Patent Publication Number: US-8968036-B2

Title: Electrical connector having keyways with alignment features

Description:
RELATED APPLICATION 
     The present application claims priority to U.S. Provisional Patent Application No. 61/697,484, filed Sep. 6, 2012, and titled “Keyway Visual Alignment Feature,” the entire content of which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to multi-pin plug and receptacle combinations, and more particularly to systems, methods, and devices for properly aligning a multi-pin plug and receptacle. 
     BACKGROUND 
     A variety of industrial and commercial environments require plug and receptacle combinations that conduct relatively large amperage currents. Plugs and receptacles in such commercial and industrial environments can be difficult to connect due to their size and multiple pins. Connecting the plugs and receptacles can be further complicated by the fact that there are often multiple keys and keyways on the connectors. In the past, workers connecting such plugs and receptacles often push them together and twist them until the proper key is aligned with the corresponding keyway. This push and twist approach is used because there is no easily visible means for aligning the plug and receptacle. However, pushing and twisting the plugs and receptacles together can cause damage to the plugs and receptacles when they are misaligned. Accordingly, there is a need for an improved approach to aligning plugs and receptacles so that they can be more easily connected without causing damage to the components. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: 
         FIGS. 1 ,  12  and  14  show prior art male and female connectors with no alignment features visible on the exterior of the male and female connectors. 
         FIGS. 2 and 3  show side views of a pair of male and female connectors comprising an alignment feature in accordance with certain example embodiments. 
         FIGS. 4 and 5  show front views of a female connector comprising an alignment feature in accordance with certain example embodiments. 
         FIG. 6  shows a perspective view of a male connector in accordance with certain example embodiments. 
         FIG. 7  shows a front view of an insert for as male connector in accordance with certain example embodiments. 
         FIG. 8  shows as front view of a male connector with an insert in accordance with certain example embodiments. 
         FIG. 9  shows a perspective view of a male connector in accordance with certain example embodiments. 
         FIGS. 10 and 11  show a front view of a male connector in accordance with certain example embodiments. 
         FIG. 13  shows a perspective view of a properly aligned male and female connector in accordance with certain example embodiments. 
         FIGS. 15 ,  16  and  17  show additional connectors with alignment features located in various positions in accordance with certain example embodiments. 
         FIGS. 18 and 19  show additional connectors with alignment features far a non-hazardous environment in accordance with certain example embodiments. 
     
    
    
     SUMMARY 
     The present disclosure is directed to high-amperage connectors with visual alignment features. In one embodiment, as connector can comprise a male connector with a male skirt where the male skirt has two keys on an outer surface. At least one of the keys on the outer surface of the male skirt can have an alignment feature. The connector also comprises a female connector with a female skirt where the female skirt has two keyways on an inner surface of the female skirt. At least one of the keyways can have a corresponding keyway alignment feature located on the outer surface of the female skirt. The alignment features on the male skirt and the female skirt allow a user to easily align the two connectors before connecting them. 
     In another embodiment, a connector can comprise a male connector with a male skirt where the male skirt has at least one key on an outer surface. The connector also comprises a female connector with a female skirt where the female skirt has at least one keyway on an inner surface of the female skirt. The at least one keyway can have a corresponding keyway alignment feature located on the outer surface of the female skirt. The keyway alignment feature on the outer surface of the female skirt allows a user to easily align the key on the male skirt with the keyway on the female skirt. 
     DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS 
     The example embodiments discussed herein are directed to systems, apparatuses, and methods of connecting high-amperage connectors using a keyway visual alignment feature. Embodiments of connectors using a keyway visual alignment feature can take a variety of configurations based on the amperage rating, the conductor size, the size of the plug and receptacle and the arrangement of the conductor pins. Embodiments of connectors using a keyway visual alignment feature may be compliant with one or more industry standards such as those set by Underwriters Laboratory (UL) or the National Electric Code (NEC). 
     Referring to  FIGS. 1 ,  12  and  14 , illustrations are shown of conventional male and female connectors. For example,  FIG. 1  shows a connector  100  comprising a male connector  105  and a female connector  110 . As shown in these figures, there are no features on the outside of the male and female connectors that allow a person to easily align the connectors. Accordingly, a person must push and twist the male and female connectors together blindly until the correct alignment is achieved. 
