Patent Publication Number: US-9413099-B2

Title: Feed through panel connector with seal

Description:
RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application Ser. No. 61/605,281, filed Mar. 1, 2012, which is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to electrical connectors and in particular, to bulkhead, panel or feed-through connectors for electrical use. In particular, the panel connectors disclosed herein can seal against the panel to provide some measure of water and weather resistance. More particularly, the disclosure is directed to panel connectors that can be sealingly locked to the panel by twisting or rotation of the connector and that can be locked to the panel from the outside. Even more particularly, the disclosure is directed to panel connectors that cannot be unlocked once locked to the panel. 
     BACKGROUND ART 
     Panel electrical connectors are typically used to provide electrical connections through a pass-through or feed-through hole from one side of a bulkhead, wall or panel to the other side. Typically, the panel can separate two spaces or areas from each other. For example, a panel or wall can separate an engine compartment from a passenger compartment of a vehicle. One of the areas can be referred to as a module area and another as an outer area. Generally, the module area can simply be the area that has more limited accessibility then the outer area. One example would be a panel that makes up part of an enclosure. The inside of the enclosure could be considered as the module area even though the term module area is not limited to an enclosed space. Accordingly, a panel connector can provide an electrical connection from the outside to the interior of the enclosure. Panel connectors are suitable for use in a wide variety of applications such as for example power generation and supply systems, and aeronautic and automotive applications. 
     Panel connectors may be configured to lock to the panel and allow removal or unlocking of the connector, or to prevent unlocking or removal from the panel. Some lockable panel connectors can have two parts. A mounting part can be mounted to the panel opening and the connector part can lock with the mounting part. These two-part connectors typically require access to both sides of the panel, which may be difficult especially in the case of cramped enclosures or other module areas. There are also one-piece panel connectors that are configured to interact or mate with the pass-through hole in the panel, which has complementary or interacting locking structures. 
     For certain uses, the panel connector may include the ability to seal against the panel to prevent dirt, debris or liquid from an exposed side of the panel to enter the other side of the panel. Typically, in order to provide watertight sealing and/or to prevent removal of the panel connector, the connector is made to be installed to the module area side of the panel, which can be referred to as an inside-out installation. In this type of inside-out installation, the connector can be locked against and even sealed to the panel side facing the module area with one of the connector ends extending into the module area and an opposite end extending through the pass-through hole into the other or outer area. With inside-out installations for connectors having an end passing through the panel opening and extending towards the outer area for mating with a push-in or plug-in type connector, pushing against the panel connector from the outer area can cause the panel connector to be pushed out of engagement with the panel and/or can diminish the integrity of the seal between the panel connector and the panel. Inside-out installation also tends to be difficult and/or time consuming mostly due to the tight spaces involved. 
     SUMMARY OF THE INVENTION 
     The present disclosure concerns panel connectors that provide simple locking and effective and robust sealing in an outside-in installation where the panel connector locks to the outside face or the more accessible side of the panel and provides a watertight seal. In an aspect of the disclosure a connector has a simple locking mechanism and the ability to prevent unlocking and/or disengagement of the connector from the panel. 
     In one aspect, the present disclosure is directed to an electrical connector for locking to a panel having an annular rib extending from an outer surface of the panel and surrounding a pass-through hole having an engagement lip and a stop surface. The connector includes a housing having an insertion portion at one end of the housing for entering the pass-through hole and an outer portion at an opposite end of the housing, a flange and a sealing gasket. The insertion portion includes a locking member and a first engagement member positioned about an outer wall of the insertion portion. The flange extends radially outwardly from the housing adjacent the insertion portion and includes a channel at an outer end portion thereof facing in the direction of the insertion portion for receiving the annual rib. The flange is spaced apart from the first engagement member to define a gap for receiving the engagement lip to lock the connector to the panel. The sealing gasket is disposed in the channel about an inner wall of the channel for radial compression between an inner surface of the annular rib and the inner wall, wherein insertion of the insertion portion into the pass-through hole causes the annular rib to enter the channel, and rotation of the connector causes the engagement lip to enter the gap to lock the connector to the panel and moves the locking member into engagement with the stop surface to restrict counter-rotation and removal of the connector. 
