Patent Publication Number: US-7896687-B1

Title: Electrical connector with slide mounted adaptor

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to electrical connectors and, more specifically, to an electrical connector that facilitates the assembly of the connector. 
     2. Description of the Related Art 
     Electrical connectors are used in a wide variety of applications. The use of standardized electrical connectors provides an easy and convenient method for establishing an electrical connection between two separate elements of an electrical circuit. The use of such electrical connectors is well known in the art. The manufacture of electrical connectors can, however, present difficulties. 
     For some applications, the size of one or both of the electrical connectors must be relatively small. This can present manufacturing difficulties. For example, many military vehicles have a communication system that utilizes a first electrical connector that is mounted within the vehicle. A communication device having a second electrical connector can be deployed with the vehicle by detachably connecting the second electrical connector with the first electrical connector. In such applications, physical size limitations are often imposed on the electrical connectors. The resulting electrical connectors are often referred to as “low profile” connectors. 
     The reduced size of such low profile connectors can present manufacturing difficulties. For example, low profile connectors typically include a connector body having a compact longitudinal length and an adaptor that extends laterally outwardly from the connector body. An insert having a plurality of either male or female contacts is mounted in the connector body for engagement with the other electrical connector. A wire bundle extends through adaptor and the individual wires of the bundle are each connected with one of the contacts on the insert. For such low profile connectors it is common to first attach the adaptor to the connector body, machine the adaptor after installation on the body and insert the wire bundle through the adaptor after machining the adaptor. Each of the wires are connected to one of the contacts on the insert after inserting the wire bundle through the adaptor and only then is the insert installed in the connector body. This sequence of events typically requires a wire-clearance cut-out on the insert to allow the insert to be installed in the connector body. 
     When manufacturing a connector in this manner, the post-installation machining of the adaptor significantly increases the expense of manufacturing the electrical connector and the wire-passage cut-out on the insert forms an undesirable manufacturing artifact on the final product. An electrical connector design that provided for the manufacture of a low profile electrical connector which eliminated one or both of these attributes of existing low profile connectors is desirable. 
     SUMMARY OF THE INVENTION 
     The present invention provides an electrical connector that can be readily assembled and facilitates the efficient manufacture of a low-profile connector. 
     The invention comprises, in one form thereof, an electrical connector that includes a body defining a passage extending from a first opening to a second opening. The body defines an open-ended slot that extends from the second opening. The connector also includes an adapter having a mounting section and a hollow elongate stem. The mounting section and the slot are slidably engageable such that the adapter is mountable on the body by sliding the mounting section into the slot with the stem extending outwardly from the body. An insert is disposed within the body and has a first surface, an opposite second surface, and a plurality of electrical contacts extending from the first surface to the second surface. The insert is positioned within the body with the first surface of the insert being operably accessible through the first opening of the passage. A plurality of wires extend through the hollow stem into the passage with each of the wires being conductively engaged with one of the electrical contacts. A cap is securable to the body wherein securement of the cap to the body closes the second opening. 
     The invention comprises, in another form thereof, an electrical connector that includes a body defining a passage extending from a first opening to a second opening. The body defines a radially inwardly projecting stop surface within the passage with the stop surface facing the second opening and an open-ended slot extending from the second opening. The connector also includes an adapter having a mounting section and a hollow elongate stem. The mounting section and the slot are slidably engageable wherein the adapter is mountable on the body by sliding the mounting section into the slot with the stem extending outwardly from the body. An insert is disposed within the body wherein the insert has a first surface, an opposite second surface, and a plurality of electrical contacts extending from the first surface to the second surface. The insert is positioned within the body with the first surface being operably accessible through the first opening of the passage. A plurality of wires extends through the hollow stem into the passage with each of the wires being conductively engaged with one of the electrical contacts. A cap is securable to the body proximate the second opening of the passage. A spacer is disposed within the passage between the cap and the insert wherein securement of the cap to the body secures the adapter within the slot, closes the second opening and biases the spacer toward the insert whereby the insert is securely positioned between the stop surface and the spacer. 
