Patent Publication Number: US-9413102-B1

Title: Electrical connector assembly for data traces on a structural surface

Description:
FIELD 
     The present disclosure relates to electrical connectors, and more particularly to an electrical connector assembly for data traces formed on a structural surface. 
     BACKGROUND 
     Direct-write data traces or printed conductive traces or circuitry may be formed on metal, composite or other types of surfaces of structures of vehicles, such as aircraft, aerospace vehicles, terrestrial vehicles, watercraft and other vehicles or systems. Current electrical connectors that are configured to electrically connect to data traces on such structural surfaces and to transmit data signals from these data traces to other vehicle systems or components have several disadvantages. The electrical connectors are typically mechanically fastened to the structural surface or backing surface by screws, bolts or similar mechanical fasteners, that may not be ideally suitable for some structures, such as for example, a honeycomb or sandwich panel that may include a one or more layers of material on both sides of a layer of structural material that may include a honeycomb type structure or the like, as is commonly used in aircraft and aerospace vehicles, may be disposed between the one or more layers of material. Mechanically fastening electrical connectors to these structural surfaces can significantly increase the manufacturing costs and increase the weight of the vehicle. Additionally, fluids or moisture can infiltrate such electrical connectors at gaps between the connector shell and the structural surface. The moisture infiltration can damage the connector wiring and cause false signals to be transmitted to other systems of the vehicle. 
     SUMMARY 
     In accordance with an embodiment, an electrical connector assembly may include a connector body and a resilient spring contact configured to electrically contact a data trace formed on a structural surface. The resilient spring contact is enclosed within the connector body when the connector body is attached to the structural surface. The electrical connector assembly may also include a connector arrangement configured to electrically couple the resilient spring contact to a system. 
     In accordance with another embodiment, an electrical connector assembly may include a connector body and a plurality of resilient spring contacts. Each resilient spring contact may be configured to electrically contact a respective data trace of a plurality of data traces formed on a structural surface. The resilient spring contacts are enclosed within the connector body when the connector body is attached to the structural surface. The connector body is configured to be attached to the structural surface allowing ingress of the data traces and prevent infiltration of moisture into an interior of the connector body. The electrical connector may also include a connector arrangement configured to electrically couple the resilient spring contacts to a system of a vehicle. 
     In accordance with a further embodiment, a method for making an electrical connector may include forming a connector body and forming a resilient spring contact configured to electrically contact a data trace formed on a structural surface. The resilient spring contact is enclosed within the connector body when the connector body is attached to the structural surface. The method may also include attaching a connector arrangement to the connector body. The connector arrangement is configured to electrically couple the resilient spring contact to a system. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF DRAWINGS 
       The following detailed description of embodiments refers to the accompanying drawings, which illustrate specific embodiments of the disclosure. Other embodiments having different structures and operations do not depart from the scope of the present disclosure. 
         FIG. 1A  is a side elevation view of an example of an electrical connector assembly for electrically connecting a data trace to a system of a vehicle in accordance with an embodiment of the present disclosure. 
         FIG. 1B  is a side elevation view of the electrical connector assembly of  FIG. 1  showing the electrical connector assembly attached to a structural surface of a vehicle system in accordance with an embodiment of the present disclosure. 
         FIG. 2A  is a perspective view of an upper portion of an example of an electrical connector assembly for electrically connecting a data trace to a vehicle system in accordance with an embodiment of the present disclosure. 
         FIG. 2B  is a perspective view of an underside of the electrical connector assembly of  FIG. 2A . 
         FIG. 3  is a side elevation view of an example of a resilient spring contact in accordance with an embodiment of the present disclosure. 
         FIG. 4  is a side elevation view of an example of a resilient spring contact in accordance with another embodiment of the present disclosure. 
         FIG. 5  is a perspective view of an example of an assembly of resilient spring contacts and contact connecting links in accordance with an embodiment of the present disclosure. 
