Abstract:
A system and method for providing an electrical and mechanical connection is provided. The system and method include features that permit two connectors to mate with each other at a specific attitude and maintain both a mechanical and an electrical connection under a variety of conditions including bumping of the connection under everyday situations. A predetermined level of force acting to separate the two connectors will cause the connectors to separate without causing substantial damage to the connector.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates generally to electrical connectors. More particularly, the present invention relates to an connector system and method connecting an electrical plug and a receptacle.  
       BACKGROUND OF THE INVENTION  
       [0002]     Nurses in hospitals can be very busy and responsible for a large amount of patients at one time. In order to enable nurses to quickly identify particular needs of an individual patient, nurse call and alert systems have been developed. For example, a patient having a problem or needing the attention of a nurse can activate an actuator located in the patient&#39;s room and it will indicate to the nurses located at a central nurses station that a patient is requesting assistance. In other systems, electronic medical devices that monitor and/or treat patients can have alarms when patient&#39;s vital signs or treatment schedule is outside a predetermined parameter. In such cases, these machines can send a signal to a nurses station alerting the nurse of the problem.  
         [0003]     Many of these nurse call systems include cables or wires running from the patient&#39;s room to the nurses station and connect to a terminal unit at the nurses station. A connector system and method may be used in order to connect the cable running from the patient&#39;s room to the terminal located at the nurses station.  
         [0004]     Connector systems often connect a cable with another cable or with a terminal unit by making both an electric and mechanical connection. Desirable features of an electrical connection include positive contact between the electrical portions in each side of the connector in order to provide a reliable electronic connection. Desirable features associated with mechanical connection include a mechanical connection strong enough so that the connectors will not come apart if they are knocked or jostled in everyday use.  
         [0005]     In addition, it may be desirable to permit the connectors to separate if a force acting to separate the connecting reaches a predetermined level. Ideally, separation will not damage the connectors, and they can be repeatedly connected and separated. Further, it may be desirable for some electrical connections to mechanically permit the connectors to only come together in certain predetermined attitudes with respect to each other to ensure the proper electrical leads contact corresponding electrical leads in the connection.  
         [0006]     Accordingly, it is desirable to provide a system and method for making both an electric and mechanical connection between the cable and the terminal unit that ensures a positive electrical contact and keeps the connectors together so they do not easily come apart during normal jostling or everyday use. Further, in some applications it may desirable to provide a connection that mechanically can only be connected with the connectors approaching each other in a single attitude in order to assure proper electrical leads match up with the corresponding leads on the other side of the connection.  
       SUMMARY OF THE INVENTION  
       [0007]     The foregoing needs are met, to a great extent, by the present invention, wherein in one aspect an apparatus is provided that in some embodiments provides an electrical and mechanical connection between a cable and a terminal unit creating a positive electrical connection. In some embodiments the connection creates a mechanical connection strong enough to avoid the connectors from separating during everyday use. Some embodiments provide an electrical connection that can come together in only one attitude with respect to each other to ensure that the proper electrical leads connect only to corresponding electrical leads on the other side of the connection.  
         [0008]     In accordance with one embodiment of the present invention, a mechanical and electrical connector is provided. The connector includes: a housing having a face; an electrical connector mounted to the housing configured to engage with a second electrical connector and when engaged, provide an electrical connection; and a receiver connected to the housing and encompassing at least part of the electrical connector, the receiver defining a key slot configured to cause the second electrical connector to engage the electrical connector at a specific orientation, and the receiver further defining a groove configured to communicate with a corresponding ridge associated with the second electrical connector to hold the second electrical connector in engagement with the electrical connector up to a predetermined level of force exerted on the second electrical connector to pull the second electrical connector away from engaging the electrical connector and resiliently flexing at least one of the ridge and the receiver to allow the ridge to move out of the slot when the force is greater than the predetermined level.  
         [0009]     In accordance with another embodiment of the present invention, a mechanical and electrical connector is provided. The connector includes: means for housing; means for establishing an electrical connection mounted to the housing and configured to connect with a second means for establishing an electrical connection; and means for receiving connected to the housing means and encompassing at least part of the means for establishing an electrical connection, the receiving means defining a key slot configured to cause the second electrical connecting means to engage the means for establishing an electrical connector at a specific orientation, and the receiver further defining a groove configured to communicate with a corresponding ridge associated with the second electrical connector to hold the second electrical connector in engagement with the means for providing an electrical connection up to a predetermined level of force exerted on the second electrical connecting means to pull the second means for establishing an electrical connection away from engaging the means for establishing an electrical connection and resiliently flexing at least one of the ridge and the receiving means to allow the ridge to move out of the slot when the force is greater than the predetermined level.  
         [0010]     In accordance with another embodiment of the present invention, a method of establishing an electrical and mechanical connection is provided. The method provides: aligning a first electrical connector to a second electrical receiver; inserting an alignment key into an alignment key shaft; flexing at least one of receiver and a ridge while moving the first electrical connector toward the second electrical connector; and electrically connecting the first electrical connector with the second electrical connector.  