     The invention comprises, in yet another form thereof, a method of assembling an electrical connector. The method includes providing a connector body and forming a passage extending from a first opening to a second opening. An open-ended slot is also formed in the body wherein the slot extends axially from the second opening. The method also includes providing an insert having a first surface and an opposite second surface with a plurality of electrical contacts extending through the insert from the first surface to the second surface and an adapter with a mounting section and a hollow elongate stem. A plurality of wires are conductively engaged to the plurality of contacts and the insert is positioned within the passage of the body with the first surface facing the first opening after conductively engaging the plurality of wires to the plurality of contacts. The plurality of wires are extended through the hollow stem and the adaptor is installed on the body by sliding the mounting section into the slot at the second opening of the passage. A cap is installed on the body and closes the second opening. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above mentioned and other features of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein: 
         FIG. 1  is an exploded and partially cut-away side view of an electrical connector. 
         FIG. 2  is a bottom view of the connector body. 
         FIG. 3  is an end view of the insert. 
         FIG. 4  is an end view of the spacer. 
         FIG. 5  is a top (relative to  FIG. 1 ) view of the spacer. 
         FIG. 6  is an end view of the adaptor. 
         FIG. 7  is a bottom view of the adaptor. 
         FIG. 8  is a top view of the adaptor. 
         FIG. 9  is an end view of the connector body. 
         FIG. 10  is a cross sectional side view of an assembled connector. 
         FIG. 11  is an exploded and schematic perspective view of the adaptor and connector body. 
         FIG. 12  is another exploded and schematic perspective view of the adaptor and connector body. 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the several views. Although the exemplification set out herein illustrates an embodiment of the invention, in one form, the embodiment disclosed below is not intended to be exhaustive or to be construed as limiting the scope of the invention to the precise form disclosed. 
     DETAILED DESCRIPTION OF THE INVENTION 
     An electrical connector  20  in accordance with the present invention is shown in an exploded view in  FIG. 1 . After describing the various parts of the illustrated connector  20 , the assembly of connector  20  will be discussed. Connector  20  includes a connector body  22 , an insert  24 , a plurality of wires  26 , an adaptor  28 , a spacer  30 , a resilient annular member  32  and a cap  34 . An EMI (electromagnetic interference) sheathing  36  is attached to adaptor  28  to shield the braided wire cable  27  formed by wires  26  from electromagnetic interference. Sheathing  36  extends outwardly from adaptor  28  but does not form a part of the electrical connector  20 . 
     Turning first to body  22 , a passage  38  extends from a first opening  40  to a second opening  42  and defines an axis  44 . The inner surface  46  of body  22  defines passage  38  and includes an annular flange  48  that projects radially inwardly into passage  38 . Flange  48  defines a stop surface  50  that faces second opening  42 . Insert  24  is installed in passage  38  by insertion through second opening  42  and stop surface  50  limits the axial movement of insert  24  toward first opening  40 . Flange  48  also includes two assymetrically located notches  63 . 
     Insert  24  is shown in  FIGS. 1 and 3  and includes a plurality of electrical contacts  52  that extend from a first surface  54  to an opposite second surface  56  of the insert  24 . The body  58  of insert  24  through which contacts  52  extend is formed out of an electrically insulative material. In the illustrated embodiment, insert body  58  is formed out of a polymeric material and takes the form of two cylindrical disks with the smaller diameter portion adjacent first surface  54  fitting within the opening of annular flange  48  and the larger diameter portion of insulative body  58  forming an annular surface  60  that engages stop surface  50 . Insert  24  also includes two projecting tabs  61  that extend from surface  60 . Tabs  61  are seated within notches  63  when installing insert  24 . The assymetrical positioning of tabs  61 /notches  63  requires that insert  24  be installed at a particular rotational orientation within passage  38 . 