         FIG. 6  is a perspective view of an example of dielectric frame or plate assembly with resilient spring contacts and contact connecting links in accordance with an embodiment of the present disclosure. 
         FIG. 7A  is a perspective view of an example of a resilient spring contact in accordance with another embodiment of the disclosure. 
         FIG. 7B  is a side elevation view of the exemplary resilient spring contact of  FIG. 7A  and portion of a connector body. 
         FIG. 8  is a flow chart of an example of a method for making an electrical connector and attaching the electrical connector to a structural surface in accordance with an embodiment of the present disclosure. 
     
    
    
     DESCRIPTION 
     The following detailed description of embodiments refers to the accompanying drawings, which illustrate specific embodiments of the disclosure. Other embodiments having different structures and operations do not depart from the scope of the present disclosure. Like reference numerals may refer to the same element or component in the different drawings. 
       FIG. 1  is a side elevation view of an example of an electrical connector assembly  100  for electrically connecting a data trace  102  to a system  104  or systems of a vehicle  106  in accordance with an embodiment of the present disclosure. The vehicle  106  may be a land or terrestrial vehicle, a watercraft or vessel, an aircraft or aerospace vehicle or other vehicle or system that may utilize the electrical connector assembly  100  as described herein. The data trace  102  may be a direct-written data trace or printed circuit including an electrically conductive material. The data trace  102  may be formed as a linearly deposited trace or line of conductive material similar to that illustrated in  FIGS. 2A and 2B , although the embodiments described herein may also be adapted for use with other configurations. The data trace  102  may be a single data trace or a plurality of data traces  204   a - 204   d  similar to that illustrated in  FIGS. 2A, 2B, 5 and 6 . 
     The data trace  102  may be deposited or formed on a structural surface  108 . The structural surface  108  may be any type of structural surface. For example, the structural surface  108  may be (a non-exhaustive list) a backing structure on a removable item or panel, such as a thrust reverser or can cowl door of an aircraft. The structural surface  108  may also be a sandwich panel including a honeycomb structure interior portion similar to that previously described. The structural surface  108  may include a composite material, a metal, a metal alloy or other material. 
     The electrical connector assembly  100  may include a connector body  110  and a resilient spring contact  112  configured to electrically contact the data trace  102 . The resilient spring contact  112  may be formed from an electrically conductive material or semiconductor material. As described in more detail herein, the resilient spring contact  112  may be retained within the connector body  110  by a retaining mechanism  114  (shown in phantom in  FIG. 1A ) which will be described in more detail with reference to  FIGS. 2B and 6 . The resilient spring contact  112  may be configured to extend a predetermined distance “D” below the connector body  110  prior to attachment of the connector body  110  to the structural surface  108 . The resilient spring contact  112  will flexibly electrically contact the data trace  102  when the connector body  110  is placed on the structural surface  108  for attaching the connector body  110  to the structural surface  108 . The resilient spring contact  112  in electrical contact with the data trace  102  will flex into the connector body  110  and will be enclosed within the connector body  110  when the connector body  110  is attached to the structural surface  108  as will be described in more detail with reference to  FIG. 1B . 
     The electrical connector assembly  100  may also include a connector arrangement  116  or plug mounted in an upper wall  118  of the connector body  110  opposite the resilient spring contact  112 . The connector arrangement  116  may be a threaded cannon-plug connector that may be screwed into a matingly threaded opening formed in the upper wall  118  of the connector body  110 . Other types of connector plugs may also be used for the connector arrangement  116  depending upon the particular application. Signal wiring  120  may be connected from the connector arrangement  116  to the vehicle system  104  for transmitting data signals from the data trace  102  through the electrical connector assembly  100  to the vehicle system  104 . 
