Patent Description:
Connectors or connector assemblies are often mechanically secured to mating connectors, connector assemblies or panels to prevent the unwanted removal of the connector assembly from the mating connector assembly or panels. Mechanically secured connector assemblies typically employ push-pull, lever-actuated, partial-turn, or other manual locking mechanisms that are designed to release only with specific user intervention initiated directly at the connector interface and are otherwise engineered to hold tight - sometimes withstanding a pull force of dozens or even hundreds of pounds.

However, in many applications there is a need for connectors that are engineered to hold tight up to a predetermined point and then, when that force is reached, smoothly and cleanly let go. Breakaway connectors, which are also known as quick-release or quick-disconnect connectors, are often employed in applications including aviation and military helmets and headsets that attached to consoles or portable equipment with cables, mobile medical monitoring equipment attached to patients, and in other environments in order to prevent cord entanglement, snags, and pulls from hindering or harming the user and equipment they're attached to.

While various breakaway, quick-release or quick-disconnect connectors are currently available, such connectors are generally designed to release when an appropriate force is applied to the cable or connector in a direction which is in line with the longitudinal axis of the connector. However, such connectors fail to properly release if a force is applied to the cable or connector in a direction other than in line with the longitudinal axis of the connector, such as a force applied with a component which is perpendicular to in line with the longitudinal axis of the connector. The inability to release when such a force is applied can cause damage to the equipment and harm to the user.

In addition, many breakaway connectors do not allow mating from any direction. This can cause difficulties, as in many environments, it is difficult to properly align the mating connectors, as connection needs to be done quickly or without a clear line of sight.

It would be, therefore, beneficial to provide an electrical connector or connector assembly which can be easily mated from any direction and which can easily breakaway from a mating connector, connector assembly or panel upon the application of designated force, regardless of the direction the force is applied to the connector or connector assembly. Electrical connectors are disclosed in <CIT> and <CIT>. <CIT> discloses an electrical connector as a cylindrical insert having circular electrical contacts that are positioned concentrically about an axis and a locking feature that can be a magnet. <CIT> discloses the preamble of independent claim <NUM>.

In accordance with the invention, there is provided an electrical connector assembly for mating with a mating connector assembly as defined in independent claim <NUM> and a breakaway electrical connector assembly as defined in dependent claim <NUM>.

As shown in <FIG>, an illustrative electrical connector assembly <NUM> has a housing <NUM> with a cable receiving portion <NUM> and a mating portion <NUM>. The housing <NUM> has a first surface <NUM> and an oppositely facing second surface <NUM>. Sidewalls <NUM> extend between the first surface <NUM> and the second surface <NUM>.

In the illustrative embodiment shown, the mating portion <NUM> has a circular configuration. However, the mating portion <NUM> may have other configurations without departing from the scope of the invention as defined in the claims. The mating portion <NUM> may be a singular, unitary member or may having more than two housings which form the mating portion <NUM>.

As shown in <FIG> and <FIG>, a mating projection <NUM> extends from the first surface <NUM> in a direction away from the second surface <NUM>. The mating projection <NUM> has a generally circular cross-sectional configuration.

The mating projection <NUM> has an angled or sloped surface or wall <NUM> which extends from the first surface <NUM> to a mating face <NUM>. Positioning or securing projections <NUM> (<FIG>) are provided on an inside surface of the angled or sloped wall <NUM>. A positioning shoulder <NUM> extends about the circumferences of the inside surface of the angled or sloped wall <NUM>. The positioning shoulder <NUM> is spaced from the mating face <NUM>.

The angled or sloped wall <NUM> is angled relative to the first surface <NUM> and the mating face <NUM>. While the angle may vary depending upon the length of the mating projection <NUM>, in the illustrative embodiment shown, the angled or sloped wall <NUM> is angled <NUM> approximately <NUM> to <NUM> degrees relative to the mating face <NUM>. The angled or sloped wall <NUM> is angled <NUM> less than <NUM> degrees relative to the mating face <NUM>. A nonconductive coating <NUM> is applied to the angled or sloped wall <NUM>.

One or more metallic members <NUM> are provided on the first surface <NUM>. The one or more metallic members <NUM> are positioned about at least a portion of the circumference of the outside surface of the angled or sloped wall <NUM>. In the illustrative embodiment shown, the one or more metallic members <NUM> are a ring <NUM> which extends about the entire circumference of the outside surface of the angled or sloped wall <NUM>. According to the invention, the one or more metallic members <NUM> are made of any material which provides a magnetic attraction to magnets provided in the mating electrical connector assembly <NUM>. The nonconductive coating <NUM> may also be applied to the one or more metallic members <NUM>. The one or more metallic members <NUM> may be mounted using mounting hardware <NUM>, or by other known mounting methods.