     At the first surface  54 , contacts  52  form a standardized interface that allows insert  24  to be electrically coupled with a cooperating electrical connector  18 . For example, the illustrated insert  24  forms a male insert with contacts  52  projecting outwardly from insulative body  58  and being engageable with a corresponding female component. In alternative embodiments of the present invention, insert  24  could be a female connector or have a custom, non-standardized configuration. 
     When insert  24  is installed within passage  38  with surface  60  engaged with stop surface  50 , the standardized electrical connector interface formed by electrical contacts  52  at first surface  54  will be operably accessible through first opening  40  of passage  38 . In other words, a cooperating electrical connector  18 , schematically depicted in  FIG. 1 , can be inserted through opening  40  to conductively engage contacts  52 . As can be seen in  FIG. 1 , a groove  62  can be formed in passage  38  proximate first opening  40  for holding an O-ring  64  to thereby sealingly engage the cooperating electrical connector  18  inserted into opening  40 . Connector body  22  also includes exterior axially extending ridges  23  over a significant portion of its exterior surface that allow a user to more easily grasp connector body  22  when connecting or disconnecting the cooperating electrical connector  18 . 
     At the second surface  56  of insert  24 , contacts  52  form a cylindrical opening to thereby allow the conductive element of an individual wire  26  to be inserted into each of the contacts  52 . Solder  55  is used to mechanically secure and form an electrically conductive engagement between the wires  26  and their respective contacts  52 . Alternative methods of mechanically securing and conductively engaging wires  26  and contacts  52  can also be used. 
     Body  22  also includes an open-ended slot  66  that extends axially from second opening  42  and is defined by an edge  68 . As can be seen in  FIG. 2 , slot  66  has a generally U-shaped configuration with the open-end of slot  66  terminating at second opening  42  to allow adaptor  28  to be installed in slot  66  by sliding adaptor  28  into slot  66  at opening  42 . Adaptor  28  has a groove  70  that extends along a portion of its outer perimeter. Groove  70  firmly receives slot edge  68  when sliding adaptor  28  into slot  66  to thereby securely hold adaptor  28  within slot  66 . 
     As can also be seen in  FIG. 1 , body  22  includes a helical thread  72  within passage  38  at second opening  42  and a radially inwardly projecting shoulder surface  74 . Shoulder surface is positioned proximate second opening  42  and faces second opening  42 . Thread  72  is located between shoulder  74  and second opening  42 . Resilient annular member  32  is positioned on shoulder surface  74  and takes the form of a rubber washer in the illustrated embodiment. Cap  34  includes an exterior helical thread  76 . Cap  34  is detachably secured to body  22  by engaging threads  72  and  76 . 
     When cap  34  is secured to body  22 , cap  34  compresses annular member  32  against shoulder surface  74 . Annular member  32  is also compressed against spacer  30  and adaptor  28  when cap  34  is secured to body  22 . Adaptor  28  and insert  24  are thereby secured in place by the installation of cap  34 . Cap  34  includes a slot or other engagement feature  78  that allows cap  34  to be engaged manually or with a tool when securing cap  34  with body  22 . In the illustrated embodiment, cap  34  includes a slot  78  that can be engaged with a flat-head screw driver. 
     Turning now to the adaptor  28 , adaptor  28  includes a mounting portion  80  and a hollow elongate stem  82 . When adaptor  28  is installed in slot  66 , stem  82  extends outwardly from body  22  and a wire passage  84  extending through stem  82  is in communication with passage  38 . In the illustrated embodiment, the exterior of stem  82  includes a knurled portion  86  located between two raised collars  88  to facilitate the termination and securement of EMI sheath  36  about the exterior of stem  82 . 