         [0011]     In accordance with yet another embodiment of the present invention, a system for providing an electrical connection is provided. The system includes: a first connector; a second connector configured to communicate electrically and mechanically with the first connector; wherein the electrical connection is accomplished by a pin contacting an electric lead. The mechanical connection is accomplished by: receivers encompassing one of the first and second electrical connectors and upon the first and second electrical connecter coming in close proximity with each other, a ridge located on the other connector than the connector having the receivers slides across the receivers causing at least one of the ridge and receivers to flex at least until the ridge enters a groove defined by the other connector than the connector having a ridge, and an alignment key located on one of the first and second connector configured to enter an alignment slot located on the other connector than the connector having the alignment key.  
         [0012]     There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.  
         [0013]     In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.  
         [0014]     As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]      FIG. 1  is a perspective view of a plug connected to a receptacle forming a both mechanical and electrical connection in accordance with a preferred embodiment of the present invention.  
         [0016]      FIG. 2  is a perspective view of the plug approaching the receptacle of  FIG. 1 .  
         [0017]      FIG. 3  is a perspective view of a front side the receptacle shown in  FIG. 1 .  
         [0018]      FIG. 4  is a perspective view of the back side of the receptacle shown in  FIG. 1 .  
         [0019]      FIG. 5  is a front perspective view of the plug of  FIG. 1 .  
         [0020]      FIG. 6  is a top view of the plug and receptacle of  FIG. 1 .  
         [0021]      FIG. 7  is a back view of the receptacle of  FIG. 1 .  
         [0022]      FIG. 8  is a cross section view take along line AA in  FIG. 7 .  
         [0023]      FIG. 9  is a cross section view taken along the line BB in  FIG. 7 . 
     
    
     DETAILED DESCRIPTION  
       [0024]     The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. An embodiment in accordance with the present invention provides a plug that is configured to both mechanically and electrically connect to a receptacle.  
         [0025]     An embodiment of the present inventive apparatus is illustrated in  FIG. 1 .  FIG. 1  shows a connector system  10 . The connector system  10  includes a receptor  12  and a plug  14 . The plug  14  is shown inserted into the receptor  12 . The receptor  12  includes a housing  16 . The housing  16  may be metal or plastic or any other suitable material. As shown in  FIG. 2  three receivers  18  are mounted on the housing  16  of the receptor  12 . The receivers  18  have a generally circular shape. The receivers  18  are configured to meet with, and receive the plug housing  50 .  
         [0026]     As shown in  FIG. 2 , located between the receivers  18  are relief slots  30 . A key slot  26  is defined by two of the receivers  18 . The key slot  26  is a generally rectangular shape and is configured to receive a corresponding key  32  located on the plug  14 . One purpose of the key  32  and key slot  26  is to prevent the plug  14  from entering the receptor  12  at any attitude other than the one with the key  32  fits into the key slot  26 . Permitting the plug  14  to only fit in the receptor  12  in one way helps ensure that the electrical contact made between the plug  14  and the receptor  12  is appropriate and the electrical connectors not intended to contact each other do not contact. Inside the key slot  26  is a key hole shaft  58  shown in  FIG. 2 . The key hole shaft  58  fits into a corresponding hole  56  (see  FIG. 5 ) located within the key  32 .  
         [0027]     Turning now to  FIG. 2 , a contact face  28  is located within the area defined by the receivers  18 . The contact face  28  has embedded within it contact pads  54 . The contact pads contact pins  48  mounted into the plug  14  (see  FIG. 5 ).  
         [0028]     The receptor  12  has within the housing  16  bolt holes  40 . The bolt holes  40  permit the receptor  12  to be mounted on to a structure such as a terminal structure for a nurse call station. In some embodiments of the invention, self threaded screws will be inserted and turned in the bolt holes  40  to mount the receptor  12  to a terminal housing. Mounted behind the housing  16  are bolt housings  42  which will provide spacing between the housing  16  and the device to which the receptor  12  is mounted.  
         [0029]     On the opposite side of the receptor  12  that receives the plug  14 , extend printed circuit board contacts  38 . In some embodiments the invention, the circuit board contacts  38  may be molded into a plastic housing  16  of the receptor  12 .  
         [0030]     On the back side of the plug  14  are solder cups  36  which, in some embodiments of the invention, are molded into a plastic housing  50  of the plug  14 . The solder cups  36  are electrically connected to wires within a cable that extends to a patient&#39;s room in a nurse call system. The plug  14  terminates the cable and permits the cable to be connected to a terminal.  
         [0031]     According to some embodiments of the invention, the plug  14  mates with the receptor  12  to form a mechanical connection that resists disconnecting when subjected to a force pulling the plug  14  away from the receptor  12  until the force reaches a predetermined level. Further, once the mechanical connector is broken, it can be reformed and broken again without substantial loss integrity of the connection  10 .  