       FIG. 1B  is a side elevation view of the electrical connector assembly  100  of  FIG. 1A  showing the electrical connector assembly  100  attached to the structural surface  108  in accordance with an embodiment of the present disclosure. The electrical connector assembly  100  may be attached to the structural surface  108  by any suitable mechanism that may prevent fluids or moisture from entering an interior of the connector body  110 . For example, a seal  124  may be formed between the bottom of the connector body  110  and the structural surface  108 . The seal  124  is configured to prevent the infiltration of moisture within the connector body  110  when the connector body  110  is attached to the structural surface  108 . The seal  124  may include firewall sealant depending upon the application to protect the resilient spring contact  112  from temperatures that could damage the resilient spring contacts  112 . In another embodiment, the firewall sealant may be used in conjunction with the seal  124  to protect the resilient spring contact  112  from damage due to high temperatures. 
     In another embodiment, the seal  124  may be a fillet seal or other type seal between the connector body  110  and the structural surface  108  configured to prevent infiltration of moisture within the connector body  110 . 
     Referring also to  FIGS. 2A and 2B ,  FIG. 2A  is a perspective view of an upper portion  200  of an example of an electrical connector assembly  202  for electrically connecting an electrically conductive data trace  204   a  or plurality of data traces  204   a - 204   d  to a vehicle system, such as vehicle system  104  in  FIG. 1  in accordance with an embodiment of the present disclosure.  FIG. 2B  is a perspective view of an underside  206  of the electrical connector assembly  202  of  FIG. 2A . While four conductive data traces  204   a - 204   d  are shown in  FIGS. 2A and 2B  for purposes of explanation, the electrical connector assembly  202  may be configured to contact any number of data traces. The electrical connector assembly  202  may be used for the electrical connector assembly  100  in  FIG. 1 . The connector assembly  202  may include a connector body  208  similar to the connector body  110  in  FIG. 1 . The connector body  208  may be substantially box shaped similar to that illustrated in  FIGS. 2A and 2B , although other shapes of the connector body  208  may also be used depending upon the particular application. For example, the connector body  208  may be cylindrically shaped or multi-sided. 
     As best shown in  FIG. 2B , the electrical connector assembly  202  may include a plurality of resilient spring contacts  210   a - 210   d  each configured to electrically contact a respective data trace  204   a - 204   d  formed on a structural surface (not shown in  FIGS. 2A and 2B ), such as structural surface  108  in  FIG. 1 . The resilient spring contacts  210   a - 210   d  are formed from an electrically conductive material or semiconductor material. The resilient spring contacts  210   a - 210   d  will be enclosed within the connector body  208  when the connector body  208  is attached to the structural surface. As described in more detail herein, the connector body  208  is configured to be attached to the structural surface allowing ingress of the data traces  204   a - 204   d  and also prevent infiltration of moisture into an interior  211  of the connector body  208 . 
     The electrical connector assembly  202  may also include a connector arrangement  212  mounted in an upper wall  214  of the connector body  208 . Similar to that previously described, the connector arrangement  212  may be a threaded cannon-plug connector or similar connector that may be attached to the connector body  208  by screwing into a matingly threaded opening  216  formed in the upper wall  214  of the connector body  208 . Accordingly, the connector arrangement  212  may be removably attached to the connector body  208 . Other types of connector plugs could also be used for the connector arrangement  212 . The connector arrangement  212  or plug may include one or more connector pins  218  ( FIG. 2A ) that are each electrically coupled to a respective one of the resilient spring contacts  210   a - 210   d . The connector arrangement  212  may be configured to receive a mating connector arrangement (not shown in  FIGS. 2A and 2B ) for electrically coupling the data traces  204   a - 204   d  to a system of a vehicle similar to that previously described. 
