Data current coupler

Abstract: A data coupler assembly (30) provides an improved electromagnet insert (52) having conductive wires (22A,22B) positioned within arcuate channels formed along with the electromagnet insert. Sealing means to position and seal the conductor wires to the assembly are included. Improved electromagnetic shielding by using metallic plating on the upper member of the coupler assembly provides effective, but lightweight, EMF/RFI protection. A rugged resilient spring means improves the formation of an electromagnetic core by biasing the electromagnet insert (52), and thereby biasing together each electromagnet pair to form electromagnet cores having a minimal air gap. A quick-action panel mounting means secures the coupler assembly to a panel (42), and improved aligning means precisely secures the upper member of the coupler assembly to the lower member.

Description: The present invention relates to the field of electrical connectors and more particularly to noninvasive coupler assemblies and component parts thereof, useful for sensing and transmitting electrical signals from conductor wires of a twisted pair cable of a data bus. U.S. Patent No. 4,904,879 describes a data current coupler/assembly, and method of making and assembling the coupler, for receiving signals from conductor wires of a twisted pair of a data bus and transmitting signals therealong. The coupler assembly noninvasively couples the data bus to the conductor wires by using mating pairs of E-shaped electromagnets having windings about central legs of the magnets which are electrically connected to a control unit to sense and transmit signals along the data bus. A lower member, having a cavity to receive conductor wires of the data bus positioned adjacent to the lower electromagnets, is mounted to a panel. An upper member with upper electromagnets includes a circuit substrate having trace windings about substrate apertures, an electronic subassembly to which the windings are electrically connected to amplify transmitted and received signals, and a shielded electrical connector secured at a connector end connected to circuits of the electronic subassembly and matable with a connector of a cable extending to the control unit. The upper member is releasable connected to the upper member via a fastening means and securing means. U.S. Patent No. 4,264,827 discloses a method of sensing the transmission of low-level signal current through an electrical conductor without an electrical connection to the conductor, using a continuous closed loop conductor wire extending from a current source with coils of the conductor looped around electromagnetic coil articles connected to electronic devices, which arrangement senses changes in the electromagnetic field established by the current. The arrangement can be repeated at a plurality of locations spaced along the conductor with minimal effect to the signal transmission, and can allow signaling of a plurality of electronic devices in response to the signal current passing through the conductor. Such a current sensing system is desired to be placed aboard aircraft for use with black boxes and other electronic control units, as is disclosed in Proposed ARINC Standard 629 presently being considered by the Airlines Electronic Engineering Committee (AEEC) of Aeronautical Radio, Inc. (ARINC) of Annapolis, MD, and AEEC Letters Nos. 87-094/SAI-309, 87-122/SAI-313, and 88-077/SAI-331. Such a system may also be used in other environments where it is desired that a single closed loop data bus be used. The couplers above provide important advantages in operation and assembly. Nevertheless, none of these couplers uses an improved electromagnet structure to provide improved coupler performance including an improved conductive wire positioning within the wire channels along with electromagnet insert having sealing means to position and seal the conductor wires to the assembly, improved electromagnetic interference ("EMI") shielding using metallic plating on the upper member rather than a separate shield member, a rugged electromagnet biasing means to improve formation of an electromagnetic core, a quick action panel mounting means, and improved aligning means to secure the upper member to the lower member. It is desired to devise an improved noninvasive coupler assembly for sensing and transmitting electrical signals from a twisted pair of a data bus, and a method of assembly of such a coupler assembly, which provides these important advantages. It is an objective of the present invention to provide an improved electromagnet core for a coupler assembly to minimize the dissipation of the strength of signals passing through the data bus system and not interfere with the integrity of the signals through impedance during long term use. It is a further objective to provide an improved shielding which protects the components of a data current coupler from EMI/RFI without a separate shield member. It is yet a further objective to provide such a coupler housing which physically protects and seals the conductor wires to the coupler assembly over long-term in-service use. It is another objective to provide a coupler housing which is easy to assemble on a panel, connected to a data bus system, disassembled therefrom, and removed from the panel. It is another objective of the invention to provide improved aligning means to secure the upper member of the coupler to the lower means. The present invention consists in a coupler assembly as defined in claim 1. WO-A-90/03697 discloses a coupler assembly according to the preamble of claim 1. According to an embodiment of the invention, the coupler assembly includes a lower member to which is secured an upper member forming an assembly for noninvasive coupling to a twisted pair of signal conductor wires of a closed loop data bus to read signals being transmitted therealong by a series of electromagnet cores interlaced with loops of the twisted pair. The electromagnet cores comprise opposing electromagnets positioned in each member and disposed within one or the other of the upper and lower members. Opposing end faces of the legs of the electromagnetic magnets, which may be E-shaped, engage each other preferably under slight compression by a resilient spring means. Portions of the conductor wires of the twisted pair are placed at a selected location therealong in formed arcuate channels extending around the central leg of the permanent magnets in the lower member, and upon the upper member then being secured to the lower member. The coupler assembly also can either transmit and amplify signals therealong by generating an appropriate electromotive force via an electromagnetic field, and also receive and therefor verify the signal it transmits. Embedded within the dielectric material covering the upper member is a circuit substrate, including electrical components and at least a plurality of layers of trace windings about the center legs of the electromagnets and electrically connected to the electrical components. In turn, the electrical components are electrically connectable at an electrical connector of the upper member with a cable assembly which extends to a corresponding control unit, with