     Referring now to  FIG. 2 , an example male and female portions of a connector are shown in accordance with one embodiment. In the embodiment shown in  FIG. 2 , the connector  200  comprises a male connector  202 , which comprises a coupling nut  215  and as male skirt  205 . The female connector  203  comprises threads  220  and female skirt  210 . One difference between the male connectors shown in  FIG. 1  and  FIG. 2  is that the coupling nut  215  in  FIG. 2  has a greater range of motion allowing it to be pushed back further to show the key  225  (the 12 o&#39;clock key) on the male skirt  205 . When the connectors are properly aligned and connected, the key  225  located on the male skirt  205  must fit within a keyway (not shown in  FIG. 2 ) located on the inside surface of the female skirt  210 . 
     Also shown in the example connector  200  of  FIG. 2 , key  225  includes an alignment feature  230  in the form of a groove on the key  225 . The female skirt  210  includes alignment feature  235  which is also in the form of a groove in this example. When a person attempts to connect the male connector  202  with the female connector  203 , the person can align alignment feature  230  and keyway alignment feature  235  as shown in  FIG. 2  and in  FIG. 13 . When the two alignment features  230  and  235  are properly aligned, the key  225  and keyway (not shown in  FIG. 2 ) are also properly aligned. 
     While the alignment features  230  and  235  are shown as grooves in the example embodiments shown in  FIGS. 2 and 13 , in alternate embodiments, the alignment features can take a variety of other forms, including but not limited to, a notch, an arrow, a dimple, a pilot hole, a painted mark, or a mark left using a masking technique during an anodizing process. Likewise, in alternate embodiments the alignment features can be located at different axial positions along the male connector and female connector. For example, in the embodiment shown in  FIG. 2 , keyway alignment feature  235  is located near the leading edge of the female skirt  210 . However, in alternate embodiments, such as those described further below in connection with  FIGS. 15 ,  16  and  17 , the keyway alignment feature on the female skirt can be positioned further back from the edge of the female skirt  210  closer to the threads  220  or on the other side of the threads (the right side of the threads in  FIG. 2 ). 
       FIG. 3  shows a view of the same pair of connectors from the opposite side. In the view shown in  FIG. 3 , the other key  250  (not the 12 o&#39;clock key) is visible on the opposite side of the male skirt  205 . The female skirt  210  does not show an alignment feature on the side shown in  FIG. 3 . The alignment feature on the female skirt  210  is not visible in  FIG. 3  because it is located on the opposite side and aligned with the 12 o&#39;clock key as shown in  FIG. 2 . The single alignment feature on the female skirt, as shown in  FIG. 2 , allows a person to quickly and easily align the 12 o&#39;clock keyway on the female skirt with the 12 o&#39;clock key on the male skirt. 
     In an alternate embodiment, a male connector may have only a single key on the outer surface of the male skirt instead of two or more keys. Similarly, the female connector may have only a single keyway located on an inner surface of the female skirt instead of two or more keyways. In such an embodiment, a keyway alignment feature located an the outside surface of the female skirt corresponds with the position of the keyway on the inner surface of the female skirt. The keyway alignment feature located on the outside surface of the female skirt allows for easy alignment of the keyway on the inner surface of the female skirt with the key on the outer surface of the male skirt. In such an embodiment where there is only a single key on the male skirt, it is not necessary to have an alignment feature on the key on the male skirt. The keyway alignment feature of such an embodiment can be helpful where it is not easy to look into the barrel of the female connector in order to align the male key with the female keyway. 
     Referring to the example embodiment shown in  FIGS. 4 and 5 , a front view looking down the barrel of the female connector is shown.  FIG. 5  is an enlarged view of a portion of  FIG. 4 . In the enlarged view shown in  FIG. 5 , the keyway alignment feature  235  is shown in cross-section as a groove along the outside of the female skirt  210 . Also visible in  FIG. 5  is the keyway  260  located on the inner surface of the female skirt  210 . When the male connector and female connector are properly aligned and connected, the key  225  fits into keyway  260 . Also shown in  FIG. 5  is insert key  510  which allows one to determine if an insert is aligned as described in greater detail in connection with  FIGS. 7 and 8 . 
     Referring to  FIG. 6 , an exploded perspective view of the male connector  202  is shown in accordance with an example embodiment.  FIG. 6  shows male skirt  205  with male key  225  and male alignment feature  230 . Also shown in  FIG. 6  are the conductor pins  615 , rigid insert  605  and resilient insert  610 . When assembled, the conductor pins  615  pass through the apertures in the rigid insert  605  and the resilient insert  610 . 