     A gap  220  may be formed in a base portion  222  of a side wall  224  of the connector body  208  for ingress of the data traces  204   a - 204   d  into an interior  211  ( FIG. 2B ) of the connector body  208  when the connector body  208  is attached to the structural surface. A seal  226  ( FIG. 2A ) may be disposed in the gap  220 . The seal  226  is configured to prevent moisture from entering into the interior  211  of the connector body  208 . The seal  226  may be made from any type of material capable of forming a flexible removable seal that can prevent infiltration of moisture within the connector body  208  when the connector body  208  is attached to a structural surface, such as the structural surface  108  in  FIG. 1 . For example, the seal  226  may include a compression elastomeric material that may form a bulb-type seal, compressible tube-type seal or other type seal. A firewall sealant  228  may also be in conjunction with the seal  226  depending upon the application. 
     The electrical connector assembly  200  may also include a retaining mechanism  230  to retain the resilient spring contacts  210   a - 210   d  electrically separate from one another and in a position relative to one another for aligning electrical contact with the respective data traces  204   a - 204   d  on the structural surface. The retaining mechanism  230  may be a dielectric frame or plate that may be attached within an interior  211  of the connector body  208  by any suitable arrangement. For example, the retaining mechanism may be attached within the interior  211  of the connector body  208  by an adhesive, welding, brazing, bonding, a fastener or other mechanical mechanism. The dielectric plate or fame may be similar to the dielectric frame or plate described with reference to  FIG. 6 . 
       FIG. 3  is a side elevation view of an example of a resilient spring contact  300  in accordance with an embodiment of the present disclosure. The resilient spring contact  300  may be used for the resilient spring contacts  210   a - 210   d  in  FIGS. 2A and 2B  and or the resilient spring contact  112  in  FIG. 1 . The resilient spring contact  300  may include a substantially U-shaped band  302 . The U-shaped band  302  may be described as being substantially U-shaped in that the U-shaped band  302  may form a flattened U-shape or may define a convex shape with upturned ends  306  and  308 . Similar to that previously described, the substantially U-shaped band  302  may be made from an electrically conductive material or semiconductor material. The substantially U-shaped band  302  may be configured to flex to conform to the data trace  304  and make electrical contact with the data trace  304  when a connector body, such as connector body  208  in  FIGS. 2A and 2B  or connector body  110  in  FIG. 1  are attached to a structural surface similar to that previously described. 
     A contact connecting link  310  may be attached to one end  306  of the substantially U-shaped band  302 . The contact connecting link  310  may be configured to electrically connect the U-shaped band  302  to a connector pin of a connector arrangement, such as connector pin  218  of connector arrangement  212  in  FIG. 2A , or to electrically connect the U-shaped band  302  to some other electrical connection within an electrical connector assembly. 
       FIG. 4  is a side elevation view of an example of a resilient spring contact  400  in accordance with another embodiment of the present disclosure. The resilient spring contact  400  may be similar to the substantially U-shaped band  302  shown in  FIG. 3  and may include a substantially U-shaped band  402  with ends  406  and  408 . The end  408  of the U-shaped band  402  may be free or not connected to anything. A loop back member  404  may extend from the end  406  of the U-shaped band  402  back over at least a portion of the substantially U-shaped band  402 . For example, the loop back member  404  may extend back about half the length of the U-shaped band  402  from the end  406 . The loop back member  404  may be formed by an extension of the U-shaped band  402  being folded or bent back over the U-shaped band  402 , or the loop back member  404  may be attached to the end  406  of the U-shaped band  402 . The loop back member  404  may be attached to the end  406  of the U-shaped band  402  by brazing, bonding, welding or other suitable attachment mechanism. 