the control unit providing electrical power to the electrical components as well as signal and ground connection. The upper member includes shielding formed by metallic plating on the inner surface of the upper member completely around the electronic subassembly and the connections thereof with the connector interface for EMI/RFI protection, which is then covered by an insulative covering. In accordance with one embodiment of the present invention, an alignment means is provided to precisely align the upper coupler member with the lower member upon mating. Pivot pins of the lower member at the connector end of the coupler are disposed within elbow slots of the upper member and pivot therewithin. A projection of the upper member near the upper electromagnets during pivoting enters a corresponding recess of the lower member closely corresponding in shape and dimension thereto and incrementally adjusts the alignment of the upper member essentially at a single point spaced from the pivot point; the projection and recess define reference datums of the upper and lower members respectively. Preferably, an electromagnet insert for a data coupler comprises a dielectric member defining positions for at least one electromagnet with mating faces exposed in one direction in a planar surface. The electromagnet insert includes wire-receiving arcuate channels coursing from one side to another side of the member and defining pathways on each side of a central core of the electromagnet. The arcuate channels are shaped to match the optimum-shaped loop of a twisted pair cable of a data bus. A sealing lip and side seal extensions are provided to protect the face of the electromagnet. Also, a spring member defines a platform such as for resiliently supporting the electromagnet insert of the data coupler upwardly within a cavity of the lower coupler member, comprising a pair of spring arms formed on a support surface and disposed at opposite ends of the support surface to each other. Each of the spring arms has an end in an adjacent relationship to the opposite spring arm. The spring arms extend toward each other and outwardly from the platform to define a bearing surface disposed to engage a biasing surface of another member such as the lower coupler member. A pair of spring ends are disposed to extend from the support surface and together provide balanced support for the support surface. There is also disclosed herein a mounting means for mounting the lower member to another member such as a panel through a simple procedure entirely on one side of the panel without separate fasteners. The mounting means has a plurality of pre-determined engaging surfaces formed on the panel such as edge surfaces of spaced apertures or a cutout therethrough. The mounting means includes at least one fixed engaging member disposed on the member to engage one of the panel's engaging surfaces. At least one movable engaging member is also disposed to engage another of the panel's engaging surfaces. The movable engaging member is positioned on a support member operable between a disengaged and any one of a plurality of potential engaged positions whereby the movable engaging member positions both of the engaging members into engagement in the operable position and disengagement in the inoperable position. Embodiments of the invention will now be described by way of example with reference to the accompanying drawings, in which: FIGURE 1 is a diagrammatic view of a data bus system; FIGURE 2 is an isometric view of the coupler assembly of the present invention coupled to a pair of conductor wires of the data bus of Figure 1; FIGURE 3 is an exploded top view in perspective of the lower member of the coupler assembly of Figure 2, and FIGURE 4 is an exploded bottom view in isometric of the lower member of coupler of Figure 2; FIGURE 5 is an exploded top isometric view of the upper member of the coupler assembly of Figure 2; FIGURES 6 and 7 are top and bottom isometric views respectively of the upper member of Figure 2; FIGURE 8 is a longitudinal cross-sectional view taken along line 8-8 of the upper and lower members of the coupler of Figure 2 being secured together to the conductor wires, and FIGURE 9 is a longitudinal cross-sectional view of the upper and lower members of Figure 2 secured together to the conductor wires; FIGURES 10 and 11 are top and bottom isometric views respectively of a cam of the panel mounting means; FIGURE 12 is a top isometric view of the cam follower of the panel mounting means; FIGURE 13 is a top isometric view of the cam follower of panel mounting means of Figure 12 rotated about ninety degrees; and FIGURE 14 is a bottom isometric view of the cam follower of the panel mounting means of Figure 12;. FIGURES 15 and 16 are top views of the cam member in the disengaged and engaged panel positions, respectively, and FIGURES 17 and 18 are longitudinal cross-sectional views taken along lines 17-17 and 18-18, respectively of Figures 15 and 16; FIGURE 19 is an isometric view of an electromagnet insert of the lower member, FIGURE 20 is a cross-sectional view taken along line B-B of Figure 19 and FIGURE 21 is a cross-section view along line C-C of Figure 19 and FIGURE 22 is an end view of the electromagnet insert of Figure 19; FIGURE 23 is an isometric view of an E-shaped electromagnet; FIGURE 24 is an isometric view of a resilient spring means of the lower member; FIGURE 25 is a top plan view of the resilient spring means of Figure 24; FIGURE 26 is a side view of the resilient spring means of Figure 23; and FIGURE 27 is an end view of the resilient spring means of Figure 19; FIGURE 28 is a top isometric view of a circuit substrate of the upper member of the coupler having surface mounted electrical components on the upper surface of the circuit substrate, which is also illustrative of a bottom isometric view of the circuit substrate having electrical components surface mounted on the bottom of the circuit substrate; FIGURE 29 is an isometric upper view of one of the internal layers of the circuit substrate of Figure 5, showing two of a plurality of traces having inductance coils for the electromagnets; FIGURE 30 is an illustration of the electromagnets and windings therearound, coupled to the conductor wires; FIGURE 31 is an isometric view of an alternative embodiment of the present invention showing a single electromagnet used for either sending or receiving signals, and FIGURE 32 is an isometric view of an alternative embodiment of an electromagnet insert used for either sending or receiving signals; and FIGURE 33 is an alternative embodiment of a resilient spring means for the lower member. Figure 1 is a representation of the data bus system 20 to which the present invention is relevant. A twisted pair cable 22 of conductor wires 22A,22B extends between end terminations 24,26 and comprises a closed loop, and a plurality of loops 28 occur at selected spacing, each loop 28 having a length and shape selected to minimize impedance effects and signal reflection. At selected ones of otherwise closed loops 28 are mounted coupler assemblies 30 each having a width preferably less than a loop length to minimize distorting the desired length and shape of an open