     In another aspect, the present disclosure is directed to a twist-lock electrical connector for use with a panel separating an open area and a module area with the panel having a pass-through hole including two engaging lips having detent surfaces, a deflecting tab defining a mating slot having a stop surface and an annular rib circumscribing the opening and extending into the open area. The connector includes a housing having a cylindrical insertion portion at one end for entering the pass-through hole and a mating connector portion at an opposite end; a resilient locking member and two locking tabs disposed about the cylindrical insertion portion, one of the locking tabs includes a detent member; a flange extending radially outwardly from the housing adjacent the insertion portion and spaced axially apart from the locking tabs to define first and second gaps therebetween for capturing the first and second engaging lips to lock the connector to the panel; a channel formed around the outer end of the flange and facing in the direction of the panel for receiving the annular rib, the channel defined by an inner wall, a base wall and an outer wall; and a sealing gasket positioned in the channel and against the inner wall such that an engagement surface faces the outer wall for sealing compression between the inner wall and an inner surface of the annular rib to form a seal between the connector and the panel. Insertion of the insertion portion into the pass-through hole causes the annular rib to engage the channel and rotation of the connector causes the locking member to engage the deflecting tab and deflect until mating with the mating slot at which point the detent member engages the detent surface to restrict continued rotation and wherein the stop surface cooperates with the locking member to restrict counter-rotation. 
     In yet another aspect, the present disclosure is directed to a twist-lock connector for locking engagement to a panel. The connector includes a housing having an insertion portion, an intermediate portion and an end portion; a deflectable locking arm disposed on an outer cylindrical surface of the insertion portion; a flange extending radially from the intermediate portion and having a channel at an outer end thereof, the channel facing in the direction of the insertion portion, first and second locking tabs disposed on the outer cylindrical surface of the insertion portion and spaced apart from the flange to define first and second gaps respectively therebetween, at least one of the first and second locking tabs including a detent member; and a sealing gasket positioned in the channel and against an inner wall of the channel such that an engagement surface of the sealing gasket faces an opposing outer wall of the channel for radial sealing compression. Insertion of the insertion portion into a pass-through hole in a panel moves an annular rib surrounding the pass-through hole into the channel for sealing engagement with the sealing gasket, and rotation of the twist lock connector causes entry of engagement members of the panel into first and second gaps, capture by the locking tabs and deflection of the locking arm, until the detent member engages a detent surface of the panel opening to restrict continued rotation at which point the locking arm engages a slot in the opening of a panel to restrict counter-rotation of the twist-lock connector. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the following detailed description, reference will be made to the following drawings, in which like reference numerals refer to like components, and in which: 
         FIG. 1  is a perspective view of one embodiment of a panel connector for locking to a panel according to the present disclosure; 
         FIG. 2  is a perspective view of the panel connector of  FIG. 1  locked to a panel according to the present disclosure; 
         FIG. 3  is a perspective view of another embodiment of a panel connector according to the present disclosure locked to a panel that is part of an enclosure; 
         FIG. 4  is a perspective view of another embodiment of a panel connector according to the present disclosure; 
         FIG. 5  is a perspective view of a one embodiment of a panel for locking with a panel connector according to the present disclosure; 
         FIG. 6  is another perspective view of the panel connector shown in  FIG. 4  according to the present disclosure; 
         FIG. 7  is an elevation view of the panel connector shown in  FIG. 6  locked to a panel according to the present disclosure; 
         FIG. 8  is a cross-sectional view taken along line  8 - 8  of  FIG. 7 ; 
         FIG. 9  is a perspective view of one embodiment of a sealing gasket according to the present enclosure; 
         FIG. 10  is yet another perspective view of the panel connector shown in  FIG. 4  according to the present disclosure; 
         FIG. 11  is an elevation view of the panel connector shown in  FIG. 6  inserted into a panel according to the present disclosure; 
         FIG. 12  is a detailed perspective view of the panel connector shown in  FIG. 11  inserted into a panel just prior to being locked to the panel according to the present disclosure; and 
         FIG. 13  is a perspective view of the panel connector of  FIG. 6  locked to a panel according to the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The detailed embodiments disclosed herein are merely exemplary of the inventions disclosed herein, which may be embodied in various forms, and specific details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present approach in virtually any appropriate manner. 
       FIGS. 1 and 2  show one embodiment of a panel connector  10  disengaged and engaged to a panel “P”, respectively. Panel “P” can be part of a wall of an enclosure as shown in  FIG. 3  or a wall separating two compartments (not shown). The connector  10  can include features which interact or cooperate with complementary features of panel “P”. The features of the panel which cooperate with connector  10  to providing locking, sealing and/or removal prevention can be included as part of the panel or can be included on a separate panel opening adapter which can mount to a typical pass through hole of a panel “P”. Accordingly, the term “panel” used herein is understood to refer to either panel itself or a panel adapter. 