     Referring also to  FIG. 5 ,  FIG. 5  is a perspective view of an example of an assembly  500  of resilient spring contacts  502   a - 502   d  and contact connecting links  504   a - 504   d  in accordance with an embodiment of the present disclosure. The resilient spring contacts  502   a - 502   d  may each be similar to the resilient spring contact  400  in  FIG. 4 . A contact connecting link  504   a - 504   d  may be electrically connected to each respective resilient spring contact  502   a - 502   d  by respectively connecting the contact connecting link  504   a - 504   d  to the loop back member  506   a - 506   d  of each resilient spring contact  502   a - 502   d  by any suitable attachment mechanism. For example, the contact connecting links  504   a - 504   d  may be respectively electrically connected to each respective loop back member  502   a - 502   d  by brazing, bonding, welding or other suitable attachment arrangement. Each contact connecting link  504   a - 504   d  may be configured to electrically connect an associated U-shaped band or resilient spring contact  502   a - 502   d  to a connector pin of a connector arrangement or connector plug, such as connector pin  218  of connector arrangement  212  in  FIG. 2A  or to electrically connect the respective resilient spring contacts  502   a - 502   d  to some other electrical connection within an electrical connector assembly, such as electrical connector assembly  200 . 
       FIG. 6  is a perspective view of an example of dielectric frame  600  or plate assembled with the resilient spring contacts  502   a - 502   d  and associated contact connecting links  504   a - 504   d  in accordance with an embodiment of the present disclosure. The dielectric frame  600  may be configured to retain the resilient spring contacts  502   a - 502   d  electrically separate from one another and in a position relative to one another for aligning electrical contact with the respective data traces  204   a - 204   d  on the structural surface, such as structural surface  108  in  FIG. 1 . Similar to that previously described, the dielectric frame  600  may define a retaining mechanism for the resilient spring contacts  502   a  and  502   d  that can be attached within the connector body, such as connector body  208  in  FIGS. 2A and 2B . 
       FIG. 7A  is a perspective view of an example of a resilient spring contact  700  in accordance with another embodiment of the disclosure. While a single resilient contact spring  700  is shown in  FIG. 7A  for purposes of explanation, any number of resilient contact springs may be used in a particular electrical connector assembly depending upon the number of conductive data traces that may need to be electrically contacted. Referring also to  FIG. 7B ,  FIG. 7B  is a side elevation view of the exemplary resilient spring contact  700  of  FIG. 7A  and portion of an upper wall  701  of a connector body  702 . The resilient spring contact  700  may include a leaf-style contact pad  704  configured to electrically contact a conductive data trace  706  on structural surface  708 . The resilient spring contact  700  is made from an electrically conductive material or semiconductive material. The resilient spring contact  700  may include a free-end portion  710  connected to one end of the leaf-style contact pad  704 . The free-end portion  710  is not connected or coupled to anything within the connector body  702 . The free-end portion  710  may extend from the leaf-style contact pad  704  at some predetermined angle away from the data trace  706  when the connector body is attached to the structural surface  714 . An opposite end of the leaf-style contact pad  704  may be pivotably or flexibly, electrically connected or coupled to a connector link  712 . The connector link  712  may electrically connect the resilient spring contact  700  to a connector pin of a connector arrangement or connector plug. The connector arrangement and pin may be similar to the connector arrangement  212  and connector pin  218  described with reference to  FIG. 2A . The connector link  712  may be electrically coupled to the leaf-style contact pad  704  by a hinge arrangement  714  or other mechanism that allows the leaf-style contact pad  704  to pivot relative to the connector link  712  for making electrical contact with the conductive data trace  706  when the connector body  702  is attached to the structural surface  708 . 
     A coil spring  716  or other type spring may be disposed between the leaf-style contact pad  704  and the upper wall  701  of the connector body  702 . The coil spring  716  biases the leaf-style contact pad  704  against the data trace  706  to insure an electrical connection between the resilient spring connector  700  and the data trace  706  when the connector body  702  is attached to the structural surface  708 . The coil spring  716  is electrically isolated from the leaf-style contact pad  704 . For example, a layer of insulation material may be disposed on a surface of the contact pad  704  where the coil spring  716  contacts the contact pad  704  if the coil spring  716  is made from a conductive material. The coil spring  716  could also be made from a non-conductive material. 
