Abstract:
The invention includes an electrical contact capable of mating with an electrical connector. The electrical contact has an intermediate contact having a flexible connection medium, and an outer contact surrounding the intermediate contact. The electrical contact also has a first insulator surrounding the intermediate contact and the flexible connection medium. The first insulator provides electrical isolation of the intermediate contact from the outer contact. The front insulator also has a front face that protects the flexible connection medium from being distorted by an electrical connector. The outer contact surrounds the first insulator, and a center contact is surrounded by the intermediate contact. The front face may have a flange that isolates a front portion of the flexible connection medium from the mating connector.

Description:
FIELD OF THE INVENTION  
         [0001]    The invention relates to the field of electrical connectors. More specifically, the invention relates to pin contacts having flexible connection members.  
         BACKGROUND OF THE INVENTION  
         [0002]    Many applications require multiple transmission paths between electrical components. For such applications, certain electrical cables have been developed to satisfy the multiple conducting paths. These electrical cables often also provide shielding to protect the multiple conducting paths from the undesired effect of electromagnetic interference. One type of cable that provides these multiple conducting paths is known in the industry as a “triaxial” cable. The triaxial cable typically has a center wire conductor surrounded by a first dielectric with braided shield layers. The first dielectric in turn is surrounded by a second dielectric with braided shield layers.  
           [0003]    Although these cables serve a necessary purpose, in practice, their use has been limited by the industry&#39;s failure to develop inexpensive and suitable connecting devices to satisfy their particular applications. A triaxial pin contact is one such connecting device that is designed to be connected to a triaxial cable on one end (i.e., “cable interface”), and to a mating triaxial connector on the other end (i.e., “coupling interface”). The cable interface often provides any number of connections, such as either a solderable or crimpable connection to the triaxial cable. The coupling interface typically has either a male or female contact adapted to receive a corresponding female or male triaxial connector, respectively.  
           [0004]    One problem typically is found in male triaxial pin contacts having a flexible intermediate contact interface. These male triaxial pin contacts are designed to receive female contacts of various shapes and sizes. However, certain female contacts as well as other objects may bend and distort the male contact&#39;s flexible intermediate contact interface beyond its intended boundaries. For example, a female connector or other object may tend to bend the flexible intermediate contact inward and toward another contact, called the center contact. As a result, the flexible intermediate contact undesirably touches the center contact, thus making the pin contact unusable. Although this problem has been described with reference to a male triaxial pin contact, the problem exists in any type of contact having a flexible contact interface.  
           [0005]    Therefore, there is a need to provide a pin contact that protects the flexible contact medium from being bent and damaged.  
         SUMMARY OF THE INVENTION  
         [0006]    The invention includes an electrical contact capable of mating with an electrical connector. The electrical contact has an intermediate contact having a flexible connection medium, and an outer contact surrounding the intermediate contact. The electrical contact also has a first insulator surrounding the intermediate contact and the flexible connection medium. The first insulator provides electrical isolation of the intermediate contact from the outer contact. The front insulator also has a front face that protects the flexible connection medium from being distorted by an electrical connector. The outer contact surrounds the first insulator, and a center contact is surrounded by the intermediate contact. The front face may have a flange that isolates a front portion of the flexible connection medium from the mating connector. The front face also may have a ledge, such that a front portion of the flexible connection medium is located below the ledge. The front portion of the flexible connection medium may have a taper that guides the mating connector within the flexible connection medium.  
