Abstract:
A panel mounted power module is disclosed having an insulating housing and a conductive jacket. The insulating housing and the conductive jacket have corresponding flanges which oppose each other and are profiled to trap therebetween a panel. The power module includes a spring positioned between the insulating housing and conductive jacket, to spring load the flanges towards each other. The power module has at least one ground terminal and the spring commons the ground terminal and the conductive jacket together.

Description:
FIELD OF THE INVENTION 
       [0001]    The subject invention relates to a jacketed power module that is attachable to an equipment panel. The power module may include a conductive jacket electrically connected to a conductive panel. 
       BACKGROUND OF THE INVENTION 
       [0002]    It is known in the power connector technology to provide an electrical connector for a power connection through the enclosure of equipment. The equipment is typically provided with a conductive shell into which all of the hardware is mounted. The power module is typically provided as a socket which is mounted to a cutout in the rear panel of the equipment. An electrical extension cord is then plugged into the socket where contacts of the cord electrically connect terminals in the power module socket to provide power to the equipment. 
         [0003]    It is also known to common a conductive jacket of the module to the conductive panel of the desktop computer. This is shown in Applicant&#39;s SRB series modules. 
         [0004]    It is also generally known in the connector art to common a shield of an electrical connector to a conductive panel, by way of contacts on the shield to increase the conductivity between the shield and the panel, see for example, U.S. Pat. No. 5,752,854. Such contacts however, may become plastically deformed or may provide only point contacts between the shield and the panel. 
       SUMMARY OF THE INVENTION 
       [0005]    The objects have been accomplished by providing a power module comprising an insulating housing; electrical terminals positioned in the housing; a jacket surrounding at least a portion of the insulating housing; and a spring positioned intermediate the housing and the jacket, spring loading the housing and the jacket in opposite directions along a substantially common axis. 
         [0006]    In another aspect, a power module comprises an insulating housing; electrical terminals positioned in the housing, comprised of at least one ground terminal; a jacket surrounding at least a portion of the insulating housing; and a spring positioned intermediate the housing and the jacket, the spring commoning the ground terminal to the jacket. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a front perspective view of the power module of the present invention; 
           [0008]      FIG. 2  is an exploded view of the module of  FIG. 1 ; 
           [0009]      FIGS. 3 and 4  are front and rear perspective views respectively, of an insulating housing used in the power module; 
           [0010]      FIGS. 5 and 6  show front and rear view respectively, of the outer jacket for use with the power module of  FIG. 1 ; 
           [0011]      FIG. 7  shows a perspective view of the grounding spring; 
           [0012]      FIG. 8  shows a side plan view of the grounding spring shown in  FIG. 7 ; 
           [0013]      FIG. 9  shows a partially fragmented view of the power module of  FIG. 1 ; 
           [0014]      FIG. 10  is a cross-sectional view through lines  10 - 10  of  FIG. 1 ; and 
           [0015]      FIG. 11  shows a cross-sectional view similar to that of  FIG. 10  where the power module is connected to a conductive panel. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    With reference to  FIGS. 1 and 2 , power module  2  is generally comprised of an insulating housing  4 , a jacket  6 , power terminals  8 , a ground terminal  10 , a spring  12 , where the power module  2  is connectable to power conductors  14 , and to a ground conductor  16 , where the power conductors and the ground conductor form a power cable. With the above elements generally described, each of the elements will now be described in greater detail. 
         [0017]    With reference now to  FIGS. 1 ,  3  and  4 , insulating housing  4  will be described in greater detail. Insulating housing  4  is comprised of an insulating flange  20  and an insulating body portion  22 . As shown best in  FIGS. 1 and 3 , insulating housing  4  includes a front face  24  having a socket portion  26  extending therein which houses power terminals  8  and ground terminal  10 . With respect to  FIG. 4 , the opposite end of body portion  22  shows bosses  28  and  30 , where boss  30  provides a planar surface  32  providing an end face. With reference still to  FIG. 4 , bosses  28  circumscribe terminal receiving openings  36  for receipt of the power terminals  8 . Boss  30  circumscribes terminal receiving opening  38  for receipt of ground terminal  10 . Finally flange  20  defines a rearwardly facing surface  40  which, as will be described in greater detail later, is profiled for abutment against a panel. 