     In one embodiment, panel connector  10  can be a single piece connector for locking to a panel through rotation of the connector and can provide electrical connection from one side of the panel to the other. The panel can include a pass through hole structured to cooperate with structures of connector  10 . Connector  10  can provide electrical connection including signal and/or power through the pass through hole and can include a variety of electrical connection interfaces at both ends of the connector  10 . The connector  10  can lock to the panel with or without providing sealing to retard or prevent passage of dirt, debris and/or liquid through the pass through hole. In one embodiment, connector  10  can be locked to the panel “P” to provide a desired sealing rating. The connector can also include features to prevent removal or unlocking of the connector from the panel. Indeed, the panel connector can include one or more of the above identified features in any combination. 
     In one embodiment shown in  FIG. 4 , panel connector  10  can have housing  12 . Housing  12  can have an insertion portion  14  at one end, an outer portion  16  at an opposite end and an intermediate portion  18  therebetween. Insertion portion  14  can have a cylindrical wall  20  configured to enter a module area through a panel pass through hole or opening such as opening “O” of one embodiment of a panel “P” shown in  FIG. 5 .  FIG. 5 . shows panel “P” from the outer area. Intermediate portion  18  can be sized larger than opening “O” to prevent connector  10  from completely passing through the opening “O”. Outer portion  16  can reside on the outer area of panel “P” when insertion portion  14  is inserted into opening “O” as shown in  FIG. 2 . Outer portion  16  can have a generally rectangular wall  22 . It is understood that the shape of the housing can vary and is not limited to the embodiment shown in  FIG. 4 . It is preferable that the shape of intermediate portion  16  generally corresponds to the shape of the pass through opening especially when sealing of the opening is desired. 
     In one embodiment, connector  10  can include at least one engagement member  24  to lock or secure connector  10  to panel “P”. As shown in  FIG. 6 , connector  10  can have two engagement members  24 ,  26  disposed on outer surface  28  of circular wall  20 . In another embodiment, connector  10  can have more than two engagement members. As shown in  FIG. 6  engagement members  24 ,  26  can be disposed at opposite sides of circular wall  20  and spaced apart from annular surface  30  of intermediate portion  18  to define gaps  32 ,  34  therebetween. Gaps  32 ,  34  can receive portions of the panel “P”. For example, with reference to  FIG. 5 , panel opening “O” can include two slots “S 1 ”, “S 2 ” sized to allow engagement members  24 ,  26  to enter opening “O” therethrough. Slots “S 1 ”, “S 2 ” can define adjacent engagement lips “E 1 ”, “E 2 ” which upon rotation of connector  10  can enter gaps  32 ,  34 . Engagement lips “E 1 ”, “E 2 ” can be the portions of panel “P” that are adjacent corresponding slots “S 1 ”, “S 2 ” in the direction of locking rotation. The locking rotation as viewed in  FIG. 5  is the clockwise direction shown by arrow “CR”. The portions of engagement lips “E 1 ”, “E 2 ” received in gaps  32 ,  34  can be trapped between engagement members  24 ,  26  and annular surface  30  to secure or lock connector  10  to panel “P”.  FIG. 7  shows connector  10  in the locked position as viewed from the module area. 
     Optionally, one or more of engagement members  24 ,  26  can each include a cam surface  25 ,  27  respectively ( FIGS. 4 and 6 ). In particular, cam surfaces  25 ,  27  can be positioned on the leading side or the side facing the direction of rotation such that on the occasion that insertion portion  14  is not fully inserted through pass-through opening “O” rotation of connector  10  sloping surfaces  25 ,  27  can contact the axially extending faces F 1 , F 2  of engagement lips E 1 , E 2  and transfer some of the rotational motion to axial movement in the direction of insertion. The angle of cam surfaces  25 ,  27  can be from about 15 to about 60 degrees, more preferably from about 25 to about 50 degrees and even more preferably from about 30 to about 45 degrees. In the embodiment shown in  FIGS. 4 and 6  the angle of cam surfaces  25 ,  27  can be about 45 degrees. 
     In one embodiment, engagement members  24 ,  26  and corresponding slots S 1 , S 2  can be sized or shaped differently to provide a keying function to ensure desired alignment of the connector such that the connector cannot be mounted to the panel in an inverted position. For example, engagement member  24  and slot S 1  can have a greater radial length than engagement member  26  and slot S 2 . In another embodiment, instead of being differently sized or shaped to ensure proper alignment, engagement members  24 ,  26  can be disposed asymmetrically about circular wall  20 . For example, instead of having engagement members  24 ,  26  disposed at directly opposite sides of circular wall  20 , i.e. positioned at 180 degrees from each other, engagement members  24 ,  26  can be disposed at from about 170 to about 179 degrees from each other. 