loop, thereby avoiding impedance effects and signal reflection. Stub cables 32 extend from the respective coupler assemblies 30 to respective control units 34, such as black boxes, providing electrical connections therebetween. Each control unit 34 preferably has a Serial Interface Module (not shown) for modifying digital signals from Manchester Encoded Signals into doublet signals to be transmitted along the data bus system 20, and correspondingly for translating such encoded signals into digital signals for integrated circuits within the control unit. Each control unit 34 will also provide power for the amplifiers in the coupler assembly 30 to boost received and transmitted signals. Figure 2 illustrates the coupler assembly 30 of the present invention coupled to the twisted pair cable 22 of conductor wires 22A,22B of a data bus system 20 such as that of Figure 1 and as disclosed in U.S. Patent Nos. 4,904,879 and 4,264,827, and the AEEC Letters referred to herein. Coupler assembly 30 is noninvasively affixed at a selected location therealong at a loop 28 of the twisted pair cable 22, slightly opening the loop which would otherwise be closed along cable 22. Coupler assembly 30 comprises an upper member 36 and a lower member 38, with the lower member 38 including a base 40 mounted to a panel 42 by a panel mounting means 44 (not shown). Figures 3 to 7 show in greater detail the upper and lower members 36,38, and Figures 8 and 9 illustrate their assembly together. Figures 3 and 4 illustrate components of lower member 38 of coupler assembly 30, including base 40, resilient spring means 50, an electromagnet insert or wire holding member 52 having electromagnets 54A, 54B, a cam 56, and a cam follower 58. As shown in Figures 3 and 4, lower member 38 includes a base 40 molded of dielectric plastic material, such as nylon, or a liquid crystal polymer ("LCP"). Base 40 includes an aligning recess 60 having aligning surfaces 62 to receive the upper member aligning means such as projection 66, pivot pins 68 positioned at one end 78, or "pivot end" of base 40, an electromagnet insert-receiving cavity 70, and a cam-receiving cavity 72 having a cam follower guide path 74. End 76 of base 40 opposite the pivot pins 68 or "coupling end", includes a fastener-receiving cavity 80 and fixed engaging members 82, such as "elephant" feet 82′, extending in a downwardly direction. As illustrated in Figures 8 and 9, for precision alignment of the upper and lower members of the data coupler, base 40 of lower member 38 has a tapered aligning surface 62 formed on aligning recess 60, which engages projection 66 of upper member 36 located adjacent the first and second electromagnets near coupling end 76. Both projection 66 and aligning recess 60 are molded to precise corresponding shapes and dimensions, and in each of the upper and lower members all other features molded thereinto are measured from the location of the centerlines of the projection and recess which comprise respective reference datums for molded parts. Projection 66, coupled with pivot pins 68 formed on base 40 of lower member 38 which fit within an elbow slot 84 of upper member 36, provides means to precisely align upper member 36 to lower member 38. This in turn precisely positions electromagnets 54A,54B of lower member 38 to electromagnets 86A,86B positioned in upper member 36. Projection 66 and recess 60 are adapted to engage and incrementally adjust the position of upper member 36 with respect to lower member 38 upon initial entry of said projection into said aperture until projection 66 is coaxial with aperture 60, thus providing alignment of upper and lower members 36,38 determined by means integral therewith and essentially at a single point substantially spaced from the pivot point. As shown in Figures 3, 4 and 10 to 14, panel mounting means 44 comprise the "quick action" cam 56 which activates cam follower 58 having a movable engaging member 88, such as an "elephant" foot 88', to grasp panel 42. Cam follower 58 has side engaging surfaces 90 and shoulder engaging surfaces 94 which fit into and are guided by vertical and horizontal surfaces 92,96 of cam follower guide path 74 formed in lower member 38. As shown in Figure 4 and 11, cam 56 has a cylindrical base 100 which fits into cam-receiving cavity 72 formed within base 40 of lower member 38. Cam-receiving cavity 72 includes a lower opening 102, which receives cylindrical base 100 of cam 56. A "C"-shaped retention ring 104 secures cam 56 via a groove 106 formed on cylindrical base 100 to base 40. A spring washer 108 spaced between "C"-shaped retention ring 104 and lower surface 110 of base 40 allows cam 56 a degree of vertical movement along the major axis 112 of cylindrical base 100. A handle 114 is formed on top of cam 56 for turning cam 56 between engaged and disengaged positions. While a counter-clockwise cam movement for engagement of cam follower 58 to panel 42 is illustrated in Figure 11, a clockwise cam movement may also be used for initial engagement with the reverse movement providing the movement for disengagement. As shown in Figures 15 to 18, a plurality of predetermined engagement surfaces 120, such as side walls formed by openings 122, are formed on panel 42. The fixed engaging members 82, such as elephant feet 82', at first fit loosely within associated openings 122 defining the engagement surfaces 120, and movable engaging member 88, such as elephant foot 88', at first fits loosely within opening 122 having engaging surface 120 and then is firmly engaged upon appropriate rotation of cam 38. As shown in Figures 12 to 14 and 17 and 18 cam follower 58 defining movable engaging member 88 has a projection 124 which fits within a cam slot 126, which defines a cam actuating surface 128 when rotated. The mating of projection 124 to cam slot 126 assures that cam follower 58 tracks the position of cam 56. As shown in Figures 6 to 9, cam 56 via cam slot 126 and surface 128 engages the surface of projection 124 of cam follower 58 which forces engaging arm 88 in the proper engagement with engagement surface 120 of panel 42. Cam 56 applies the precise pressure setting to the engaging surfaces 120 via the movable engaging member 88 by movement of the cam handle 114 in a counter-clockwise direction to engage a plurality of engaging surfaces or base teeth 130, formed in cam-receiving cavity 72 of lower member 38. Cam 56 may be moved in a vertical direction along major axis 112 by compressing the spring washer 108, so that a plurality of corresponding engaging surfaces or cam teeth 132 formed on lower surface 134 of cam 56 can engage and disengage base teeth 130 of lower member 38 as cam 56 is rotated. Each engaging member 82,88 includes a locking surface 140, which engages the engaging surface 120 of panel 42, defined by a tapered surface which biases lower member 38 against panel 42 as cam 56 actuates the movable engaging member 88 and fixed engaging member 82 into engagement with engagement surfaces 120 of panel 42. As shown in Figure 9, when upper member 36 is secured over lower member 38, lower surface 142 of upper member 36 bears against cam handle 114 and locks cam handle 114 so that engaging members 82,88 are ruggedly secured in