Abstract:
A quickly separable and disconnectable electrical connector device ( 10 ) comprises a pin section ( 14 ) having a socket receptacle ( 40 ) and a socket section ( 16 ). A mounting flange ( 18 ) is mounted about the socket receptacle and is coupled to a supporting structure ( 26 ) on the socket section. A force member configured as a ring ( 32 ) surrounds the pin engageable end of socket receptacle ( 40 ) and is adapted to abut the pin section. An adjustable spring ( 28 ) on the socket receptacle urges force member ( 32 ) against pin section ( 14 ), and is located adjacent to one side of flange ( 18 ) for reducing the force required to separate the pin and socket sections from one another and thereby for aiding separation therebetween.

Description:
TECHNICAL FIELD OF THE INVENTION 
     The invention relates to pin and socket connector devices for providing a temporary, easily severed, multi-channeled data connection between two objects, such as a satellite and a launch vehicle. 
     BACKGROUND OF THE INVENTION 
     In the aerospace industry it is often necessary to provide an electrical data and/or power connection between two structures that can be easily and quickly separated from each other at the proper time (e.g., upon the launch of a satellite or stage separation of a launch vehicle). This typically takes the form of a two-part connection assembly comprising a unit having pins and a unit having a like number of sockets. By way of an example, a satellite may require a 41-pin connection between stages of a launch vehicle (or to an adjoining satellite in a “stacked” configuration) until the moment of release. Such a connector must mate easily, stay in place and then release easily. 
     Typically in such units, the pin size is standardized to strict military specifications. Conversely, the military standards for sockets allow a wide variety in retention force. Therefore, for each connector to connector assembly, the individual sockets may exert differing amounts of drag against the pins during separation. For instance, in a common configuration in which the sockets average about 1.5 pounds of drag each, there is considerable variation between sockets from that average (perhaps between 4 and 18 ounces of force). Moreover, the force needed to uncouple the 41 sockets in the above example can easily vary between 164 and 738 ounces of force. 
     Because of the force required to disengage the connector assembly, springs are typically used to counterbalance some of that force. For instance, if a certain pin and socket combination required 78 pounds of force to disengage, a spring exerting 75 pounds of force might be included so that the actual separation force would be an acceptable 3 pounds. This has presented a problem with prior art devices, due to the above-noted variance in the sockets. One solution has been to package the “pin connector” and the “socket connector” as a matched pair, with an adjustment spring on the pin connector. In such devices, the spring tension is factory-adjusted to compensate for the particular socket connector being employed. This has the disadvantage of creating an otherwise-standardized set of pins that mates only with a particular set of sockets. 
     Another problem with prior art units is that they are prone to misalignment upon initial mating (e.g., when mounting the satellite to the launch vehicle). Because the two connector units are often rigidly attached to their respective parts (one to the launch vehicle, one to the satellite) it is difficult to maneuver the smaller device (the satellite in this example) so that the pins and sockets precisely mesh. Thus it is advantageous to have one of the connectors capable of limited movement to match the orientation of the other connector. One solution that has been employed is the use of spring-loaded adjustable screws which movably mount the connector to the structure. Unfortunately, this has been found to result in a number of problems. First, the user must take great pains to mount the device and properly tighten the screws (too tight and the spring is so compressed that there is no “play”. Second, it takes up valuable space in applications where space is scarce (the additional area necessary for the springs increases geometrically with the number of adjustable connectors). Thirdly, to avoid electromagnetic interference, a backshaft is often necessary. Unfortunately, to give the user access to adjust the springs of the spring-loaded screws, a backshaft is not practical. 
     A further problem with the prior art is that if the pins are rotated even slightly relative to the sockets, the device will either not mate properly or the pin ends may be bent, causing device failure. 
     What is needed is a pin and socket connector device in which the pin section can be used with a number of socket sections, that allows for some misalignment upon mating, and prevents damage due to rotation of one part relative to another prior to mating, without the above noted problems. 
     SUMMARY OF THE INVENTION 
     In a first embodiment, the present invention provides a quickly separable and disconnectable electrical connector device for transmitting a plurality of electrical signals between a first station having a first signal source and a second station having a second signal source. A pin section is electrically connectable to the first signal source at the first station. A socket section is electrically connectable to the second signal source at the second station. The pin section includes a housing which supports a plurality of pins held within a pin receiving body or pin shaft. The socket section includes a housing which supports a plurality of sockets pins held within a socket receiving body or socket shaft. The sockets are adapted to receive the pins in an electrically conductive relationship. A force member, preferably embodied as a ring integral with the socket section housing, surrounds the pin engaging end of the socket shaft (socket receiving body) for applying an ejection force against the pin section. An adjustable spring on the socket shaft urges the force member or ring against the pin section. When the pin section is urged against the socket section with a force sufficient to overcome the adjustable spring, the pins are inserted to the sockets to complete the electrical connection therebetween, and the force needed to separate the pin section from the socket section is reduced by the force of the adjustable spring bearing against the pin section. 