     Connector  10  can also include the ability to seal the pass-through hole “O” of panel “P”. In one embodiment, Intermediate portion  18  can have flange  36  extending radially outwardly therefrom. Flange  36  can include annual surface  30  at its inner end and channel  38  at an outer end of the flange  36 . Channel  38  can be open in the direction of the insertion portion  14  for receiving annular rib “R” which can extend from the side “OA” of the panel facing the outer area as shown in  FIG. 5 . As shown in  FIG. 8 , channel  38  can have parallel inner wall  40  and outer wall  42  both extending in an axial direction and a bridging wall  44  extending in a radial direction connecting inner wall  40  and outer wall  42 . 
     An annular sealing gasket  46  can be disposed in channel  38 . Annular sealing gasket  46  shown in  FIG. 9  can have a resting surface  48  and an opposite engaging surface  50 . Engaging surface can be ribbed or have ridges  52  for sealing against annular rib “R” in a radial direction. As shown in  FIG. 8  resting surface  48  can be disposed against inner wall  40  such that ridges  52  extend in the radial direction. Sealing gasket  46  can have a diameter smaller than the diameter of intermediate portion  18  and in particular smaller than the diameter measured between opposite sides of inner wall  40  such that sealing gasket  46  can be stretched in order to be placed about inner wall  40 . The elasticity of the sealing gasket  46  can hold gasket  46  in place. Channel  38  can be sized such that entry of the annular rib “R” compresses radially against ridges  52  to create a seal. In one embodiment, the seal created by the above-described arrangement can have an I6K7 and/or IP6K9K sealing performance For example the combination of radial sealing compression combined with protective outer wall  42  can provide a seal effective against pressurized water spray testing. Sealing gasket  46  can be made from an elastomeric material such as rubber based elastomeric material, a silicone based elastomeric material or a composite elastomeric material. In one embodiment sealing gasket  46  can be made from a silicone elastomeric material. 
     Optionally, connector  10  can include a locking mechanism for preventing or resisting unlocking connector  10  from the panel “P”. In one embodiment shown in  FIG. 10 , connector  10  can have a resilient locking member  54 . Locking member  54  can have a cantilevered arm  56  and a locking tab  58  at an end of the arm  56 . Tab  58  can extend radially outwardly in a direction away from circular wall  20 . Cantilever arm  56  can move from the locked or rest position shown in  FIG. 10  to a retracted position (see  FIG. 12 ). Cantilevered arm  56  can be formed from a cut-out region of circular wall  20 . Tab  58  can include an angled surface  60  on the side of tab  58  facing the direction of rotation and an upright surface  62  on the opposite side of tab  58  as shown in  FIGS. 7 and 10 . Locking member  54  can cooperate with panel “P” to resist counter-rotation and unlocking of connector  10  once the locking member has properly engaged panel “P” as discussed below. 
     With reference to  FIG. 5  which shows the side “OA” of panel “P” facing the outer area and  FIG. 7  which shows the side of panel “P” facing the module area, opening “ 0 ” can have an entry slot “ES” for allowing entry of tab  58  and locking slot “LS” for receiving tab  54  following deflection of tab  58  when the connector  10  is in the locked position. Tab  58  can be positioned axially along circular wall  20  such that when insertion portion  14  has entered opening “O”, rib “R” has entered channel  38  and engagement members  24 ,  26  have entered through slots “S 1 ”, “S 2 ” tab  54  can reside in entry slot “ES”. Entry slot “ES” can include a biasing surface “BS” positioned to engage angled surface  60  of tab  58  upon rotation in the locking direction, and locking slot “LS” can include an upright stop surface “SS” in facing relation with and for contacting upright surface  62  of tab  58  when connector  10  is in the locked position. Alternatively, biasing surface “BS” and stop surface “SS” can be considered as part of a biasing tab positioned between entry slot “ES” and locking slot “LS”. The slope or angle of biasing surface “BS” and angled surface  60  can be similar to each other. For example, biasing surface “BS” and angled surface  60  each can be from about 15 to about 60 degrees, more preferably from about 25 to about 50 degrees and even more preferably from about 30 to about 45 degrees. In one embodiment, the angle of both biasing surface “BS” and angled surface  60  can be about 30 degrees. 
     At the insertion position shown in  FIG. 11 , locking tab  58  resides in entry slot “ES”. Rotation of the connector  10  is shown by the counter-clockwise arrow since the view is from the module side of the panel “P”. Such rotation can cause angled surface  60  to contact biasing surface “BS” and deflect tab  58  radially inwardly towards the center of connector  10  as shown in  FIG. 12 . Tab  58  can remain in this deflected position with further rotation until the tab rebounds upon encountering locking slot “LS” as shown in  FIG. 7 .  FIG. 7  shows the connector  10  in the locked position. Support post  59  positioned on the inside of circular wall  20  can prevent cantilever arm  56  from over deflection such as during handling or shipment. 
     In this locked position, the connector can resist counter-rotation to resist or prevent removal of connector  10  since counter-rotation can result in upright surface  62  of tab  58  abutting or contacting stop surface “SS” of locking slot “LS”. The contacting of stop surface “SS” with upright surface  62  can prevent counter rotation once tab  58  mates or engages with locking slot “LS”. Connector  10  can also prevent or resist unlocking or removal of connector  10  from panel “P” by resisting or preventing continued rotation or rotation in the locking direction, i.e. clockwise when viewed from the outer area as shown in  FIG. 5  and counter-clockwise when viewed from the module area as shown in  FIGS. 7 and 11 . 
     In one embodiment, tab  58  can have an a second upright surface instead of angled surface  60  for contacting opposing stop surface “OS” shown in  FIG. 7  when the connector  10  is further rotated in the locking direction. The upright surface which can replace angled surface  60  can still allow tab  58  to be deflected by biasing surface “BS” with an appropriately sloped surface such as biasing surface having a 10-30 degree inclination. 
     In another embodiment as shown in  FIG. 10 , connector  10  can have a detent member  64  for engaging or contacting a stop surface of panel “P”. In the embodiment shown in  FIG. 10 , detent member  64  can be part of one of the engagement member such as engagement member  26  and extend axially from an end opposite sloping surface  27  in the direction towards outer end  16 . When connector  10  is rotated in the locking direction, detent member  64  can contact axially extending face “F 2 ” of engagement lip E 2  upon tab  58  engaging locking slot “LS” or slightly thereafter (see  FIG. 5 ). In other words, the distance traveled by tab  58  from entry slot “ES” to locking slot “LS” should equal or be slightly less than the distance traveled by detent member  64  before contacting a detent surface such as axially extend face “F 2 ”. In another embodiment both engagement members  24 ,  26  can have a detent member. Alternatively, the side of panel “P” facing the module area can have a stop surface which can be contacted by another part of engagement members  24 ,  26 , such as forward or leading surface  65  shown in  FIG. 10 . 
     Connector  10  can house a variety of connection interfaces to permit electrical connection to insertion portion  14  and outer portion  16 . For example, insertion portion  14  can have one or more female connection ports for receiving terminals from another connector or electrical device in the module area and outer portion  16  can have male terminals or contacts for connecting to another mating connector or electrical device. This arrangement can also be reversed. In one embodiment, connector  10  can have one or more passages  66  as shown in  FIGS. 8 and 10  that can extend from the insertion portion towards the outer portion. Passages  66  can receive blade terminals (not shown) attached to wires or other conductors such that the ends of the blade terminal extend through passages  66  and towards and emerging at the outer end portion  16  for subsequent mating with a mating connector shown in  FIG. 3 . Connector  10  can have two rows of 4, 6, or 8 passages  66 . Interior of connector  10  can include positive latch reinforcement (PLR) features  68 . Connector  10  can also include connector position assurance (CPA) components. 
     Optionally, housing  12  can include a latch member  70  at the outer portion  16  for locking connector  10  to a mating connector mated at the outer portion  16 . In addition, housing  12  can include a visual marker to signal that the connector is in the fully locked position. For example flange  36  can include marker  70  ( FIG. 6 ) which can align with complementary marker “M” on panel “P” as shown in  FIG. 13  when in connector  10  is in the locked position. 
     Many different materials can be used to construct housing  12 . In one embodiment housing  12  can be made from a plastic or polymer material or polymer composite material. For example housing  12  can be made from a composite nylon polymer. In one embodiment connector housing  12  can be made from 20% glass filled SPS nylon blend. 
     While the present subject matter disclosed herein has been described in detail with reference to the foregoing embodiments, other changes and modifications may still be made without departing from the spirit or scope of what is disclosed. It is understood that the specific structures, and arrangements described herein are not to be limited by the embodiments described herein.