12) arranged with the first and second insert assemblies; said ring (12) being in cooperative arrangement with said shell undercut (18) for enabling the first insert assembly to be ring staked to the shell; a connector grommet (10); means for bonding the second insert (4) assembly to the grommet (10); and, means (28) for sealing the second insert assembly to the shell. An electrical connector as claimed in claim 1, wherein said ring (12) is in cooperative relation with said shell (16) and the connector is further characterized in that said ring is made of a deformable material; and in that upon pressure being applied to said ring, said ring is deformed to be fully seated in said shell undercut (18) and against a shell shoulder (24). An electrical connector claimed in claim 1 or 2 characterized in that the second insert assembly (4) is positioned on the grommet (10) for bonding thereto; and by retaining ring (26) for holding the second inset assembly in position on the grommet; and means (28) disposed between the shell (16) and the second insert assembly (4) to provide a seal therebetween. An electrical connector claimed in claim 3 characterized in that the means (28) disposed between the shell (16) and the second insert assembly (4) to provide a seal therebetween is a sealant adhesive. An electrical connector as claimed in any previous claim characterized in that said shell (16) has an internal circumferential surface (20) for receiving a sealant adhesive whereby a seal is provided between the first insert assembly (2) and the shell (16). An electrical connector as claimed in any previous claim characterized in that the first insert assembly (2) has an external circumferential surface (22) for receiving a sealant adhesive, whereby a seal is provided between said first insert assembly (2) and the shell (16). A method for assembling an electrical connector as claimed in claims 1 through 6, characterized by the steps of: disposing one insert assembly of a pin insert assembly (2) and a socket insert assembly and having captivated unremovable contacts above a socket insert assembly (4) having captivated removable contacts (4A); providing a connector shell (16) having an internal ring stake undercut (18) therein; arranging a ring (12) with the one and the socket insert assemblies (2, 4) and with the connector shell (16) for enabling the one insert assembly (2) to be ring staked to the shell (16); bonding the socket insert assembly (4) to a connector grommet (10); and sealing the socket insert assembly in the shell (16). A method as described by claim 7 characterized in that the step of arranging a ring (12) with the one and the socket insert assemblies (2, 4) and with the connector shell (16) includes deforming the ring (12) to fully seat the ring in an internal ring stake undercut (18) carried by the shell (16). A method as described by claims 7 or 8 characterized by: positioning the socket insert assembly (4) on the grommet (10) for bonding said insert assembly (4) to said grommet; retaining the socket insert assembly (4) in position on the grommet (10); and providing a seal between the shell (16) and the socket insert assembly (4). A method as described by claims 7, 8 or 9 characterized by providing an internal circumferential surface (20) on the shell (16) for receiving a sealant adhesive for providing a seal between the one insert assembly (2) and the shell; and providing an external surface (22) on the one insert assembly for receiving a sealant adhesive for providing a seal between the one insert assembly (2) and the shell (16).

Inventors: GALLUSSER, DAVID O., PUNAKO, STEPHEN, WILLIAMS, WARREN R., JR.
Applicants: AMPHENOL CORPORATION
Application year: 1988
Main classification: H01R13
IPC codes: H01R13