     As shown in  FIG. 7 , the rigid insert  605  has a 12 o&#39;clock insert keyway  705  and another insert keyway  710 . In alternate embodiments, the rigid insert  605  can comprise more than two insert keyways. An insert key, such as the insert key  510  illustrated in  FIG. 5 , can be inserted into insert keyway  705  or insert keyway  710 .  FIG. 8  shows a front view of the assembled male connector  202  with the rigid insert  605  inserted. In the embodiment shown in  FIG. 8 , the rigid insert  605  has been “reclocked,” meaning that it has been rotated from the position shown in  FIG. 7 . In  FIG. 8 , the rigid insert  605  has been rotated such that insert keyway  710  (near the number 6 pin) is aligned with the 12 o&#39;clock key  225 . As illustrated in  FIG. 8 , an added benefit of the alignment feature  230  on key  225  is that it permits a person to determine which key is the 12 o&#39;clock key for alignment of an insert. 
     Referring to  FIG. 9 , a perspective view of male connector  202  is shown in accordance with an example embodiment. The perspective view of male connector  202  shows key  250  on the exterior of male skirt  205  and insert key  910  located on the inside surface of the male skirt  205 . As shown in the front cross-sectional view in  FIG. 10 , the insert key  910  is aligned with key  225 . The insert key  910  can be used to align an insert.  FIG. 11  is an enlarged view of a portion of  FIG. 10  showing insert key  910 , key  225  and alignment feature  230 . 
       FIGS. 15 ,  16  and  17  show alternate embodiments where the keyway alignment feature on the female connector is located in different locations. For example, the female connector  1503  in  FIG. 15  shows three potential options for locating a keyway alignment feature. Female connector  1503  shows a keyway alignment feature  1570  located on the hex and a keyway alignment feature  1575  located on the collar. An additional keyway alignment feature  1580  is provided by aligning the beginning of the threads  1520  with the keyway (not shown) on the female connector  1503 . Keyway alignment feature  1580  is different from keyway alignment features  1570  and  1575  in that keyway alignment feature  1580  is not an additional feature that is machined or applied to the female connector  1503 . Each of keyway alignment features  1570 ,  1575  and  1580  are aligned with the 12 o&#39;clock keyway (not shown) located on the inside surface of the female skirt. In one embodiment, all of keyway alignment features  1570 ,  1575  and  1580  can be included. In another embodiment, only one or two of keyway alignment features  1570 ,  1575  and  1580  can be included. 
       FIG. 16  shows yet another embodiment with keyway alignment features on female connector  1603 . In female connector  1603 , keyway alignment feature  1635  and keyway alignment feature  1670  are shown aligned with the 12 o&#39;clock keyway  1660  located on the inside surface of the female skirt. 
       FIG. 17  shows yet another embodiment with keyway alignment features on female connector  1703 . In the example shown in  FIG. 17 , keyway alignment features  1735 ,  1775  and  1770  are aligned with the 12 o&#39;clock keyway located on the inside surface of the female skirt  1710 . Additionally, the beginning of the threads on female connector  1703  are also aligned with the 12 o&#39;clock keyway on the inside surface of the female skirt  1710 . As shown in  FIG. 17 , the keyway alignment features on the female connector  1703  are aligned with the alignment feature  1730  on the key  1725  on the male connector  1702 . As illustrated in  FIGS. 15 ,  16 , and  17 , the components of the connectors, including the skirts, threads, hex and collar can be located in various arrangements in different types of connectors. Consistent with these various arrangements, one or more alignment features can be located at various positions on the outside of the connector to assist the user in aligning the male and female connectors. 
       FIGS. 18 and 19  show yet other embodiments of connectors with alignment features. The examples shown in  FIGS. 18 and 19  are connectors for non-hazardous environments. As with the previous embodiments,  FIGS. 18 and 19  each comprise a male connector with an alignment feature  1830  and  1930  located on a key.  FIGS. 18 and 19  also show a female connector with a keyway alignment feature  1835  and  1935 . Unlike the hazardous environment connectors shown in previous embodiments, the female connectors of the embodiments shown in  FIGS. 18 and 19  have threads relatively close to the leading edge of the female connector. Given the placement of the threads on the female connectors in  FIGS. 18 and 19 , the keyway alignment features  1835  and  1935  are disposed adjacent to both the threads and the leading edge of the female connector. 
     Alternate embodiments of electrical connectors can use alignment indicators of different types and in different locations than those shown in the example embodiments described above. Moreover, multiple different types of alignment indicators can be used for connectors having more than two keys. 
     While the example embodiments of connectors with a keyway visual alignment feature are discussed herein, the principles of the described embodiments can be applied to a variety of types of electrical connectors. Accordingly, many modifications of the embodiments set forth herein will come to mind to one skilled in the art to which pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings, many modifications of the embodiments set forth herein will come to the mind of one skilled in the art. Therefore, it is to be understood that keyway visual alignment features for electrical connectors are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of this application. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.