engagement with engagement surfaces 120 of panel 42. Thus, cam teeth 130 remain in engagement contact with base teeth 130. This prevents cam 56 from moving in a vertical direction, compressing spring washer 108 and disengaging cam teeth 132 of cam 56 from base teeth 130 of lower member 38. This provides a rugged panel-mounting means 44 to withstand vibrations, temperature and pressure changes, and cycling, yet provides quick action connection and disconnection from panel 42. It is also shown in Figures 8 and 9 that panel 42 may be slightly nonplanar, such as being gently arcuate as is common in aircraft, and that by reason of engaging surfaces 140 being tapered and thus providing a limited range of corner engaging positions, firm engagement can be generated, using cam 56, of engaging surfaces 140 with corresponding panel engaging surfaces 120 of panels of varying thicknesses within a limited range, and that the panel engaging surfaces may be opposing edges of a single aperture through the panel (or panel cutout) rather than discrete apertures. Turning now to Figures 5 to 7, upper member 36 comprises a top body member 150, a circuit substrate 152 having a plurality of surface mounted electrical components 154 connected to an electrical receptacle connector 156, the electromagnets 86A,86B, and a bottom body member 158. As shown in Figures 8 and 9, upper member 36 is fastened to lower member 38 about conductor wires 22A,22B at a coupling section 160 by fastener means 162 and at a connector section 164 by pivot pins 68 in lower member 38 held by and rotatable within an elbow slot 84 having arcuate bearing surfaces 166 in upper member 36. Pivot pins 68 extend between flanges of lower member 38 whereby they are substantially physically protected by portions of the lower member against inadvertent contact and damage during handling prior to assembly to upper member 36, and elbow slots extend transversely to communicate with side surfaces of upper member 36 along the vertical and horizontal slot portions to accommodate the flanges of lower member 38. Connector section 164 includes an electrical receptacle connector 156, having a plurality of terminals 170 matable with a plug connector (not shown) terminating the end of a stub cable 32 of Figure 1 connected to a control unit or black box 34. A square shouldered flange 172 fits into a square flange-receiving cavity 176 formed within top and bottom body members 150,158 which allows fastening of a pair of spaced horizontal flanges 178 of electrical receptacle connector 156 to upper member 36 using screws 168, for example. In this manner, electrical receptacle connector 156 is secured to top and bottom body members 150,158 together upon their mating together to enclose the circuit substrate. As shown in Figures 19 to 22, the electromagnet insert 52 comprises an insert body 174, and the pair of electromagnetic magnets 54A,54B, each having a central leg 180 and outer legs 182 extending from transverse portion 184. One electromagnet 54A is used for receiving signals and the other electromagnet 54B is used for sending signals. As shown in Figure 23, "E"-shaped electromagnets are preferably used. Electromagnets 54A,54B are preformed ferrite cores, which are embedded in insert body 174 formed of elastomeric material, such as silicon rubber, in a manner that secures the electromagnets 54A,54B. Electromagnets 54A,54B may be of the type sold by Ferroxcube Division of Amperex Electronic Corporation of Sangerties, NY, which are made from conventional material, such as linear ferrite, a ceramic filled with ferrous particles. Faces 186,188 are preferably smooth and precisely coplanar, with a variation in the height of legs 180,182 from about 0.005 to 0.0127 mm (0.2 to 0.5 mils). As shown in Figures 7 and 9, the faces 186,188 of the central and outer legs 180,182 are exposed to engage with corresponding exposed faces 192,194 of central and outer legs 196,198 respectively, of corresponding E-shaped electromagnets 86A,86B formed on a transverse portion 200, which is secured within upper member 36 upon assembly. The exposed faces 186,188,192,194 may be covered with paper, plastic film or grease or suitable covering to prevent oxidation of faces 186,188 of electromagnets 54A,54B prior to complete coupler assembly, and is removed at assembly. As shown in Figures 19 to 22, insert body 174 includes a pair of gently arcuate channels 210A,210B across upper surface 212 from first channel ends 214A,214B at first side 216 to second channel ends 218A,218B at second side 220 and between legs 180,182 of electromagnets 54A,54B. Arcuate channels 210A,210B generally take the configuration of loop 28 of twisted pair cable 22 and form a convex path away from each other which encloses central legs 180 of electromagnets 54A,54B. The slope of channel bottom 230 may be gradual as shown in Figure 20. Alternatively, arcuate channels 210A,210B may be shaped in a vertical profile where the entire vertical rise of arcuate channels 210A,210B is defined to occur outwardly from the passage of arcuate channels 210A,210B past central legs 180 of electromagnets 54A, 54B. In this manner, arcuate channels 210A,210B position loop 28 of twisted pair cable 22 in an essentially horizontal run past central legs 180 of electromagnets 54A,54B, which could provide for greater sensitivity to receiving or transmitting signals. Preferably, electromagnets 54A,54B may be shaped to the contour and shape of arcuate channels 210A,210B in order to provide maximum electromagnetic sensitivity. For example, as shown in Figure 23, the center leg 180 may include a taper 208 to allow arcuate channels 210A,210B to position the twisted pair cable 22 in very close proximity to the central leg 180 of electromagnets 54A,54B. As shown in Figure 21, arcuate channels 210A,210B are constructed to have a relatively thin electromagnet insert wall 204 adjacent to the central leg 180 of the electromagnet or central leg wall 204, as compared to the electromagnet insert wall 206 adjacent outer leg 182 or outer leg wall 206. Typically, insert body 174 has a wall spacing of 0.0635 cm (0.025 inches) between arcuate channels 210A,210B and central leg 180. Conductor wires 22A,22B will be received and held along bottom 230 of arcuate channel 210A,210B because the distance between arcuate channel walls 222,224 is less than the diameter of conductor wires 22A,22B at least near the channel ends. This assures that conductor wires 22A,22B will be rigidly secured along arcuate channels 210A,210B between outer legs 182 and central leg 180 of each of electromagnets 54A,54B upon assembly. As pointed out above, in order to assist in the proper positioning of conductor wires 22A,22B in arcuate channels 210A,210B, the particular three-dimensional shape of arcuate channels 210A,210B is enhanced by the taper 208 formed on center leg 180 of the E-shaped electromagnets 54A,54B. This holds conductor wires 22A,22B in the shape of loop 28 of the twisted pair cable, which reduces impedance and minimizes reflectivity of signal transmission along the wires. As shown in Figure 3, electromagnet insert 52 is received into and secured within electromagnet insert-receiving cavity 70, preferably under interference