           [0007]    The electrical contact also may have a second insulator located between the intermediate contact and the center contact. The second insulator may provide electrical isolation of the center contact from the intermediate contact. The electrical contact also may have a third insulator surrounding the center contact. The third insulator provides electrical isolation of the center contact. The center contact may be connected to a center pin that extends from a rear side of the outer contact such that the center contact is within a plane of the outer contact. The center pin may carry a data or ground signal. The intermediate contact may be connected to an intermediate pin that extends fiom a rear side of the outer contact such that the center contact is within a plane of the outer contact. The intermediate pin may carry a data or ground signal. The outer contact may be connected to an outer pin that extends from a rear side of the outer contact such that the center contact is within a plane of the outer contact. The outer pin may carry a data or ground signal.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]    Other uses and advantages of the invention will become apparent to those skilled in the art upon reference to the specification and the drawings, in which:  
         [0009]    [0009]FIG. 1 is an exploded isometric view of a triaxial pin contact, according to the invention;  
         [0010]    [0010]FIG. 2 provides a front view of an assembled triaxial pin contact, according to the invention;  
         [0011]    [0011]FIG. 3 provides a rear view of the assembled triaxial pin contact, according to the invention and  
         [0012]    [0012]FIG. 4 provides a front cut away view of the assembled triaxial pin contact, according to the invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0013]    [0013]FIG. 1 is an exploded isometric view of one example embodiment of a triaxial pin contact  100 . As shown in FIG. 1, triaxial pin contact  100  includes an outer contact  101 . Outer contact  101  may be may be constructed of a brass alloy or other suitable material substance. Outer contact  101  has a front opening  114 , a rear opening  115 , and an outer pin  102  attached to its rear portion. As will be discussed further, outer pin  102  extends beyond rear opening  115  of outer contact  101  to facilitate the connection of outer contact  101  with a communication medium. Such communication medium may include a cable or substrate (e.g., printed circuit board). Outer pin  102  may carry a ground potential or signal between the communication medium and outer contact  101 . Front opening  114  receives a corresponding mating connector.  
         [0014]    A first insulator  103  fits within outer contact  101  and provides an insulative barrier between the signal or ground conducting outer contact  101  and an intermediate contact  104 . First insulator may be constructed of a plastic or polymer compound, for example Victrex Peek™ polymer, manufactured by Victrex. Intermediate contact  104  may be constructed of a copper alloy or other suitable material substance. First insulator  103  and outer contact  101  may have an interference fit such that a front end  111  of first insulator  103  fits securely within front opening  114  of outer contact  101 .  
         [0015]    First insulator  103  also has a rear end  112  that receives an intermediate contact  104 . Intermediate contact  104  has flexible members  105  that act as “fingers” in conducting a signal or ground to an intermediate pin  106 , located on the rear portion of intermediate contact  104 . Intermediate contact  104  and first insulator  103  may have an interference fit such that the front portion of intermediate contact  104  (i.e., flexible members  105 ) fits securely with front end  111  of first insulator  103 . Moreover, front end  111  of first insulator  103  has a surface that protects flexible members  105  from being undesirably bent or distorted. Such damage typically is referred to in the industry as probe damage and/or over-sized pin damage, for example. For example, front end  111  of first insulator  103  may be have a taper or other surface that prevents a mating connector or other object from accessing the exterior side of flexible members  105 , so as to undesirably bend flexible members  105 .  
         [0016]    A second insulator  107  has through holes to receive and electrically isolate intermediate pin  106  and intermediate contact  104  from a center contact  108 . Center contact  108  may be constructed of a copper alloy or other suitable material substance. Second insulator  107  may be made from a plastic, rubber or other insulating material. Center contact  108  may be positioned to be located within the center, or nearly so, of both outer contact  101  and intermediate contact  104  by second insulator  107 . Also, second insulator  107  may be in an interference fit with a protrusion  113  on center contact  108 . The interference fit of second insulator  107  and protrusion  113  permits a front end of center contact  108  to be at or near front opening  114  of outer contact  101 , such that center contact  108  may make electrical connection with a mating connector entering front opening  114  of outer contact  101 .  
         [0017]    Center contact  108  also has a center pin  110  on its rear portion. Center pin  110  permits a ground or signal to be carried from a mating connector that makes contact with the front end of center contact  108  to a communication medium (e.g., cable or substrate) connected to center pin  110 . A third insulator  109  has through holes that permit the passage of center pin  110 , intermediate pin  106 , and outer pin  102 . Second insulator  107  may be made from a plastic, rubber or other insulating material. Third insulator  109  fits within rear opening  115  of outer contact  101 . Third insulator  109  may be made from a plastic, rubber or other insulating material.  
         [0018]    Although triaxial pin contact  100  is shown in FIG. 1 as having a substantially circular shape, it should be appreciated that the components in triaxial contact  100  may have any shape suitable for a particular application. For example, in certain applications triaxial contact may have a tubular or square shape. Furthermore, it should be appreciated that the invention contemplates any type of pin contact, including those other than triaxial pin contacts, that require the protection of flexible members (like flexible members  105 ) from being distorted and bent. For example, the invention contemplates a contact, similar to the contact in FIG. 1 that does not have a center contact. In this case, insulator  103  protects flexible members  105  from becoming bent and unusable by either a mating connector or another foreign object.  