     As mentioned above, adaptor  28  includes a groove  70  that extends along a portion of the outer perimeter of mounting section  80 . Mounting section  80  includes a portion  81  that projects inwardly into passage  38 . The inwardly projecting portion  81  defines a ledge surface  90  at its upper end. Inwardly projection portion  81  also defines a flange  83  along its perimeter. Surface  83   a  of flange  83  forms one sidewall of groove  70 . Flange  83  and groove  70  extend along the outer perimeter of mounting section  80  from one end  90   a  of ledge surface  90  to the opposite end  90   b  of ledge surface  90 . When adaptor  28  is installed in slot  66 , ledge surface  90  is positioned substantially planar with shoulder surface  74  and forms a continuation of shoulder surface  74  across slot  66  such that ledge surface  90  and shoulder surface  74  extend along the entire circumference of passage  38 . Annular member  32  engages either shoulder surface  74  or ledge surface  90  along the entire circumference of passage  38  when member  32  is compressed by the installation of cap  34 . In the illustrated embodiment, that portion of mounting section  80  that is disposed between ledge  90  and second opening  42  is cutback and forms arcuate surface  75 . Surface  75  does not project inwardly into passage  38  or interfere with the rotation of cap  34  as it is installed on body  22 . 
     U-shaped groove  70  is formed by three surfaces, bottom surface  70   a  and sidewall surfaces  71   a  and  83   a . As mentioned above, sidewall surface  83   a  is located on flange  83 . Surface  71   a  is located on flange  71 . Flange  71  extends along the perimeter of adaptor  28  opposite flange  83 . Instead of terminating near surface  90 , however, flange  71  extends to opposite ends of upper surface  73 . Upper surface  73  of adaptor  28  is positioned substantially flush with surface  41  located at the axial end of connector body  22  when adaptor  28  is fully seated within slot  66 . 
     When adaptor  28  is installed on connector body  22 , bottom groove surface  70   a  engages edge surface  68 , sidewall surface  71   a  engages surface  69  located adjacent slot  66  on the exterior surface of connector body  22 , and sidewall surface  83   a  engages surface  67  located on adjacent slot  66  on inner surface of connector body  22 . The engagement of the groove surfaces  70   a ,  71   a  and  83   a  with connector body  22  prevents relative movement between adaptor  28  and connector body  22  in all but the axial direction. Installation of cap  34  and the biasing of annular member  32  against surface  90  prevents axial movement of adaptor  28  in the assembled connector  20 . It is also noted that the engagement of surface  70   a  with edge  68  and the engagement of surface  71   a  with surface  69  both extend for the full length of slot  66 . 
     The assembled connector  20  also includes a spacer  30  that is disposed within passage  38  and positioned between insert  24  and cap  34 . Spacer  30  is illustrated in  FIGS. 1 ,  4  and  5  and has a generally C-shaped cross section. A gap  92  is defined between the two opposing limbs of the C-shaped configuration. Gap  92  extends axially and is aligned with stem passage  84  when spacer  30  is installed in passage  38  to allow for the passage of braided cable  27 . An indentation  94  with an axially extending slot  96  is located opposite gap  92 . Indentation  94  and slot  96  do not extend the full axial length of the polymeric spacer  30 . The radially inwardly projecting indentation  94  ensures that spacer  30  will be engaged with annular member  32 . 
     When cap  34  is attached to connector body  22 , the cap  34  biases spacer  30  toward insert  24  and spacer  24  thereby biases insert  24  toward stop surface  50 . As a result, insert  24  is securely held within the assembled connector  20  between stop surface  50  and spacer  30 . When cap  34  is installed on body  22 , the biasing of spacer  30  by cap  34  may be by either direct engagement of spacer  30  with cap  34  or through an intermediate part. For example, in the illustrated embodiment, spacer  30  engages annular member  32  instead of cap  34  with cap  34  biasing spacer  30  toward insert  24  indirectly through annular member  32 . Similarly, intermediate parts can be located between spacer  30  and insert  24  and/or between insert  24  and stop surface  50 . In the illustrated embodiment, insert  24  directly engages both stop surface  50  and spacer  30 . 
     After assembling connector  20 , including the installation of cap  34  on body  22 , passage  38  forms an interior chamber  100  between insert  24  and cap  34  with stem passage  84  defining the sole opening into interior chamber  100 . This interior chamber  100  is substantially sealed from the external environment due to the presence of annular member  32  and the engagement of annular surface  60  of insert  24  with annular surface  50  of flange  48  along the entire circumference of passage  38 . 
