Abstract:
An electrical shuttle connector is capable of being used in high electrical power applications without incurring contact erosion upon the primary electrical contact location with a male pin. A shuttle which receives the male pin is contained by and slides axially within a receptacle of the connector between a mated position and a disengaged position and through an unmated position. An arcing contact face of the receptacle and a leading arcing contact surface of the shuttle incurs any high voltage electrical arcing when mating or un-mating the electrical shuttle connector. As such, when un-mating, the arcing contact face and the leading arcing contact surface disconnect prior to the electrical disconnection of the shuttle from the male pin. When mating the connector, the shuttle establishes electrical continuity with the male pin prior to the electrical engagement of the arcing contact face with the leading arcing contact surface. The male pin is completely free from the receptacle when the shuttle is in the disengaged position, however, the shuttle remains secured within the receptacle.

Description:
TECHNICAL FIELD OF THE INVENTION 
     This invention relates to an electrical connector and more particularly, to an electrical shuttle connector for high voltage applications. 
     BACKGROUND OF THE INVENTION 
     Power and signal distribution connectors mechanically and electrically connect at least two conductors at ideally the lowest possible power loss. Connectors are not designed to make and break a hot electrical circuit as are switches, relays and contactors. Nevertheless, during their service life connectors can be plugged and unplugged under load many times (i.e. hot plugged). Very often this connection under load occurs when physically switching off the power in advance would be considered time consuming and inconvenient. Also, connectors in automotive power networks are plugged and unplugged under load during diagnostic procedures, fuses are plugged at short circuit conditions, and so forth. 
     In the present 14 volt direct current, VDC, automotive power networks, no serious consequences are associated with plugging and unplugging under load due to very short break arcs (the system voltage is approximately the same as the minimum arc voltage of the contact material). However, the world&#39;s leading car manufactures and component suppliers are promoting 42 VDC power networks to meet the high power requirements of future vehicles. Unfortunately, even one mating or disconnect under a 42 VDC load may damage a standard connector terminal beyond repair. In other words, under specific conditions, a long arc may be generated at matings or disconnects which may cause high contact erosion. This erosion may damage the physical shape of the connector terminal preventing re-mating or hindering proper terminal contact forces after mating. 
     SUMMARY OF THE INVENTION 
     An electrical shuttle connector is capable of being used in high electrical power applications without incurring contact erosion upon the primary electrical contact location with a male pin. A shuttle which receives the male pin is contained by and slides axially within a receptacle of the connector between a mated position and a disengaged position and through an unmated position. An arcing contact face of the receptacle and a leading arcing contact surface of the shuttle incurs any high voltage electrical arcing when mating or un-mating the electrical shuttle connector. As such, when un-mating, the arcing contact face and the leading arcing contact surface disconnect prior to the electrical disconnection of the shuttle from the male pin. When mating the connector, the shuttle establishes electrical continuity with the male pin prior to the electrical engagement of the arcing contact face with the leading arcing contact surface. The male pin is completely free from the receptacle when the shuttle is in the disengaged position, however, the shuttle remains secured within the receptacle. 
     The shuttle slides axially and co-linearly with the male pin between the mated, un-mated and disengaged positions. A primary contact surface of the shuttle faces laterally inward and moves laterally when the shuttle moves between the un-mated and disengaged positions, thereby engaging to or disengaging from the sides of the male pin. With the primary electrical connection made, the arcing contact face of the receptacle and the leading arcing contact surface of the shuttle engages and disengages from one another when the shuttle moves between the mated and un-mated positions and the primary contact remains engaged. 