fit. As shown in Figures 19 to 21, upper surface 212 of insert body 174 includes a sealing lip 228, such as an "0" shaped lip 228', formed about its periphery, and a pair of side seal extensions 232 to seal around first channel ends 214A,214B and second channel ends 218A,218B of arcuate channels 210A,210B. Side seal extensions 232 deform around conductor wires 22A,22B when upper member 36 is joined to lower member 38, such as shown in Figure 9. As shown in Figure 3, upon assembly of insert body 174 into electromagnet insert-receiving cavity 70, first and second slots 234,236 define cable exits at the top of electromagnet insert-receiving cavity 70 and receive extensions of the insert containing first channel ends 214A,214B and second channel ends 218A,218B respectively so that both conductor wires 22A,22B are received together through first slot 234, then into respective first channel ends 214A,214B, along the arcuate channels 210A,210B to second channel ends 218A,218B and together through second slot 236. The electromagnet insert-receiving cavity 70 includes a support ledge 242 to receive spring arms 244 of the resilient spring means 50, a plurality of holes 246 therethrough for the venting of air upon insertion of electromagnet insert 52 into electromagnet insert-receiving cavity 70 under interference fit, and a vertical support rib 248. Vertical support rib 248 is located between electromagnets 54A and 54B and includes posts extending upwardly between opposing outer legs 182 and opposing central legs 180 of the electromagnets, with rib 248 and its posts extending into corresponding recesses into the bottom surface of the elastomeric material forming insert body 174 of electromagnet insert 52, as seen in Figure 4, and thus tend to rigidify insert body 174 between the pairs of legs of the lower member electromagnets 54A,54B for stabilizing each electromagnet against strain applied by twisted pair cable 22. Electromagnet insert 52 has at least one resilient spring means 50, and preferably a pair of resilient spring means 50 for independent spring biasing of electromagnets 54A,54B to permit insert body 174 to sustain further compression when urged downwardly by the assembly of upper member 36 to lower member 38. Referring to Figures 8, 9 and 24 to 27, resilient spring means 50 is provided to keep lower member electromagnets 54A,54B closely adjacent to, and in contact with, upper member electromagnets 86A,86B to minimize the air gap, which enhances transfer of energy. The resilient spring means 50 comprises a unitary member having a pair of spring arms 244 formed in a juxtaposed "X" configuration from a portion of a support surface 250, which engage support ledge 242 of electromagnet insert-receiving cavity 70. Spring arms 244 extend from each end of support or biasing surface 250 downwardly to form the juxtaposed "X" configuration, and are tapered towards free ends 252 of spring arms 244 engaging support ledge 242. Ends 252 of spring arms 244 are slightly bent upwardly to form a smooth bearing surface 260 to engage support ledge 242. A suitable material to construct the resilient spring means is stainless steel, or other materials including plastics having suitable spring characteristics. Two sides 254 of resilient spring means 50 extend from each end 256 of support surface 250 and have outwardly extending locking tabs 258. These locking tabs 258 engage downwardly facing ledges along sidewalls 262 (Figures 8 and 9) of electromagnet insert-receiving cavity 70 to secure resilient spring means 50 within electromagnet insert-receiving cavity 70. As shown in Figures 24 and 25, tapered spring arms 244 of resilient spring means 50 provide a maximum degree of structural material at the point of spring action which assures reliable spring action during intense vibrations, temperature and pressure cycling and other stresses. This assures continued engagement between upper and lower member electromagnets 54A,54B,86A,86B to form an electromagnet core 264, as shown in Figure 9, which has essentially no air gap. After electromagnet insert 52 is secured within electromagnet insert-receiving cavity 70, the end faces 186,188 of the electromagnet central and outer legs 180,182 may be covered with a protective paper, grease or the like which will be removed just prior to placement of conductor wires 22A,22B into arcuate channels 210A,210B. As illustrated in Figure 8, upper surface 226 of electromagnet insert 52 is preferably raised slightly above the top of electromagnet insert-receiving cavity 70 prior to complete assembly of coupler assembly 30 via upper member 36; lower member 38 is shown mounted to panel 42 by panel-mounting means 44, and conductor wires 22A,22B are in place in arcuate channels 210A,210B of electromagnet insert 52. Referring now to Figure 5, upper member 36 comprises top body member 150, bottom body member 158, circuit substrate 152, electrical components 154 preferably surface mounted on the upper and lower surfaces of circuit substrate 152, electrical receptacle connector 156 which interconnects circuit substrate 152 to stub cables 32 and control units 34, and the pair of "E"-shaped electromagnets 86A,86B. A suitable material for forming the top and bottom body members is a liquid crystal polymer ("LCP"), which can be plated with metallic materials, and may be VECTRA C-810 or alternatively may be VECTRA A-130 (trademark of Celanese Corporation). Electromagnets 86A,86B are constructed of preformed ferrite cores, similar to lower member electromagnets 54A,54B. Electrical receptacle connector 156 includes a dielectric housing 266 containing the plurality of terminals 170, and a metal shell 270 secured around housing 266. Square flange 172 fits within square flange-receiving cavity 176, which by its square shape enables electrical receptacle connector 156 to be secured to upper member 36, when top and bottom body members 150,158 are joined together around the circuit substrate to form upper member 36. Generally, electrical receptacle connector 156 may be a conventional type, such as one meeting Military Specification 26500, or other suitable electrical receptacle connector. Electromagnets 86A,86B each include central leg 196, having the same taper 208 of central leg 180 of electromagnets 54A,54B, and two outer legs 198 extending from the transverse portion 200. Coupling end 76 of circuit substrate 152 includes central and outer leg-receiving apertures 272,274 to receive central leg 196 and outer legs 198, respectively of electromagnets 86A,86B therethrough. Screws 284 secure circuit substrate 152 to top body member 150, with electromagnets 86A,86B secured therebetween. As shown in Figures 5, 8 and 9, electromagnetic shielding to provide electromagnetic interference ("EMI") or radio frequency interference ("RFI") protection of the electrical components 154 is accomplished by plating the top and bottom body members 150,158 of upper member 36. Plating 280 on top and bottom upper body members 150,158, along with either conductive adhesive or electromagnetic taping of all seams between the plating 280 of the top and bottom upper body members 150,158, provides a continuous three-dimensional shield surrounding the electronic package for