         [0032]     In other words, breaking the connection  10  does not normally involve breaking any of the parts of the connectors  12  and  18 . For example, a mechanical connection in accordance with the invention can be accomplished by putting a groove  34  into the housing  50  of the plug  14 . The groove  34  will contact and connect with a ridge  60  protruding from the receivers  18  as shown in  FIGS. 8 and 9 . When the plug  14  is inserted into the receptor  12  the housing  50  of the plug  14  will contact the protruding groove  60  and push the receivers  18  and flex them slightly out of the way. To aid in the flexing of the receivers  18  relief slots  30  and  26  are provided. The slots  30  and  26  permit or facilitate the flexing of the receivers  18  and either embodiments of the invention rather than the receivers  18  flexing the plug housing  50  could flex or in some embodiments flexure could occur in both the receivers  18  and the plug housing  50 . Once the slot  34  is in place and aligned with the protruding ridge  60 , the receivers  18  move back to the original position or near the original position and hold the plug  14  in place as shown in  FIGS. 8 and 9 .  
         [0033]     According to some embodiments of the invention, the electrical contact between the plug  14  and the receptor  12  is accomplished as follows. As shown in  FIG. 5 , the plug  14  has pins  48 , which in some embodiments of the invention are spring probe pins  48  which are extended in an outmost position by internal springs. The spring probe pins  48  will come in contact with corresponding contacts pads  54  and the spring probe pins  48  will change length slightly as the springs compress due to the close contact with the contact pads  54 . In some embodiments of the invention, there are nineteen (19) spring probe pins  48  and nineteen (19) corresponding contact pads  54 .  
         [0034]     The pins  48  are given protection from an extended portion  46  of the housing  50 . The extended portion  46  extends beyond the maximum length of the pins  48  long enough to render the plug  14  scoop proof. The term scoop proof refers to the problem of pins or other fragile elements being damaged by being “scooped” when they are protected by an extension on a housing that provides general protection of the pins. In some instances, the pins can be damaged by an object having a curved surface. (Often another connector having an extended portion of the housing protecting recessed electrical components.) If the two connectors come together in a skewed manner, there is a potential for the extended housing in one connector could contact the pins on the other connector and bend, break, or otherwise damage them. Scoop proofing the connectors done by giving the extended portion of the housing sufficient length that a corresponding connector could not scoop deep enough to contact the pins.  
         [0035]     The contact pads  54  are located to be substantially coplanar with the contact face  28 . When the plug  14  mates with the receptor  12  the spring probe pins  48  will contact and butt up against the contact pads  54  as shown in  FIGS. 8 and 9 . The actual physical contact between the spring probe pins  48  and the contact pads  54  provide the electrical connection between the plug  14  and the receptacle  12 . The springs in the spring probe pins  48  assist in ensuring the contact with the contact pads  54 .  
         [0036]     As illustrated in  FIGS. 8 and 9  the spring probe pins  48  directly connect through the housing of the plug to the solder cups  36  of the plug  14 . Likewise, the contact pads  54  of the receptor  12  directly connect to the printed circuit board connector leads  38 . In preferred embodiments of the invention, there is a one to one correspondence between the spring probe pins  48 , the contact pads  54 , the printed circuit board receptors  38  and the solder cups  36 . In the preferred embodiments of the invention there are 19 of each of these elements  48 ,  54 ,  38 , and  36 .  
         [0037]     In some embodiments of the invention, as shown in  FIGS. 7 and 8 , the back of the housing  16  has spacers  62  mounted near the printed circuit board leads  38 . The spacers  62  permit a gap to exist between the housing  16  and the printed circuit board when the printed circuit board leads  38  are inserted into the printed circuit board.  
         [0038]     In some embodiments of the invention, the plug  14  on the plug housing  50  includes grippers  68  as shown in  FIGS. 8 and 9 . A gripper  68  located on the plug housing  50  and is configured to grip a cable covering that is pushed up and surrounding, at least part, the housing  50 . Substantially, in some embodiments of the invention, the receivers  18  substantially form a flat surface  24  on the receptor  12 . Further, in some embodiments of the invention, when the key  32  is inserted into the key slot  26 , the key  32  helps to define the flat surface  24 . In embodiments of the invention where a key hole shaft  58  is configured to fit within the hole  56  in the key  32  the key hole shaft  58  will fit into the key hole  56  and the key  32  as substantially as shown in  FIG. 8 .  
         [0039]     It will be understood that the connectors  14  and  16  and connector systems can be modified from the exemplary embodiment shown and still be in accordance with the invention. For example, features that are shown and described herein as existing on one connector  12  or  14  and having a corresponding feature or the other connector may be reversed as to which connector, the plug  14  or the receptor  12  the feature is located on. Whether the plug  14  or the receptor  12  contains the key, it will be the other connector that contains the key slot  26 . Likewise, the key hole shaft  58  and the hole in the key  56  can also be reversed upon which element, the plug  14  or the receptor  12  is found. In addition, the spring probe pins  48  can be carried on the receptor  12 , rather than on the plug  14 . The protrusion ridge  60  and the corresponding groove  52  can be reversed as to whether they are found on the plug  14  on the receptor  12 .  
         [0040]     The question of whether the receptor  12  or the plug  14  carries a particular element configured to aid in the mating of the two parts, the plug  14  and the receptor  12 , is a design choice that may be made by one skilled in the art after having reviewed this disclosure to meet the specific needs as an individual application.  
         [0041]     The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.