     An advantage of the present invention is the elimination of electrical arcing erosion of the male pin of an electrical connector. Another advantage of the present invention is the ability to connect and disconnect the electrical connector used within a hot electrical circuit, thereby saving time when performing maintenance or repairs. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The presently preferred embodiments of the invention are disclosed in the following description and in the accompanying drawings, wherein: 
     FIG. 1 is a longitudinal cross-sectional view of an electrical shuttle connector of the present invention; 
     FIG. 2 is a cross-sectional view of the electrical shuttle having a male pin moving in a rearward direction as indicated by the arrow; 
     FIG. 3 is a cross-sectional view of the electrical shuttle connector moving in a rearward direction as indicated by the arrow and being in an unmated position; 
     FIG. 4 is cross-sectional view of the electrical shuttle connector shown in a disengaged position; 
     FIG. 5 is a fragmentary cross-sectional view of the electrical shuttle connector shown in a relay environment; 
     FIG. 6 is a cross-sectional view of the electrical shuttle connector for blade pins taken along line  6 — 6  of FIG. 1; and 
     FIG. 7 is a cross-sectional view of a second embodiment of the electrical shuttle connector for round pins similar to FIG.  6 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to FIGS. 1-6, an electrical shuttle connector  10  of the present invention has a receptacle  12  which receives a planar male bar or pin  14  along a central axis  16 . Electrical shuttle connector  10  is ideal for repeatable high power connections because it diverts the electrical arcs, created during the un-mating process and common in high power circuits, from the male pin  14  thereby protecting the male pin  14  from arc induced corrosion. The electrical arc is diverted to a shuttle  20  carried slideably in an axial direction and resiliently in a lateral direction by an insulator housing  18  of the receptacle  12 . Shuttle  20  moves along the central axis  16  from a mated position  22 , as best shown in FIG. 1, to an intermediate or unmated position  24 , as best shown in FIG. 3, and into a disengaged position  26 , as best shown in FIG.  4 . Mating of connector  10  or movement of the shuttle  20  from the disengaged position  26  toward the mated position  22  is caused by the insertion of the male pin  14 , and movement of the shuttle  20  away from the mated position  22  and toward the disengaged position  26  is caused by the withdrawal of male pin  14  from the receptacle  12 . 
     When the shuttle  20  is in the mated position  22  (FIGS.  1  and  2 ), an arcing contact face  28  of the receptacle  12  is engaged electrically to a leading arcing contact surface  30  of the shuttle  20 . And, two opposing primary contact surfaces  32  of the shuttle  20  (FIG.  4 ), which face radially inward toward one another about the central axis  16 , are engaged electrically to both respective planar sides of the elongated male bar or pin  14 . When the shuttle  20  is in the unmated position  24  (FIG.  3 ), the leading arcing contact surface  30  of shuttle  20  and the arcing contact face  28  of the receptacle  12  are disengaged or axially spaced from one another. Electrical arcing may occur between the leading arcing contact surface  30  and the arcing contact face  28  when the shuttle  20  is moved from the mated position  22  (FIGS. 1 and 2) to the unmated position  24  (FIG.  3 ). When in the unmated position  24 , the two opposing primary contact surfaces  32  remain engaged to the male pin  14  even though the electrical circuit is now open, it is not until the electrical shuttle connector  10  is in the disengaged position  26  (FIG. 4) that the primary contact surfaces  32  of the shuttle  20  disengage from the male pin  14  so that the male pin  14  is free to move away from receptacle  12  without further interaction. Arcing between the male pin  14  and the primary contact surfaces  32  is prevented from occurring at this stage or position since the circuit is already open. 
     The insulator housing  18  of the receptacle  12  has a forward end portion  36  which generally traverses and is substantially centered to the central axis  16 . Projecting rearward and perpendicularly from the forward end portion  36  and engaged unitarily at two opposite lateral ends of the forward end portion  36  are two respective opposing walls  34  which extend diametrically along the central axis  16 . A void  40  centered along the axis  16  is defined laterally between the walls  34  and axially between the forward end portion  36  and a distal end  35  of each wall  34 . The shuttle  20  is completely disposed slideably and snugly within the void  40  when in the mated position  22 , and partially disposed in the void  40  when in either the unmated or disengaged positions  24 ,  26 . A leading base  41  of the shuttle  20  remains fitted snugly within the void  40  of the housing  18  regardless of shuttle position. The base  41  carries the leading arcing contact surface  30  on the leading side and defines a blind space  43  at the trailing side. The space  43  is defined laterally by two opposing parallel walls  45  of the base  41  projecting rearward and snugly fitted against the respective walls  34  of the housing  18 . 