EMI/RFI protection. As shown in Figure 8, top body member 150 includes a cavity 276 formed above circuit substrate 152 and having enough depth to receive thereinto circuit substrate 152 and the coextending planar and slightly narrower portion of bottom body member 158 so that the top and bottom body members are spaced from and fit around the electrical components 154 surface mounted on the top and the bottom of the circuit substrate 152. Bottom body member 158 includes a seal-engagement surface 268 formed on the lower surface such that upper member 36 receives sealing lip 228 of electromagnet insert 52. Plating 280 to shield EMI/RFI is positioned on all exposed surfaces of top and bottom body members 150,158, and members 150,158 are molded with generous radii at all corners to facilitate adherence of the plating material thereto. Also, it is preferred that the exposed surfaces define a microscopically irregular surface to enhance plating material adherence which may be accomplish with molds which have been sandblasted to a textured surface. Slots 282 joining the leg-receiving apertures of bottom body member 158 define plating gaps 282, which disallow conductive engagement of the plating 280 around electromagnets 86A,86B. The plating gaps 282 prevent a conductive path from being formed by a continuous winding around the legs 196,198 of electromagnets 86A,86B, which minimizes any unwanted coils and inductance generation by the plating 280 and interference with transmit or receive signals. Typically, plating 280 comprises an electrolessly plated coating of copper followed by thin coating of nickel electroplated thereonto, which forms a layer of plating from about 0.00635 to 0.01524 mm (0.250 mils to 0.600 mils) in thickness; the ratio of the copper thickness to that of the nickel may be about 5:1. For best EMI/RFI protection, all seams between the top and bottom body members 150,158 are filled with conductive adhesive when the top and bottom body members 150,158 are joined together by the adhesive material peripherally therearound and by screws 286 at the pivot end 78 to form an integral upper member 36. As illustrated in Figure 28, circuit substrate 152 includes circuit-bearing members 304 to which are secured by surface-mounting a plurality of electrical components 154 such as capacitors, resistors, transistors, diodes, and so on, defining amplifier circuits appropriate for signal amplification. Power is provided to coupler assembly 30 by control unit 34 through electrical receptacle connector 156 of upper member 36, and chassis grounding is also provided thereby. Signals received from the data bus are amplified for transmission to control unit 34. Signals are also received from control unit 34 and are amplified to be sent along the data bus system 20. Transmitted signals are preferably of the doublet type, encoded as such within control unit 34 of Figure 1 such as by means of a Serial Interface Module. The electronic components may also have appropriate circuits to provide coupler assembly 30 with redundant receiving and transmitting capability. Figure 29 shows one of a plurality of layers 310 which may comprise circuit substrate 152. The typical layer 310 includes a plurality of conductive pads 312 which engage electrical circuity 316, such as trace circuit paths 318 comprising the inductance coil windings 320. For example, heat-resistance thermoplastic film or glass fibers embedded in epoxy to isolate the circuitry on their facing surfaces may be used. Trace circuit paths of layers 310 are disposed on respective upper surface 322 and lower surfaces 324, which will be interior surfaces of layers 310, and together upon assembly will define inductance coils 326A,326B about central apertures 328A,328B respectively. The number of layers 310 is dependent on the particular characteristics of the electrical signals to be transmitted and received. For example, six layers of trace windings will provide for sufficient inductance coils 326A,326B for most applications. Further, details of other suitable circuit substrates 152, and the construction of trace circuit paths 318, are described in U.S. Patent 4,904,879, cited above. As shown in Figure 5, electromagnets 86A,86B are inserted into circuit substrate 152, with an optional resilient member 290 positioned above electromagnets 86A,86B. Top body member 150 receives the transverse portions 200 of electromagnets 86A,86B. After the insertion of electromagnets 86A,86B, the resilient member 290, if used, is placed within a recess 300 above transverse portions 200 of electromagnets 86A,86B securing them within top body member 150. This fills any incremental spaces between transverse portions 200 of electromagnets 86A,86B and the top wall 302 of the recess 300. The end faces 192,194 of central leg 196 and outer legs 198, respectively, preferably extend incrementally outwardly below the bottom surface of circuit substrate 152. After assembly of electromagnets 86A,86B into upper member 36 a protective cover, such as a piece of paper, plastic film or grease, for example, may be removably secured over end faces 192,194 until final coupling of upper and lower members 36,38, at which time protective cover is removed. Figures 8 and 9 illustrate how upper and lower members 36,38 are finally secured together about conductor wires 22A,22B. A screw 340 of a fastener means 342 has been inserted into a profiled aperture 344 through an end flange 346. A hole portion 348 is dimensioned to be slightly larger than a shaft portion 350 to allow rotation. A "C"-shaped retention ring 352 secures within a groove 354 to hole screw 340 in aperture 344. If needed, protective covers or the like are removed from the faces 186,188,192,194 of electromagnets 86A,86B. Pivot pins 68 are placed in position into elbow slots 84, and upper member 36 is then pivoted so that electromagnets 86A,86B are moved toward electromagnets 54A,54B of lower member 38. A locking end 356 of screw 340 enters a socket section 358 of a socket 362. During pivoting, the upper member aligning means 64, such as projection 66 on upper member 36 enters aligning recess 60 and engages aligning surfaces 62 of lower member 38. Preferably, the lowermost portions of projection 66 are tapered or chamfered to comprise lead-ins facilitating alignment of upper member 36 with lower member 38. The arcuate bearing surfaces 166 of elbow slots 84 of upper member 36 coupled with the upper member aligning means 64 assure proper engagement with lower member 38 prior to being secured together. Referring to Figures 8 and 9, fastener means 342 can be one-quarter-turn fasteners of the type sold by Southco, Inc. of Lester, Pennsylvania under Part Nos. 82-11-240-16, 82-32-101-20, and 82-99-205-15. It is preferred that the fastener be spring biased after turning to maintain the coupling end of the upper and lower coupler members firmly together to maintain assured mechanical engagement of the mating faces of the electromagnets, and this may easily be accomplished by a curved washer under the head of the fastener 340 with a flat washer between the curved washer and the plated plastic to protect the upper coupler member against wear, all as is conventional. Screw 340 is adapted to be