         [0018]    With respect again to  FIG. 2 , power terminals  8  and ground terminal  10  will be described in greater detail. Power terminals  8  include a male tab portion  50 , a wire-wrap portion  52  and an intermediate portion  54 . Ground terminal  10  includes male tab portion  60  and a rear contact portion  62 . 
         [0019]    With respect now to  FIGS. 5 and 6 , jacket  6  will be described in greater detail. It should be appreciated that jacket  6  may be comprised of many materials, as further described herein. However as shown jacket  6  is conductive, and is generally comprised of a conductive body portion  70  and a conductive flange portion  72 . As best shown in  FIGS. 5 and 9 , body portion  70  includes an outer peripheral wall  74  having an inwardly directed strap portion  76 , which could be stamped from the jacket itself. Meanwhile, flange portion  72  includes a forwardly facing surface  78  which circumscribes a substantial portion of body portion  70  and is located opposite the rearwardly facing insulating surface  40 , when in the position shown in  FIG. 1 . As shown in  FIG. 6 , jacket  6  also includes a rear wall  80  having apertures  82 . 
         [0020]    With reference now to  FIGS. 7 and 8 , spring  12  is shown to include a flat spring portion  90  having an aperture  92  therethrough, a spring leg  94  having a retention member  96  and a wire-wrap portion  98 . Spring  12  could also be comprised of many different materials, but as shown is conductive. As such, spring  12  is a grounding spring, and is used in a dual sense; that is, spring  12  functions as a spring load feature, as well as a commoning mechanism to common the conductive jacket  6  and the ground terminal  10 . With the above described components, the assembly of the connector will now be described. 
         [0021]    Power terminals  8  are first inserted in their respective passageways  36  into the position shown in  FIG. 9 . Ground terminal  10  is then insertable into its respective opening  38 , and as installed, rear contact portion extends beyond planar surface  32 . Spring  12  may now be positioned such that aperture  92  ( FIG. 7 ) overlies rear contact portion  62 , and such that flat spring portion  90  ( FIG. 7 ) lies substantially flat against planar surface  32  ( FIG. 4 ). These two may now be soldered together to electrically and mechanically join the two. However, while solder is described herein, any number of connections may be made such as interference fit, welding, retention lances, and the like. The wire-wrap terminal portions  52  and  98  may now be connected to their associated insulated conductors in a known manner. 
         [0022]    Jacket is now received over insulating body portion  22  whereupon spring leg  94  is receivable into strap portion  76  and whereby retention member  96  latches spring leg  94  in place. In the event that jacket  6  and spring  12  are both conductive, the strap portion  76  and spring leg  94  may also be soldered for further electrical and mechanical connection. 
         [0023]    It should be appreciated that the insulating housing  4  and jacket  6  are connectable along a common axis, and that grounding spring  12  spring loads conductive flange  76  towards insulating flange  20  along the common axis. Thus, any movement of jacket  6  away from insulating body  4  attempts to “lift” grounding spring  12 , and more particularly flat spring portion  90 , off of its boss portion  30 , and attempts to pull the two back together. 
         [0024]    For example, and as shown in  FIG. 10 , module  2  is shown prior to connection to a panel. In this condition, flange  72 , and more particularly surface  78  ( FIG. 5 ) is positioned proximate to rearwardly facing surface  40 . However, when the jacket and the insulating housing  4 , are positioned within a cutout of a panel  100  as shown in  FIG. 11 , flat spring portion  90  of spring  12  lifts off of planar surface  32  of boss  30 . Thus, when the module  2  is assembled to a panel cutout, with a panel positioned between the surfaces  40 ,  78 , flange  72  is spring loaded against its counterpart panel. 
         [0025]    It should be appreciated that only one embodiment of the invention has been depicted and the power module could take on many forms. For example, the jacket  6  could alternatively be comprised of an insulating material such as plastic, or alternatively, could be plated plastic. Also, spring many be nonconductive and only used for the spring load feature. A nonconductive spring could be used with a conductive or nonconductive jacket, or a conductive spring could be used with either conductive or nonconductive jacket. 
         [0026]    Furthermore, the grounding spring could be of any shape and/or configuration, and need not be positioned flat against the boss  30 . Moreover, the jacket  6 , grounding spring  12 , and ground terminal  8 , could be all stamped and/or formed from a single piece of common material.