     The shuttle  20  is carried at all times by the receptacle  12 . Preventing complete withdrawal of the shuttle  20  from the housing  18  when the shuttle  20  is in the disengaged position  26  is a trailing stop surface  48  of the shuttle  20  which contacts a rearward stop face  46  of the housing  18 . A lateral member  44  of the housing  18  carries the rearward stop face  46  and an angled member  38  engages unitarily between the lateral member  44  and a distal end  35  of each respective wall  34 . The angled member  38  projects rearward and laterally outward from each distal end  35 , and the lateral member  44  projects unitarily and laterally inward from the angled member  38 . The distal or diametrically opposed ends of each lateral member  44  are spaced sufficiently apart from one another to permit initial assembly or insertion of the shuttle  20  into the receptacle  12 . 
     Each trailing stop surface  48  is carried by a respective trailing portion  50  of the shuttle  20  which is cantilevered from the respective distal end of each wall  45  of the base  41 . The trailing portion  50  has a cantilevered member  52  which projects rearward and laterally outward from the wall  45  and is engaged unitarily between the wall  45  and a laterally inward extending leg  58  which defines the trailing stop face  48 . During manufacturing or initial assembly of the shuttle connector  10 , the diametrically opposed trailing portions  50  are flexed radially or laterally inward so that the shuttle  20  can fit between the distal ends of the lateral members  44  of the housing  18  while the shuttle is inserted into the receptacle  12 . Once the legs  58  of the shuttle  20  move axially forward of the lateral members  44  of the housing  18 , the trailing portion  50  of the shuttle  20  will snap resiliently and laterally outward thereby orientating the shuttle  20  into the disengaged position  26 . 
     The cantilevered member  52  of the trailing portion  50  of the shuttle  20  is orientated close to or fitted snugly against the angled member  38  of the housing  18  assuring that the shuttle  20  remains within the disengaged position  26  and will not move forward until an external axial force exerted upon the male pin  14  overcomes the resilience of the trailing portion  50  and moves the shuttle  20  forward toward the unmated position  24 . The male pin  14  has a forward segment  76  engaged co-linearly to a rearward segment  78 . Forward movement of shuttle  20  occurs when a distal end of the male pin  14  carried by the forward segment  76  forcibly contacts a bottom surface  80  of the base  41 , or bottom of space  43 . When contacted, the forward segment  76  of the male pin  14  is disposed completely within the space  43 . As the shuttle  20  moves forward toward the unmated position  24 , the cantilevered member  52  flexes laterally inward and a foot  60  of the cantilevered member  52  which substantially projects axially forward from the lateral member  44  and which carries the primary contact surface  32  engages the rearward segment  78  of the male pin  14  from a lateral direction. This engagement simultaneously signifies the unmated position  24  of the shuttle connector  10 . 
     With the distal end or tip of the male pin  14  engaged upon the leading base  41  of the shuttle  20  along the central axis  16 , and the primary contact surface  32  of the foot  60  of the shuttle  20  engaged to the longitudinal sides of the rearward segment  78  of the male pin  14 , continued insertion of pin  14  causes the shuttle  20  to move axially forward until the leading arcing contact surface  30  of the leading base  41  electrically engages the arcing contact face  28  of the receptacle  12 . 
     The arcing contact face  28  is defined by an arcing contact member  62  disposed within the bore  40  of the insulative housing  18 . The arcing contact member  62 , and likewise the leading arcing contact surface  30  have a high resistance to arc erosion and can resemble a variety of forms including rivets, contact tapes, and discs. Disposed between the arcing contact member  62  and the forward end portion  36  of the insulative housing  18  is an axially compressible spring  64 . Prior to the shuttle reaching the mated position  22 , the spring  64  is fully extended thereby positioning the arcing contact member  62  in a rearward position. Continued forward movement of the shuttle  20  causes the arcing contact member  62  to engage the leading base  41  of the shuttle  20 . The spring  64  compresses as the arcing contact member  62  is moved axially forward along the central axis  16 . The spring  64  assures a robust electrical shuttle connector  10  by providing a repeatable electrical contact connection regardless of any arcing erosion. Full insertion and therefore a mated position  22  is achieved when the insulator housing  18  snap locks to a structure  66  engaged directly to the male pin  14  via a typical mechanical snap-lock device such as a flexible lock arm projected rearward from the structure  66  and engaging the rearward stop face  46  of the housing  18  at mid-length (not shown). 