The illustrative metallic member <NUM> shown extends beyond the first surface <NUM> and is position proximate portions of the sidewalls <NUM> of the mating portion <NUM>.

As shown in <FIG>, the cable receiving portion <NUM> extends from the mating portion <NUM>. In the illustrative embodiment shown, cross-sections of the cable receiving portion <NUM> have a generally oval configuration. However, other configurations of the cable receiving portion <NUM> may be used.

As shown in <FIG>, the electrical connector assembly <NUM> has a board or substrate <NUM> through which contacts <NUM> extend. The substrate <NUM> has a first surface <NUM> and an oppositely facing second surface <NUM>. A side surface <NUM> extends between the first surface <NUM> and the second surface <NUM>. Positioning recesses <NUM> are provided on the side surfaces <NUM>.

Each of the contacts <NUM> have an engagement section <NUM>, a transition section (not shown) and a wire termination section <NUM> (<FIG>). The engagement sections <NUM> are circular tracks or contacts which are arranged concentrically about the center of the mating face <NUM>.

As shown in <FIG>, the substrate <NUM> is press fit into the interior of the housing <NUM> through the mating projection <NUM> and retained therein. The second surface <NUM> of the substrate <NUM> engages the positioning shoulder <NUM> to properly position the substrate <NUM> in the housing <NUM>. In this position, the positioning or securing projections <NUM> are positioned in the positioning recesses <NUM> on the side surfaces <NUM> of the substrate. The interaction of the positioning projections <NUM> with the positioning recesses <NUM> maintains the substrate <NUM> relative to the housing <NUM>. In this position, a cable receiving interior cavity <NUM> (<FIG>) is provided to accommodate the ends of individual wires of the cable (not shown).

With the substrate <NUM> properly positioned, the first surface <NUM> of the substrate <NUM> forms a portion of the mating face <NUM>. When assembled, the circular tracks or engagement sections <NUM> of the contacts <NUM> are positioned on the mating face <NUM>, the transition sections (not shown) extend through the substrate <NUM>, and the wire terminations section <NUM> are terminated to the wires of a cable. The termination of the wires to the wire terminations section <NUM> may be done by soldering or other known termination methods.

With the contacts <NUM> properly terminated and the board or substrate <NUM> properly positioned electrical connector assembly <NUM>, an epoxy <NUM> is provide in an interior cavity <NUM> of the electrical connector assembly <NUM> to properly maintain the substrate <NUM> in position and to seal the interior cavity <NUM> to prevent moisture or debris from interfering with the connection between the termination sections <NUM> of the contacts <NUM> and the wires (not shown).

As shown in <FIG>, an illustrative mating electrical connector assembly <NUM> has a housing <NUM> with a cable receiving portion <NUM> and a mating portion <NUM>. The housing <NUM> has a first surface <NUM> and an oppositely facing second surface <NUM>. Sidewalls <NUM> extend between the first surface <NUM> and the second surface <NUM>.

As shown in <FIG>, the mating portion <NUM> has a mating projection <NUM> that extends from the first surface <NUM> in a direction away from the second surface <NUM> to a mating surface <NUM>. The mating projection <NUM> has a circular cross-sectional configuration and has a side wall <NUM>. The side wall <NUM> forms a mating recess <NUM> which extends from the mating surface <NUM> toward the second surface <NUM>. The mating recess <NUM> has a generally circular configuration.

An angled or sloped surface or portion <NUM> of the sidewall <NUM> extends from the mating surface <NUM> to a mating face <NUM>. The angled or sloped portion <NUM> is angled relative to the mating surface <NUM> and the mating face <NUM>. While the angle may vary depending upon the depth of the mating recess <NUM>, in the illustrative embodiment shown, the angled or sloped portion <NUM> is angled approximate <NUM> to <NUM> degrees relative to the mating face <NUM>. The angled or sloped portion <NUM> is angled <NUM> less than <NUM> degrees relative to the mating face <NUM>. The angle of the angled or sloped portion <NUM> is configured to be approximately equal to the angle of the angled or sloped wall <NUM> of the mating projection <NUM> of the connector assembly <NUM>.