     In many prior art low profile electrical connectors, it was necessary to form a cut-out in the insert to allow the insert to be positioned within the connector body after extending wires through an adaptor stem and connecting the wires to the insert. The present invention allows for the use of an insert without such a cut-out and thereby allows insert  24  to engage stop surface  50  along a greater portion of the circumference of passage  38 . It also allows insert  24  to have a radial outer surface  98  that defines an outer perimeter of insert  24  that closely conforms to the dimensions of passage  38  adjacent stop surface  50 . In other words, it allows outer surface  98  to be positioned substantially adjacent inner surface  46  of passage  38  along the entirety of the outer perimeter defined by outer surface  98  when insert  24  is installed within connector  20 . This arrangement of insert  24  with the interior surface  46  of passage  38  and stop surface  50  limits the potential for moisture, dirt and other debris to enter chamber  100 . 
     The method of assembling electrical connector  20  will now be discussed. When assembling electrical connector  20 , braided cable  27  is inserted through stem passage  84  and the conductive elements of the individual wires  26  are exposed. Each of the conductive elements of wires  26 , e.g., a copper wire, is then conductively engaged with a respective one of the contacts  52 . In the illustrated embodiment, wires  26  are soldered to contacts  52 . After connecting wires  26  and contacts  52 , insert  24  is positioned in passage  38  proximate stop surface  50  with first surface  54  facing first opening  40 . Either simultaneously or after positioning insert  24  in passage  38 , adaptor  28  is installed by sliding adaptor  28  into slot  66  at opening  42  with slot edge  68  being received in groove  70 . 
     It will generally be most convenient to remove any slack in wires  26  between insert  24  and adaptor  28  prior to installing insert  24  and adaptor  28  within and on connector body  22 . This will typically mean that insert  24  will be positioned closely proximate adaptor  28  after connecting wires  26  to contacts  52  and removing any excess slack. As a result, when installing insert  24  and adaptor  28 , the insert  24  will generally enter passage  38  through opening  42  with adaptor  28  following close behind. After insert  24  enters passage  38 , adaptor  28  will be engaged with slot  66 . Insert  24  and adaptor  28  will then be moved simultaneously in an axial direction toward opening  40 . The axial insertion of insert  24  and adaptor  28  continues until insert  24  engages stop surface  50  and adaptor  28  is fully seated within slot  66 . 
     It would also be possible to engage insert  24  with stop surface  50  and only then install adaptor  28  in slot  66 . This installation sequence, however, would require additional slack in wires  26  between insert  24  and adaptor  28 . If there were insufficient space within passage  38  for the slack wire, it would be necessary to remove the excess wire by pulling wires  26  through stem opening  84  after installing insert  24  and adaptor  28  within and on connector body  22 . Thus, this alternative installation sequence will generally not provide the most desirable installation sequence. 
     After, or simultaneously with, the installation of insert  24  and adaptor  28 , spacer  30  is positioned in passage  38  proximate insert  24 . After installing spacer  30 , annular member  32  is positioned on shoulder surface  74  and then cap  34  is installed. The installation of cap  34  closes second opening  42  and biases annular member  32  against spacer  30  and ledge  90  thereby securing insert  24  and adaptor  28  in place forming an inner chamber  100 . The resulting electrical connector  20 , while not fully water-proof, can be subjected to “waterspray” and still function properly. 
     A significant advantage provided by connector  20  is that adaptor  28  can be fully machined and wires  26  can be extended through stem passage  84  and connected with contacts  52  before installing insert  24  in passage  38  or mounting adaptor  28  on connector body  22 . After connecting wires  26  with contacts  52  and extending the wires  26  through stem passage  84 , the insert  24  and adaptor  28  can be easily installed within and on connector body  22 . This configuration allows for a connector  20  having an inner chamber  100  between insert  24  and cap  34  with a relatively small axial length yet which can be manufactured and assembled with relative ease. 
     While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles.