Patent Publication Number: US-9899750-B1

Title: Modular crimp contact

Description:
FIELD OF INVENTION 
     The present invention is related generally to a custom crimp contact system and method. More particularly, the present invention relates to a crimp contact system, which is adapted to be used with circular, non-circular commercial grade connectors and cable splices for use in subsea or terrestrial applications. The present invention provides a new system and method for attaching typical electrical contact by replacing it with a custom crimp contact. 
     BACKGROUND OF THE INVENTION 
     There are many known methods for attaching a connector to the end of a conductor or wire for use as an electrical connection. These systems typically involve soldering or crimping to secure the electrical contact to the conductor. These processes or assemblies can be difficult to complete or assemble when installing on multi-contact connectors and may be susceptible to human error and/or material failure. 
     The known systems and methods for securing a connector to a conductor can be time consuming and expensive. Additionally, other methods that do not use soldering or crimping may not be suitable for high stress or high differential pressure applications such as those typically found in oil and gas extraction and mining systems. 
     Furthermore, other systems for securing a conductor to a connector that do not require soldering may not be suitably modular or repairable. For example, for known systems if the connection on the end of a conductor becomes damaged, the entire connector may have to be removed and an entirely new connection may need to be installed. 
     Thus, what is needed is a modular connection system that does not require soldering, potting, or lengthy setting and curing times that can be attached to a conductor quickly and easily. 
     SUMMARY OF THE INVENTION 
     The present invention provides a modular system and method for an electrical contact. The electrical contact comprises a connection member, a crimping member, a locking ring and a conductor. The present invention provides a faster and easier method for securing an electrical contact to the end of a conductor. 
     Known methods for soldering a typical circular, commercial grade connector are time-consuming and inefficient. Known methods may include a typical circular, commercial grade connector having three separate components: a connector body, a collar and an endbell. The current methods of soldering a connection to conductors in a cable are inefficient and negatively affect productivity due to inconsistencies which can arise from manual labor through human error and through the long process of soldering of each contact in multi-conductor assemblies. The present invention provides a more standardized process which is more consistent and reliable than the methods of the prior art. 
     The present invention strives to increase efficiency and productivity by utilizing a modular crimp contact system. The modular crimp contact system of the present invention replaces the time-consuming soldering process, with a standardized, repeatable and reliable process. The modular crimp contact system of the present invention effectively removes as many as five steps from the known soldering connection processes by crimping a crimping member onto a conductor and securing the crimping member in a connection member with a locking ring. Additionally, the present invention may further comprise a flame rated thermoplastic polyurethane that chemically bonds with the molding materials. 
     Since the endbell used by the prior art methods is not used, the present invention removes the coating process previously necessary to bond the overmold to the endbell. Furthermore, the pre-potting process previously required to reduce injection machine blowout is not necessary. Additionally, with the modular crimp contact system of the present invention, there will be a complete elimination of blow out caused by injection or compression molding and pushing out of the inserts in the connectors, since the crimping member is crimped onto the conductor instead. The present invention solves multiple issues with the current process by removing unnecessary, complicated, and time consuming steps. 
     In one embodiment the present invention provides a modular crimp contact system comprising: a conductor; a crimping member comprising a contact end and a crimping body end, the contact end having a larger diameter than the crimping body end, the crimping body end having a crimping body cavity adapted to receive the conductor, wherein the conductor is secured within the crimping body cavity by being crimped by the crimping body end of the crimping member; a locking ring disposed about the crimping body end of the crimping member; and a connection member having a connection end and a receiving end, the receiving end comprising a receiving end cavity adapted to be disposed about the contact end of the crimping member, the receiving end cavity further comprising a locking ring recess adapted to secure the locking ring. 
     The embodiment may further comprise wherein the locking ring comprises a locking ring body with a first end and a second end, the locking ring body being substantially circular and being tapered inward from the first end to the second end, wherein the first end abuts the contact end of the crimping member. The locking ring body may comprise a locking ring gap. The locking ring may be adapted to contract to fit within the receiving end cavity of the connection member and may further be adapted to expand to seat within the locking ring recess of the receiving end cavity. The locking ring, when seated in the locking ring recess, may secure the contact end of the crimping member within the receiving end cavity. The connection end of the connection member may comprise a pin. The connection end of the connection member may comprise a socket. The connection member may comprise a set of ridges. The set of ridges may be adapted to secure insulation about the connection member. The set of ridges may be adapted to secure the connection member in an injection or compression injection or compression molded socket. The contact end of the crimping member may comprise a tapered end adapted to pass through the locking ring. 
     In a second embodiment the present invention provides method for securing a connection member to a conductor, the method comprising: inserting an end of a conductor into a crimping body end of a crimping member, the crimping member further comprising a contact end; crimping the crimping body end of the crimping member to secure the end of the conductor within the crimping body end; placing a locking ring about the crimping body end of crimping member; inserting the crimping member into a receiving end of the connection member; and seating the locking ring in a locking ring recess in the receiving end of the connection member. 
     The method of the above embodiment may further comprise wherein the locking ring comprises a locking ring body with a first end and a second end, the locking ring body being substantially circular and being tapered inward from the first end to the second end, wherein the first end abuts the contact end of the crimping member. The locking ring body may comprise a locking ring gap. The receiving end may further comprise a receiving end cavity and the locking ring recess may be disposed within the receiving end cavity and the locking ring may be adapted to contract to fit within the receiving end cavity of the connection member and may be further adapted to expand to seat within the locking ring recess of the receiving end cavity. The locking ring, when seated in the locking ring recess, may secure the contact end of the crimping member within the receiving end. The connection member may further comprise a connection end. The connection end of the connection member may comprise one of a pin or a socket. The connection member may further comprise a set of ridges. The method may further comprise securing an insulation layer about the set of ridges of the connection member and the conductor. The method may further comprise injection molding the connection member into an injection molded socket or compression injection or compression molding. The contact end of the crimping member may comprise a tapered end adapted to pass through the locking ring. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order to facilitate a full understanding of the present invention, reference is now made to the accompanying drawings, in which like elements are referenced with like numerals. These drawings should not be construed as limiting the present invention, but are intended to be exemplary and for reference. 
         FIG. 1  provides a cross section view of a modular crimp contact system according to the present invention. 
         FIG. 2  provides a detailed cross section view of a locking ring, crimping member, and connection member according to the present invention. 
         FIG. 3  provides a bottom plan view of a locking ring according to the present invention. 
         FIG. 4  provides a side view of a locking ring according to the present invention. 
         FIG. 5  provides a side view of a connection member according to the present invention. 
         FIG. 6  provides a side view of a crimping member and conductor mated with a connection member according to the present invention. 
         FIG. 7  provides a partial cross-section view of a crimping member, a locking ring, and conductor according to the present invention. 
         FIG. 8  provides a side view of a connection pin member according to the present invention. 
         FIG. 9  provides a front view of a locking ring tool according to the present invention. 
         FIG. 10  provides a side view of a locking ring tool according to the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention will now be described in more detail with reference to exemplary embodiments as shown in the accompanying drawings. While the present invention is described herein with reference to the exemplary embodiments, it should be understood that the present invention is not limited to such exemplary embodiments. Those possessing ordinary skill in the art and having access to the teachings herein will recognize additional implementations, modifications, and embodiments, as well as other applications for use of the invention, which are fully contemplated herein as within the scope of the present invention as disclosed and claimed herein, and with respect to which the present invention could be of significant utility. 
     With reference to  FIG. 1 , a lateral cross-section view of a modular crimp contact system  100  according to the present invention is provided. The modular crimp contact system  100  comprises a connection socket member  200 , a crimping member  300 , a conductor  400 , and a locking ring  500 . The connection socket member  200  may be a socket, as shown in  FIGS. 1, 5 and 6 , or may be a connection pin member  600  as shown in  FIG. 8 . The connection socket member  200  comprises a connection end  204  having a connection end opening  202  and a connection end cavity  206  that terminates at connection end termination  208 . A series of ridges, first ridge  210 , second ridge  212 , and third ridge  214 , are disposed between the connection end  204  and the receiving end  216  of the connection socket member  200 . The receiving end  216  of the connection socket member  200  has a receiving end taper  218  that tapers towards the receiving end opening  222  of the receiving end cavity  220 . The crimping member  300  comprises a contact end  302 , a crimping member body  304 , and a crimping body end  306 . The locking ring  500  is disposed around the crimping member body  304  of the crimping member  300  and secures the crimping member  300  within the receiving end cavity  220  of the connection socket member  200 . The conductor  400  comprises a conductor end  402  and a conductor length  404 . The conductor length  404  may be any required length, and the conductor end  402  is the termination of the conductor  404 . The conductor end  402  is adapted to be disposed within the crimping body end  306  of the crimping member  300 . 
     The embodiment of the modular crimp contact system  100  provided in  FIG. 1  may be assembled by first taking the conductor  400  and removing any insulation or other non-electrically conductive coating that may be present on the conductor end  402 . The conductor  400  may be comprised of any suitable electrically conductive material such as copper. Before the conductor  400  is crimped to the crimping member  300 , a locking ring  500  is placed about the crimping member body  304  of the crimping member  300 . Alternatively, the locking ring  500  may first be placed within the locking ring recess  224  prior to mating the crimping member  300  with the connection socket member  200 . The conductor end  402  of the conductor  400  is placed within the crimping body end  306  of the crimping member  300 . A suitable crimping tool is then used to apply pressure to the exterior of the crimping body end  306  to securely affix or crimp the crimping body end  306  to the conductor end  402  of the conductor  400 . The joined crimping member  300  and conductor  400  may then be inserted into and joined with the connection socket member  200  by placing the contact end  302  of the crimping member  300  fully into the receiving end cavity  220  of the connection socket member  200  through the receiving end opening  222  until the crimping member  300  is secured by the locking ring  500 . The locking ring body  502  of the locking ring  500  will compress as it passes through the receiving end opening  222  of the receiving end cavity  220  until it expands to sit in the locking ring recess  224 . In another embodiment, where the locking ring  500  is first seated in the locking ring recess  224 , the locking ring body  502  of the locking ring  500  will expand or flex as the contact end  302  of the crimping member passes through it. In either embodiment, the locking ring  500  will secure the crimping member  300  within the receiving end cavity  220 . This will form an electrical connection between the conductor  400  and the connection socket member  200 , allowing electrical current or signals to pass from the connection end  204  to the receiving end  216  through the crimping member  300  and then to the conductor  400  and vice versa. 
     The connection socket member  200  may be formed entirely of a conductive material or may comprise a non-conductive outer layer with a conductive core that may for all or part of the interior of the connection socket member  200  including the connection end cavity  206  and the receiving end cavity  220 . The first ridge  210 , second ridge  212 , and third ridge  214  disposed at the middle of the connection socket member  200  may be used to secure the connection socket member  200  within an end bell or potting, or may be used to secure an injection molded covering or insulating layer about the connection socket member  200 . The covering or insulating layer may also be compression injection or compression molded. For example, a heat-shrinkable thermoplastic sleeve may be secured about the connection socket member  200  and conductor  400  by placing it about the connection socket member  200  and conductor  400  and heating the sleeve until it forms a tight seal. In another example the first ridge  210 , second ridge  212 , and third ridge  214  may secure the connection member  200  within an injection molded socket. In other embodiments, the connection socket member  200  may not have the set of ridges including the first ridge  210 , second ridge  212 , and third ridge  214 , or may have a differing number of ridges based on the application and requirements of the application. The conductor  400  may be a conductor of any suitable type including wires of varying American wire gauge (AWG) or other standard wire sizes. The conductor  400  may also have one or more insulating layers or jackets disposed about the conductor length  404  providing electrical and/or thermal insulation to the conductor  400 . 
     The design of the modular crimp contact system  100  enables for easy and fast removal or replacement of the connection socket member  200 . For example, if the connection socket member  200  becomes damaged or otherwise becomes non-functional, it may be removed from the crimping member  300  and replaced with a new connection member. Additionally, the connection socket member  200  may be replaced with a connection pin member  600  as shown in  FIG. 8  if necessary for the application in which the modular crimp contact system  100  is used. Moreover, the design of the modular crimp contact system  100  enables for fast initial assembly of the system  100  without requiring time and labor intensive steps such as soldering, brazing, etc. To secure the connection socket member  200  to the conductor  400 , an installer or assembler need only crimp the crimping member  300  to the conductor  400  and then seat the crimping member  300  within the connection socket member  200 . Insulation, jacketing, or other covers such as an injection molded covering may then be installed about the modular crimp contact system  100 , or the modular crimp contact system  100  may be installed as one of a set of contacts within a plug or cable termination. The area  2000  where the locking ring  500  secures the crimping member  300  within the connection socket member  200  is shown in greater detail in  FIG. 2 . 
     With reference now to  FIG. 2 , a detailed cross-section area  2000  showing where the locking ring  500  secures the crimping member  300  within the connection socket member  200  is provided. The conductor end  402  is shown in the crimping body cavity  308  of the crimping body end  306  and has been secured within the crimping body cavity  306  by a crimping tool. The contact end  302  of the crimping member  300  is pushed through the receiving end opening  222 . When the locking ring  500  reaches the locking ring recess  224  the locking ring body  502  expands to fit in the locking ring recess  224 . The locking ring interior  504  will not expand beyond the exterior of the contact end  302 . The expansion of the locking ring  500  secures the crimping member  300  within the receiving end cavity  220  of the receiving end  216  of the connection socket member  200 . The securing of the crimping member  300  by the locking ring  500  provides for a releasable and non-permanent means of securing the crimping member  300  within the connection socket member  200 . 