       FIG. 8  is a flow chart of an example of a method  800  for making an electrical connector assembly and attaching the electrical connector to a structural surface in accordance with an embodiment of the present disclosure. The method  800  may be used to form the electrical connector assembly  100  of  FIG. 1 , the electrical connector assembly  200  of  FIGS. 2A and 2B , or an electrical connector assembly using the resilient spring contacts  700  in  FIGS. 7A and 7B , and to attach the electrical connector assembly to a structural surface similar to that illustrated in  FIG. 1B . In block  802 , a connector body may be formed. An opening may be formed in an upper wall of the connector body for attaching a connector arrangement, connector plug or receptacle similar to that previously described. A gap may be formed in a base portion of a front side wall for direct-write or printed data traces to enter into the connector body. 
     In block  804 , one or more resilient spring contacts may be formed. The resilient spring contacts may be substantially U-shaped contacts or bands similar to those described with reference to  FIGS. 3 and 4  or similar to resilient spring contact  700  of  FIG. 7A and 7B . Contact connecting links similar to contact connecting links  504   a - 504   d  described with reference to  FIGS. 5 and 6  may also be formed. 
     In block  806 , a dielectric frame or plate may be formed. The dielectric frame or plate may be similar to the dielectric plate  600  described with reference to  FIG. 6 . The dielectric frame or plate may be configured to retain the resilient contacts electrically separated from one another and in a position relative to one another for aligning electrical contact with a respective printed data trace when the connector body is installed on the structural surface similar to that previously described. 
     In block  808 , contact connecting links may be attached to the resilient contacts by any suitable mechanism. For example, each contact connecting link may be attached to a respective resilient contact by bonding, brazing, welding, an adhesive, or other suitable means. Each contact connecting link is configured to make an electrical connection between an associated resilient spring contact and a respective connector pin of the connector arrangement or receptacle within the connector body. 
     In block  810 , the dielectric frame or plate assembly may be attached within the connector body. The dielectric frame or plate assembly may be attached within the connector body by any suitable mechanism, such as by bonding, brazing, welding, an adhesive, a fastener or other means. 
     In block  812 , a connector arrangement, plug or receptacle may be attached to the opening in the upper wall of the connector body. The connector arrangement or receptacle permits removable attachment of a mating connector arrangement or plug for removal of a structure on which the electrical connector assembly may be attached while leaving the electrical connector assembly attached to the surface of the structure with resilient spring contacts remaining in contact with the data traces on the surface of the structure. Similar to that previously described, the structure may be a backing structure of a component or system of an aircraft, such as a thrust reverser or can cowl door. 
     In block  814 , a seal may be attached within a gap in the front side wall of the connector body. The seal may be a compression elastomeric material or other type material capable of forming a seal to prevent moisture infiltration into the connector body. The seal may form a bulb-type seal within the gap. The gap and seal permit entry for the data traces into the connector body. The seal may be attached within the gap by any suitable mechanism, such as an adhesive or other means. A firewall sealant may be used in conjunction with the seal as previously described. 
     In block  816 , the connector body may be attached to a surface of the structure with each resilient spring contact in electrical contact with a respective printed or direct-write data trace. Similar to that previously described, the connector body may be attached to the structure by any suitable mechanism. A seal or fillet seal may be formed between the connector body and the structural surface to prevent moisture infiltration into an interior of the connector body. A firewall type sealant may be used or may be used in conjunction with the seal. 
     While the operations or steps in  FIG. 8  are illustrated and described in a certain sequence, the present invention is not intended to be limited by the sequence or order illustrated. The steps and operations may be performed in any order unless otherwise specified. Some operations or steps may also be performed simultaneously or combined. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
     Although specific embodiments have been illustrated and described herein, those of ordinary skill in the art appreciate that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiments shown and that the embodiments herein have other applications in other environments. This application is intended to cover any adaptations or variations of the present disclosure. The following claims are in no way intended to limit the scope of the disclosure to the specific embodiments described herein.