     Disengagement, or unmating of the electrical shuttle connector  10  is achieved by pulling the male pin  14  in a rearward direction. This causes the primary contact surface  32  of the foot  60  of the shuttle  20  to slide against, while maintaining contact or continuity with, the sides of the male pin  14 . Simultaneously, the tip of the male pin  14  moves axially away from the bottom surface  80  of the leading base  41 . This sliding relationship ceases when each distal end of the feet  60  engage respective diametrically opposed fins  68  of the forward segment  76  of the male pin  14 . The fins  68  project laterally outward from each side of the male pin  14 . Axial engagement of the fin  68  to the distal end of the foot  60  rigidly engages the shuttle  20  to the male pin  14  so that continued movement of the male pin  14  in the rearward direction causes the shuttle  20  to move with it. As shuttle  20  moves, the arcing contact surface  30  of shuttle  20  becomes disengaged from the arcing contact face  28  of the arcing contact member  62  after the spring  64  is fully extended. An arc, may then occur within the bore  40  between the arcing contact member  62  and the shuttle  20 , however, because the primary contact surface  32  remains electrically engaged to the male pin  14 , the male pin  14  does not undergo any arcing erosion. Any erosion which occurs will be between the leading base  41  of the shuttle  20  and the arcing contact member  62 . 
     In order to improve erosion and welding behavior of the arcing contact, the leading base  41  and the arcing contact member  62  may carry contact pieces (e.g. rivets, or contact tapes, not shown.) The arc will then be driven directly between the contact pieces (e.g. rivets or tapes) made of contact material with high resistance to arc erosion and contact welding. 
     As shuttle  20  continues to move in the rearward direction, along with the male pin  14 , the cantilevered member  52  begins to flex radially outward substantially against the angled members  38  of the housing  18 . With this lateral outward flexing, the primary contact surface  32  moves radially outward and disengages from the male pin  14 . The foot  60  simultaneously moves radially outward enough to release the fin  68  and thereby release the male pin  14 . At this point, the trailing stop face  48  of the leg  58  is disposed near or engages the rearward stop face  46  of the lateral member  44  of the housing  18  and the electrical shuttle connector  10  is in the disengaged position  26 . 
     Referring to FIG. 5, the electrical shuttle connector  10  is shown within a relay environment. The male pin  14  is an integral part of a relay module  70  which has a second male pin  72  disposed parallel to the male pin  14 . The male pin  14  is applied to the high voltage side and the secondary male pin  72  is on the low voltage side of the relay modular  70 . As the male pin  14  mates within the receptacle  12  of the electrical shuttle connector  10  the secondary male pin, or low voltage pin  72  simultaneously mates within a standard receptacle  74  which does not have a shuttle. 
     Referring to FIG. 7, a second embodiment of the present invention is shown. A male pin  14 ′ is rod-shaped instead of planar as is the male pin  14  in the first embodiment. A housing  18 ′, preferably molded as one piece from an electrically insulative material such as plastic, is substantially tubular in shape having a single circular wall  34 ′ which defines a void or bore  40 ′. A shuttle  20 ′ disposed within the housing  18 ′ has a leading base  41 ′ which defines a space  43 ′ being substantially cylindrical in shape. Spaced equally and circumferentially about the space  43 ′ is a series of walls  45 ′, a total of four as illustrated in FIG.  7 . Likewise, a series of cantilevered members  52 ′ project rearward from the distal ends of each respective wall  45 ′. Encircling the male pin  14 ′ is a fin  68 ′ which forms a single rearward facing annular surface that engages all of the cantilevered members  52 ′ when the shuttle  20 ′ is moved rearward from the mated position  22  and into the disengaged position  26 . 
     Although the preferred embodiments of the present invention have been disclosed, various changes and modifications may be made thereto by one skilled in the art without departing from the scope and spirit of the invention as set forth in the appended claims. It is also understood that the terms used herein are merely descriptive, rather than limiting, and that various changes may be made without departing from the scope and spirit of the invention.