     With reference now to  FIGS. 3 and 4 , a bottom plan view a side view respectively of the locking ring  500  are provided. The locking ring body  502  of the locking ring  500  is not a completely closed loop. The locking ring  500  has a locking ring gap  506  in the locking ring body  502  that enables the locking ring  500  to expand and contract to fit about the crimping member body  304  and within the locking ring recess  224  and receiving end cavity  220 . The locking ring exterior  508  and locking ring interior  504  is tapered or angled such that the locking ring  500  may more easily pass through the receiving end opening  222  and into the locking ring recess  224 . The interior taper of the locking ring interior  504  enables the contact end  302  of the crimping member  300  to more easily pass through the locking ring  500  and also enables a tool such as the locking ring tool  700  shown in  FIGS. 9 and 10  to expand the locking ring  500  to remove then crimping member  300  from the connection socket member  200 . The locking ring  500  may be comprised of any suitable deformable metal or plastic capable of expanding and contracting and securing the crimping member  300  within the connection socket member  200 . 
     With reference now to  FIG. 5 , a lateral view and partial cross-section of the connection socket member  200  according to the present invention is provided. The lateral view of the connection socket member  200  shows the exterior of the connection end  204  and receiving end  216 . The connection end  204  has a connection end cavity  206  adapted to receive a pin or other connector. The connection end cavity  206  may be any shape required to receive a pin or connector used a system. The receiving end  216  has a receiving end cavity  220  accessible through a receiving end opening  222  and that also comprises a locking ring recess  224 .  FIG. 6  provides a lateral view of a modular crimp contact system  100  having a conductor  400  disposed within a crimping member  300  and secured within a connection socket member  200 . The crimping body end  306  may extend any desired length beyond the receiving end opening  222 . The conductor end  402  may or may not be exposed, and the conductor length  404  may directly abut the end of the crimping body end  306 . 
     With reference now to  FIG. 7 , a partial cross-section view of a crimping member  300 , a locking ring  500 , and conductor  400  in a mated/crimped and an un-mated state are provided. The crimping member has a contact end  302  with a contact end taper  310  that tapers to a contact end termination  312 . The taper of the contact end taper  310  enables the contact end  302  to more easily be inserted into a connection socket member  200 . The conductor end  402  and conductor length  404  is shown unmated with the crimping member  300 . The conductor end (mated)  402 A is disposed within the crimping body cavity  308  of the crimping end  306  with the locking ring  500  disposed around the exterior of the conductor end (mated)  402 A. When inside the crimping body cavity  308  the crimping member end  306  would be compressed or crimped about the conductor end (mated)  402 A to secure the conductor end (mated)  402 A within the crimping body cavity  308 . In this configuration, the locking ring  500  would be seated within the locking ring recess  224  of the connection socket member  200  by a locking ring tool  700  as shown in  FIGS. 9 and 10 . 
     With reference now to  FIG. 8 , a side view of a connection pin member  600  is provided. The connection pin member  600  is similar to the connection socket member  200  but the connection pin member  600  comprises a connection pin body  604  having a connection pin termination  602  and does not comprise a connection end opening or cavity. 
     With reference now to  FIGS. 9 and 10 , front and side views respectively of a locking ring tool  700  are provided. The locking ring tool  700  comprises a tool handle  702 , tool body  704 , tool end  708 , tool end opening  706 , and tool end termination  710 . The locking ring tool  700  is operated by a user holding the tool handle  702 . The tool end opening  706  would be placed over the crimping member body  304  and the tool end termination  710  would be placed behind the locking ring  500 . The tool end  708  would then be used to slide the locking ring  500  forward into a seated position in the locking ring recess  224  of the connection member  200 . The tool end  708  may also be slid within the locking ring interior  504  to expand the locking ring  500  to enable the crimping member  300  to be removed from the connection member  200 . 
     While the invention has been described by reference to certain preferred embodiments, it should be understood that numerous changes could be made within the spirit and scope of the inventive concept described. In implementation, the inventive concepts may be automatically or semi-automatically, i.e., with some degree of human intervention, performed. Also, the present invention is not to be limited in scope by the specific embodiments described herein. It is fully contemplated that other various embodiments of and modifications to the present invention, in addition to those described herein, will become apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such other embodiments and modifications are intended to fall within the scope of the following appended claims. Further, although the present invention has been described herein in the context of particular embodiments and implementations and applications and in particular environments, those of ordinary skill in the art will appreciate that its usefulness is not limited thereto and that the present invention can be beneficially applied in any number of ways and environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present invention as disclosed herein.