         [0019]    Triaxial pin contact  100  may be used in any connector application. For example, triaxial pin contact may be constructed in accordance with MIL-C-39029/90A specification requirements.  
         [0020]    [0020]FIG. 2 provides a front view of an assembled triaxial pin contact  100 . As shown in FIG. 2, triaxial pin contact  100  has front opening  114 . Front opening  114  receives a mating connector. Front opening  114  provides a mating connector with access to outer contact  101 , intermediate contact  104 , and center contact  108 . Front opening  114  also provides a corresponding mating connector with access to first insulator  103 . More specifically, first insulator  103  protects flexible members  105  of intermediate contact  104  from undesirably being bent by the mating connector or any other object that may come into contact with triaxial pin contact  100 . Such protection may be accomplished using a number of techniques and structures contemplated by the invention.  
         [0021]    [0021]FIG. 3 provides a cut away view of the assembled triaxial pin contact  100 , further detailing the protection of flexible members  105 . As shown in FIG. 3, first insulator  103  has a flanged portion  301 , under which the front end of flexible members  105  is seated. Flanged portion  301  provides a protective “ledge” or curved rim under which flexible members  105  are located. A mating connector designed to accept center conductor  108  and to make contact with flexible members  105  and intermediate contact  104  will ride along flanged portion  301 . By directing the mating connector in such a way, the mating connector is ensured of properly making contact with the interior portion of intermediate contact  104 , and not making an improper connection with the exterior portion of intermediate contact  104 . Preventing contact with the exterior portion of intermediate contact  104  keeps the mating connector from undesirably bending flexible members  105  inward, and perhaps making an electrical connection between flexible members  105  and center conductor  108 .  
         [0022]    In addition to flanged portion  301 , flexible members  105  may have a tapered portion  302 . Tapered portion  302  further protects the exterior portion of flexible members  105  from being undesirably contacted by a mating connector. Tapered portion  302  permits flexible members  105  to act as a ramp-like guide in shepherding the mating connector within intermediate contact  104 , thus making electrical connection with the interior of flexible members  105 . Tapered portion  302  may be tapered in an outward direction toward an outer boundary of outer contact  101 .  
         [0023]    [0023]FIG. 4 provides a rear view of the assembled triaxial pin contact  100 , further detailing one example of the layout of outer pin  102 , center pin  110 , and intermediate pin  106 . As shown in FIG. 4, intermediate pin  106  and center pin  110  are located within the circumferential area of triaxial pin contact  100 . In one embodiment, for example, center pin  110  may be located at the center of the rear portion of triaxial pin contact  100 . Outer pin  102  is attached to outer contact  101  and thus may be located on the outside rear insulator  109 . Alternatively, outer pin  102  may be located on the interior portion of the shell of outer contact  101 , and thus pass through rear insulator  109 .  
         [0024]    The length and shape of outer pin  102 , center pin  110 , and intermediate pin  106  may vary depending upon the particular application. For example, outer pin  102 , center pin  110 , and intermediate pin  106  may be substantially circular or substantially square. In addition, the diameter (i.e., if circular) or surface contact area (i.e., if square) may be of any size depending upon the desired application. Furthermore, as discussed, each of outer pin  102 , center pin  110 , and intermediate pin  106  may carry a data signal and/or ground signal from the connecting medium to a mating connector inserted into front opening  114  of triaxial pin contact  100 .  
         [0025]    The invention is directed to an electrical connection device. It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the invention. While the invention has been described with reference to certain embodiments, it is understood that the words that have been used herein are words of description and illustration, rather than words of limitation. For example, although the invention was described in the context of a triaxial electrical contact, it will be appreciated that the techniques and structure described may be equally applied to any type of electrical contact or electrical connector. Also, although the invention has been described with reference to certain components on the electrical contact or connector, it should be appreciated that the configuration described is just one example of a configuration that is capable of providing such an inventive electrical contact or connector. Accordingly, the invention contemplates any other electrical connector or contact, not described in the specification, that satisfies the example provided.  
         [0026]    Further, although the invention has been described herein with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed herein. Rather, the invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. Those skilled in the art, having the benefit of the teachings of this specification, may effect numerous modifications thereto and changes may be made without departing from the scope and spirit of the invention in its aspects. Those skilled in the art will appreciate that various changes and adaptations of the invention may be made in the form and details of these embodiments without departing from the true spirit and scope of the invention as defined by the following claims.