rotated by a screwdriver to lockingly engage the socket 362. The locking end 356 includes a pair of wing tabs 364 received along channels (not shown) formed at the top of socket section 358, whereafter upon appropriate rotation of screw 340 by a tool, wing tabs 364 override and latch behind stop surfaces defined by inward bosses (not shown) formed in the top portion of socket section 358. Socket 362 includes a knurled enlarged head 368, which is held firmly within profiled aperture 344 after being force fit thereinto. Fastener means 342 permits disassembly if desired, and other suitable fastening mechanisms can optionally be used. Electromagnet insert 52, which is slightly raised above the top surface of lower member 38, is urged further into electromagnet insert-receiving cavity 70 of lower member 38 and biased against resilient spring means 50 when upper member 36 is locked into place by screw 340 being rotate through a 90 degree turn, thereby rotating the wing tabs 364 into locking position behind and beneath corresponding bosses (not shown) of socket 362. The resilient spring means 50 via spring arms 244 becomes slightly compressed against the support ledge 242 and applies continuous slight bias of electromagnet faces 186,192 and 188,194 against each other after assembly. As illustrated in Figure 30, electromagnet faces 192,194 engage corresponding electromagnet faces 186,188 to complete the formation of two electromagnet cores 370A,370B about conductor wires 22A,22B. A first core 370A comprising electromagnets 54A,86A is a receiving core, and a second core 370B comprising electromagnets 54B,86B is a transmitting core. There are modifications and variations which may be made to the preferred embodiment described herein. For example, various types of electromagnets may be used to form the electromagnet cores suitable for use with the coupler assembly 30. For example, other electromagnets suitable for use with the data coupler 30 include those forming a "C"-core, "H"-core, and pot cores. Further, a single coupler assembly 30 may include only the single receiving core 370A, or the single transmitting core 370B. As shown in Figure 31, an electromagnet 378 forming a single pot core would provide an ideal shape to receive a single loop 28 of a twisted pair cable 22 for either transmitting or receiving signals. As shown in Figure 31 and 32, electromagnet 378 for a single pot core includes a central leg 380 and two outer legs 382, which fit within an insert body 384 having a pair of arcuate channels 386A,386B. Further, central leg 380 may be shaped in an elliptical cross section to better fit within a loop 28 of twisted pair cable 22 and minimize the formation of unwanted impedance. Alternatively, a pair of electromagnets 378, positioned into a single coupler assembly 30, can be arranged side-by-side on adjacent or non-adjacent loops 28 for receiving and transmitting signals from twisted pair cable 22. In yet another variation, the electromagnet insert 52 may be divided into two parts, one for the receiving electromagnet 54A and one the transmitting electromagnet 54B. While this embodiment of electromagnet insert 52 (shown by line Z-Z in Figure 19) may be used for both receiving and transmitting cores 370A,370B, it is also apparent that one part of the divided electromagnet insert 52 holding an "E" shaped electromagnet 54A may also be used to hold a single receiving or transmitting electromagnet 54A,54B. In another variation, spring arms 244 may, in addition to forming the juxtaposed "X" configuration, comprise either a juxtaposed "W" or "V" configuration. The selection of a particular configuration, either "W", "V" or "X" which have decreasing spring rigidity, respectively, would depend on the degree of needed spring action and required stiffness. As shown in Figure 33, resilient spring means 50 may comprise a plurality of coil springs 392 disposed between a support member 394 under electromagnet insert 52. Support member 394 has a plurality of projections 396 which lock the coil springs 392 into position on each side of support member 394. In another variation, dielectric potting compound, such as epoxy resin, may be injected within upper and lower cavities 276,278 to embed and seal the electronic components 154. The potting material is desirable to be resistant to thermal shock and to have a lower coefficient of thermal expansion to minimize stressing on electrical components 154 upon elevated temperatures, and also be compatible with the coefficients of circuit substrate 152. One such potting material is 4215 epoxy resin sold by Dexter Hysol Company of Olean, NY. In yet another variation, guide surfaces 92 of lower member 38 may direct the movable engaging member 88 in other than directions away from fixed engaging member 82. This is accomplished by positioning cam 56 to move cam follower 58 along the redirected guide surface 92, such as one which directs the movable engaging member 88 toward fixed engaging member 82. Upper and lower members 36,38, respectively, may preferably be placed in containers such as plastic blister packages for their protection prior to installation. The embodiments above provide a number of significant advantages. The coupler assembly 30 includes a quick action panel-mounting means 44 which quickly and accurately positions coupler assembly 30 onto a panel 42. In a like manner, the coupler may be quickly removed from panel 42 for replacement. In another advantage, electromagnets 54A,54B,86A,86B conform to the shape of loop 28 of twisted pair cable 22 via arcuate wire channels 210A,210B formed within electromagnet insert 52 along with the shape of the center legs of the electromagnets. This reduces impedance and minimizes reflectivity of signal receptions and transmissions along conductive wires 22A,22B. The shapes of arcuate channels 210A,210B position conductor wires 22A,22B closer to center leg 180 of electromagnets 54A,54B than outer legs 182, which also improves signal transmission and reception. As yet another advantage, a rugged resilient spring means 50 is positioned in electromagnet insert-receiving cavity 70 to assure biased engagement of the upper and lower electromagnets 54A,54B,86A,86B. This minimizes any air gap between the interfaces of electromagnet cores 370A,370B and provides a rugged construction to maintain core engagement during temperature cycles, vibrations, and pressure cycles. Sealing lip 228 of electromagnet insert 52 together with side seal extensions 232 assure an intact engagement to control moisture between the pairs of electromagnets 54A,54B,86A,86B together to form electromagnetic inducting cores 370A,370B. As yet another advantage, EMI/RFI protection is provided by the plating 280 formed by direct metallic coating onto the top and bottom upper body members 150,158. This plating, preferably of nickel and copper materials, reduces the weight and complexity of the coupler assembly 30, yet provides adequate EMI/RFI protection. Of course, it should be understood that a wide range of changes and modifications can be made to the preferred embodiment described above. It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims which are intended to define the scope of this invention.