     In a second embodiment, the pin shaft or pin receiving body further comprises at least one raised key and the socket shaft or socket receiving body further comprises at least one charnfer for receiving at least the one raised key, to prevent misalignment of the socket section with the pin section. A force member surrounds the pin engaging end of the socket shaft and is disposed to abut against the pin section. 
     In a third embodiment, the socket shaft extends through an aperture in a mounting flange which is coupled to the second station. An alignment spring, located on the socket shaft, bears against the mounting flange. The aperture is sized to be larger than the socket shaft to allow movement of the socket shaft, as restrained by the alignment spring. 
     In other embodiments, the adjustable spring is a compression spring which bears against the force member at one end, and an adjustment means at the other end of the adjustable spring varies the force exerted by the adjustment spring against the force member. The socket shaft further comprises a threaded portion and the adjustment means is a threaded nut wherein the adjustment means engages the threaded portion of the socket shaft and the adjustable spring may be adjusted by rotating the adjustment means about the socket shaft. A socket shaft passes through a flange extending out from both sides, and the alignment spring is located adjacent to the pin side of the mounting flange, and an adjustable spring on the socket shaft urges the force member against the pin section. Here, the adjustable spring is located adjacent to the pin or socket side of the flange and the adjustable spring and the alignment spring are coaxial. 
     These and other features and advantages of this invention will become further apparent from the detailed description and accompanying figures that follow. In the figures and description, numerals indicate the various features of the invention, like numerals referring to like features throughout both the drawings and the description. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an isometric view of the In Flight Disconnect connector constructed according to the present invention. 
     FIG. 1 a  is a view taken along line  1   a — 1   a  of FIG.  1 . 
     FIG. 2 is an isometric view of the socket section ( 16 ) of the present invention. 
     FIG. 3 is a top plan view of the socket section ( 16 ) of the present invention. 
     FIG. 4, is an isometric view of the pin section ( 14 ) of the present invention. 
     FIG. 5 is a top plan view of the pin section ( 14 ) of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 shows a mated connector  10  constructed according to the present invention. The mated connector  10  includes a pin section  14  and a socket section  16 . 
     In typical aerospace applications, either the pin section  14  or the socket section  16  may be connected to a lunch vehicle structure (not shown), with the other section connected to a release object (not shown). In the preferred embodiment shown, the socket section  16  is connected to the lunch vehicle structure. Pin section  14  is coupled to a first station, having a first signal source, by a cable assembly  14   a . Socket section  16  is coupled to a second station, having a second signal source, by a cable assembly  16   a.    
     The socket section  16  (see also FIG. 2) includes a mounting flange  18  for mounting the socket section  16  to a structure such as a lunch vehicle or release object. The mounting flange  18  may be attached in any number of ways, such as welding or bolting; however it has been found that four attachment screws, such as attachment screw  22 , provides satisfactory results. In a preferred embodiment, four attachment apertures  24  are also provided to receive the four attachment screws  22 . The socket section  16  has a central plug housing  26  which passes through a central aperture (not shown) in the mounting flange  18 . 
     The socket section  16  has an adjustable spring  28  which provides a force pulling against the drag created by the mating of the pin section  14  and the socket section  16 , as discussed below. The adjustable spring  28  is a compression spring, in a preferred embodiment rated at 60-70 pounds, which is resisted on one end by a front mating ring or force member  32 , and on the other end by an adjustment ring  34 . The front mating ring  32  is capable of moving laterally along the central plug housing  26 , over a distance of about {fraction (3/16)} inch in a preferred embodiment. This lateral movement is allowed and restrained by one or more pins, such as pin  38  in the front mating ring  32 , which rides in a lateral groove (not shown) in the central plug housing  26  beginning about ⅛ inch from the front mating ring end of the central plug housing  26  and extending towards the mounting flange  18  for a distance of about {fraction (3/16)} inch. In a preferred embodiment, three pins evenly spaced around the front mating ring  32  and three corresponding grooves in the central plug housing  26  are provided. As depicted in FIG. 1, housing  26  is provided with external threads  33 . 
     The adjustment ring  34  has a threaded interior  36  (not shown) which are threaded along corresponding threads  33  in the central plug housing  26 . In other embodiments, the adjustment ring  34  may not be threaded, but rather use a cam, detent, set screws, or other means with a locking mechanism to adjust and set the tension on the adjustment spring  28 . In a preferred embodiment, the adjustable spring  28  may be compressed or released by turning the adjustment ring  34 . A locking pin  42  is provided for locking the adjustment ring  34  in place, once it is threaded to the desired position (i.e., compressing the adjustable spring  28  so that the desired amount of force is exerted against the front mating ring or force member  32 ). 