Claims: A coupler assembly (30) for coupling to a data bus system (20) having a twisted pair cable (22) of signal conductor wires in a closed bus loop, the assembly being of the type having at least one electromagnet core (370) each core defined by a first (54A) and second (86A) electromagnet, a first coupler member (38) having the first electromagnet (54A) within an electromagnet insert (52), the insert comprising a dielectric member (174) defining positions for a central leg (186) of the electromagnet (54A) with a mating face (196) exposed in one direction along a surface, the dielectric member having a pair of wire-receiving channels (210A,210B) along a wire-receiving face (212) and coursing from a first common wire exit (214) at one side to a second common wire exit (218) at an opposing side of the member (52) defining pathways on each side of a central leg (194) of the electromagnet, the wire-receiving channels adapted to receive thereinto from said wire-receiving face respective ones (22A,22B) of wires of said twisted pair cable, and further having a second coupler member (36) disposed for inducting power via the second electromagnet (86A) into the electromagnet core when mated with the first coupler member (38), the second coupler member (36) having a circuit substrate (152) secured therewithin and surrounding the circuit substrate with shielding thereby protecting said electrical components from EMI\RFI interference, the electromagnet (86A) being secured within the second coupler member (36) and having leg portions (192,194) extending through leg-receiving apertures (272,274) of the circuit substrate (152) and the bottom body member (158) to mating faces (196,198) exposed for coupling with corresponding mating faces (188) of the first electromagnet, and the circuit substrate having electrical components (154) mounted on at least one surface thereof having circuits inductively coupling to the at least one electromagnet, the coupler assembly being characterized in that: the second coupler member (36) comprises an assembly of a top body member (150) and a bottom body member (158), with the top and bottom members defining a cavity (276,278) along an interface therebetween adapted to receive the circuit substrate (152) during assembly thereof; and said shielding is formed by plating (280) on said top and bottom body members (150,158) at least on surfaces around said cavity (276,278) and engaging portions of said top and bottom body members (150,158) being conductively joined at said interface surrounding said cavity after said circuit substrate (152) has been disposed therewithin. The coupler assembly (30) of claim 1 further characterized in that said bottom body member (158) has plating gaps (282) disrupting the periphery of apertures through which extend said central leg (196) of each said second electromagnet (86A) to prevent the formation of a metallic loop therearound. The coupler assembly of claim 1, further characterized in that said first coupler member (30) includes a spring member (50) disposed to provide axial pressure to said first electromagnet (54A) within said electromagnet insert (52), said spring member (50) comprising a portion defining a transverse platform (250) and a pair of adjacent spring arms (244) extending from a common face of said platform in a common axial direction, each of said arms having an end (252) in an adjacent relationship to a base of the other said spring arm, whereby said spring arms (244) extend axially in the same direction from respective said bases and transversely in opposed directions to free ends defining a pair of bearing portions disposed in a common plane to engage a common support surface (242) of said first coupler member (38) for generating resistance to movement of said platform (250) in said axial direction when said first electromagnet (54A) engages said second electromagnet (86A) upon mating of said first and second coupler members (38,36). The coupler assembly (30) as set forth in claim 1 further characterized in that each said first electromagnet (54A) is embedded within elastomeric material defining an electromagnet insert (52) shaped to be received within a corresponding electromagnet insert-receiving cavity (70) in said coupling end (76) of said first coupler member (38), said elastomeric material exposing said mating end faces (188) of said first electromagnet legs (182,186), and including a sealing lip (228) and side seal extensions (232) to seal the engagement of the first and second electromagnets (54A,86A) of each said pair, said elastomeric material including defined thereacross said wire-receiving channels (210A,210B) alignable with corresponding wire-receiving slots (234,236) in side walls of said insert-receiving cavity (70). The coupler assembly (30) as set forth in claim 1 further characterized in that said first coupler member (38) includes two said first electromagnets (54A,54B) secured therein spaced from each other, and said second coupler member (36) includes two said second electromagnets (86A,86B) secured therein spaced from each other paired with and opposed from said two first electromagnets (54A,54B) and each respectively inductively coupled by said circuit substrate (152), thereby defining a data coupler having two said electromagnetic cores (370,370B) to enable both receiving and transmitting signals from and to said data bus (20). The coupler assembly as set forth in claim 5 further characterized in that said two first electromagnets (54A,54B) are spring biased independently of each other. The coupler assembly as set forth in claim 5 further characterized in that wherein said dielectric body (174) of said electromagnet insert (52) comprises deformable elastomeric material, and said first coupler member (38) includes a rib (248) disposed within a recess of said dielectric body and between said spaced apart first electromagnets (54A,54B), said rib (248) including posts extending upwardly between respective pairs of opposing ones of said outer and central legs of said first electromagnets (54A,54B) whereby said first electromagnets are stabilized in a vertical orientation when subjected to strain applied by said twisted pair cable (22). The coupler assembly as set forth in claim 1 further characterized in that said assembly includes first (68) and second (84) securing means at a first end of said first (38) and second (36) members, first (358) and second (340) fastening means at a second end thereof, and first (60) and second (66) alignment means along intermediate portions thereof between said first and second ends, said first and second securing means (68,84) cooperable during initial stages of mating to define a pivot, said first and second fastening means (358,340) cooperable at final stages of mating to fasten together said first and second coupler members (38,36) about said signal conductor wires (22A,22B) to define said at least a first electromagnet (370) coil therearound, and said first and second alignment means (60,66) cooperable during intermediate stages of mating for precisely aligning said first and second coupler members with each other; said first securing means comprising transverse cylindrical pins (68) at said first end, and said second securing means comprising transverse elbow slots (84) defined along and into a lower surface of said second coupler member (36) having vertical portions adapted to receive thereinto said transverse pins (68) of said first coupler member (38) and further having horizontal portions extending toward said first end after said transverse pins have been received into said vertical slot portions, said horizontal portions having arcuate bearing surfaces facing said second end cooperable with surfaces of said pins (68) during pivoting; and said second alignment means comprising a projection (66) depending from said second coupler member (36) toward said first coupler member (38), and said first alignment means comprising an aperture (60) extending at least into a top surface of said first coupler member adapted to receive thereinto said projection (66) during intermediate stages of mating and having a shape and dimension corresponding closely with those of said projection, said projection (66) having tapered surfaces at a leading end thereof and said aperture (60) having tapered surfaces (67) at the entrance thereof adapted to engage and incrementally adjust the position of said second coupler member (36) with respect to said first coupler member (38) upon initial entry of said projection (66) into said aperture (60) until said projection is coaxial with said aperture, said projection and said aperture being located adjacent said first and second electromagnets (54A,86A) near said second end, and centerlines of said projection and said aperture defining reference datums for said first and second coupler members respectively with respect to which all other features of said coupler members are referenced, whereby alignment of said coupler members is determined by means integral therewith and essentially at a single point substantially spaced from the pivot point by said projection and aperture thereby enabling precise positioning during mating of all features of the second coupler member with respect to corresponding features of the first coupler member including the first and second electromagnets mounted therein respectively. The coupler assembly (30) as set forth in claim 8 further characterized in that said transverse pins (68) of said first coupler member (38) extend between flanges thereof whereby said pins (68) are substantially physically protected by portions of said first coupler member (38) against inadvertent contact and damage during handling prior to assembly to said second coupler member (36), and said transverse slots (84) communicate with side surfaces of said second coupler (36) along said vertical and horizontal portions thereof to accommodate said flanges.

Inventors: RUDY WILLIAM JESSE, SHAFFER HOWARD RICHARD, RUDY, WILLIAM JESSE, SHAFFER, HOWARD RICHARD
Applicants: WHITAKER CORP, THE WHITAKER CORPORATION
Application year: 1991
Main classification: H01R13
IPC codes: H02J17, H01F38, H01R13, H01R31