     The socket section  16  also has an alignment spring  44 , for compensating for misalignment of the socket section  16  and pin section  14  during mating. In a preferred embodiment, the alignment spring  44  is a compression spring rated at about 60 pounds, which is resisted at one end by the mounting flange  18  and at the other end by the adjustment ring  34 . Although in this preferred embodiment the alignment spring  44  is shown on the same side of the mounting flange  18  as the adjustment spring  28 , in other embodiments the alignment spring  44  may be on the opposite side of the mounting flange  18 . In a preferred embodiment, the diameter of the aperture (not shown) in the mounting flange  18  is slightly larger than that of the central plug housing  26 , such that a slight amount of “play”= 0  may be encountered. The alignment spring  44  as well as the adjustment spring  28  provide additional force when mounting the pin section  14  into the socket section  16 . For instance, in an embodiment suitable for aerospace applications, the central plug housing  26  has a diameter between about ¾ and 2.0 inches, while the aperture has a diameter between about {fraction (13/16)} and 2{fraction (1/16)} inches. In such an embodiment, the mounting flange  18  will be attached to the structure, while the pin section  14  will be attached to the release load. Should any misalignment occur on mating, the socket section  16  will have some “play” in that it can swivel about the aperture in the mounting flange  18  enough to accommodate minor misalignment. 
     FIG. 3 shows the socket section  16  schematically depicted, showing the attachment apertures  24 , mounting flange  18 , front mating ring  32 , and central plug housing  26  also shown in FIGS. 1 &amp; 2. The socket section  16  has a socket shaft or socket retaining body  40 , a socket surface  46 , which is essentially a raised platform  52  having a plurality of socket apertures  48  which each contain an individual electrical contact (not shown). The central plug housing  26  forms a wall surrounding the raised platform  52  with approximately {fraction (1/82)} inch of space between the socket surface  46  and the central plug housing  26 . In a preferred embodiment, the central plug housing  26  extends approximately ¾ inch above the mounting flange  18 , while the socket surface  46  extends only approximately ¼ inch above the mounting flange  18 . The space thus formed is designed to receive the pin section  14  (see FIGS.  4 - 5 ). The central plug housing  26  defines one or more chamfers, such as master chamfer  54 - a  and chamfers  54 - b ,  54 - c , and  54 - d  and  54 - e . To insure proper mating orientation, master chamfer  54 - a  is larger than chamfers  54 - b ,  54 - c , and  54 - d  and  54 - e . As discussed below, these will receive mating keys from the pin section  14 . 
     The pin section  14  includes a pin mounting flange  62  for mounting the pin section  14  to a structure such as a launch vehicle or release object (in a preferred embodiment, the pin section  14  will be mounted to a release object). The pin mounting flange  62  may be attached in any number of ways such as welding or bolting; however it has been found that four attachment screws (not shown) provide satisfactory results. Thus in a preferred embodiment, four attachment apertures  64  are provided through which bolts (not shown) may be used to attach the pin section  14  to a structure. The pin section  14  has a pin central shaft or pin receiving body  66  which passes through a central aperture (not shown) in the pin mounting flange  62 . Standoffs, such as standoffs  68 , are mounted to the pin mounting flange  62  and provide reactive surfaces for the front mating ring or force member  32  of the socket section  16 . In a preferred embodiment, the pin central shaft  66  extends about one inch from the pin mounting flange  62 , and the standoffs  68  extend about ⅛ inch from the pin mounting flange  62 . 
     The pin central shaft  66  includes one or more keys (in a preferred embodiment, five keys are provided), such as master key  72 - a and keys  72 - b ,  72 - c ,  72 - d , &amp;  72 - e . The keys are all of approximately the same size, except for master key  72 - a  which is larger than the others. To prevent misalignment in mating, master key  72 - a  will fit into master chamfer  54 - a  making certain that the orientation of the pin section  14  and the socket section  16  are correct relative to each other. In alternative embodiments (not shown), the keys may be positioned on the central plug housing  26  and the chamfers on the pin central shaft  66 . 
     The pin section  14  also has a plurality of pins  74 , the number of which will match the number of sockets in the socket surface  46 . In an embodiment suitable for aerospace use, 41 pins and sockets is one of many standard pin and socket configurations. 
     In operation, the user or manufacturer will first adjust the pressure on adjustable spring  28  for the standard military pin specification by turning the adjustment ring  34  until the needed counter-force is achieved. The pin section  14  and socket section  16  will then be attached and wired to their respective structures. Then the socket section  16  may be installed in a launch or release object, with the ability to receive and mate with any pin section meeting the same release force specifications. The launch structure and release object may now be mated. Any minor misalignment will be compensated for by the “play” allowed by the alignment spring  44 . Rotational alignment will be insured by the master key  72 - a  and keys  72 - b ,  72 - c  and  72 - d  mating with master chamfer  54 - a  and chamfers  54 - b ,  54 - c , and  54 - d , respectively. Friction of the pins within the sockets will hold the mated connector  10  in the mated condition until release. For example, in a standard aerospace application, a  41  pin connection will exert about 20 pounds of drag. The adjustable spring  28  will be set for about 15 pounds of force, reducing the required separation force to about 5 pounds. 
     Having now described the invention in accordance with the requirements of the patent statutes, those skilled in the art will understand how to make changes and modifications in the present invention to meet their specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention as set forth in the following claims.