The mating face <NUM> has contacts <NUM> provided thereon or extending therethrough. In this illustrative embodiment shown in <FIG>, the contacts <NUM> have mating sections <NUM>, a transition sections <NUM> and wire termination sections <NUM>.

As shown in <FIG>, <FIG>, the angled or sloped portion <NUM> has a circumferential seal receiving recess <NUM>. A seal <NUM> is positioned in the seal receiving recess <NUM>. A back wall <NUM> of the seal receiving recess <NUM> is angled at approximately the same angle as the angled or sloped surface <NUM> is angled relative to the mating face <NUM>.

Magnets <NUM> are positioned in magnet receiving openings <NUM>. In the illustrative embodiment shown the magnets <NUM> are spaced about the circumference of the mating recess <NUM>. Ten magnets <NUM> and magnet receiving openings <NUM> are shown, but other numbers of magnets and magnet receiving opening may be provided. Also, in the illustrative embodiment shown, the magnet receiving openings <NUM> extend from the mating surface <NUM>. However, the magnet receiving openings <NUM> may be provided in the second surface <NUM> and extend toward the mating surface <NUM>.

As shown in <FIG>, in the illustrative embodiment shown, the connector assembly <NUM> has a first contact receiving member <NUM> and a second contact receiving member <NUM> which are used to properly position and retain the contacts <NUM> in position. A surface of the first contact receiving member <NUM> is the mating face <NUM>.

The first contact receiving member <NUM> has openings 182a, 182b which extend therethrough and which are configured to receive the mating sections <NUM> of the contacts <NUM> therein. As shown in <FIG>, openings 182a have a smaller projection 184a which cooperates with the transition portions <NUM> of the contacts <NUM> to allow the transition portions <NUM> to be positioned essentially parallel to the mating face <NUM>. This allows the resilient mating sections <NUM> of the contacts <NUM> in openings 182b to extend a height H1 above the mating face <NUM>. Openings 182b have a larger projection 184b which cooperates with the transition portions <NUM> of the contacts <NUM> to allow the transition portions <NUM> to be positioned at an angle relative to the mating face <NUM>. This allows the mating sections <NUM> of the contacts <NUM> in openings 182a to extend a height H2 above the mating face <NUM>.

While the mating portions <NUM> of the contacts <NUM> are retained in an initial position, the mating portions <NUM> and the transition portions <NUM> are able to move in a direction which is parallel to the direction of mating of the connector assembly <NUM> with the connector assembly <NUM> to allow the contacts <NUM> to be resiliently moved as insertion occurs.

A cover <NUM> is provided on the second surface <NUM> of the connector assembly <NUM>. When assembled the cover <NUM> is mounted with hardware <NUM> and defines a cable receiving interior cavity <NUM> which accommodates the ends of individual wires of the cable (not shown).

With the contacts <NUM> properly terminated and the components properly positioned electrical connector assembly <NUM>, an epoxy <NUM> is provided in an interior cavity <NUM> of the electrical connector assembly <NUM> and epoxy <NUM> is provided in exterior cavity <NUM> to properly maintain the components in position and to seal the interior cavity <NUM> to prevent moisture or debris from interfering with the connection between the termination sections <NUM> of the contacts <NUM> and the wires (not shown).

While illustrative contacts <NUM> are shown and described above, other types of contacts may be used. For example, the contacts <NUM> may be spring probes. Spring probes would require only one contact receiving member, as the spring probes could be press fit into the contact receiving member with wires soldered on wire termination sections which are provided on ends of the contacts which are opposite the mating portions of the contacts.

In use, the connector assembly <NUM> and mating connector assembly <NUM> are mated together to form a mechanical and electrical connection therebetween, as shown in <FIG>. As the engagement sections <NUM> of the contacts <NUM> are circular tracks or contacts which are arranged concentrically about the center of the mating face <NUM>, and as the mating projection <NUM> and the mating recess <NUM> are circular, the connector assembly <NUM> may be mounted to the mating connector assembly <NUM> from any orientation (<NUM> degrees) to make the mechanical and electrical engagement. In addition, the connector assembly <NUM> may be rotated relative to the mating connector assembly <NUM>.

As the connector assembly <NUM> is moved into engagement with the connector assembly <NUM>, the angled or sloped wall <NUM> of the connector assembly <NUM> engages the seal <NUM> positioned on the angled or sloped portion <NUM> of the mating connector assembly <NUM>. The magnetic member <NUM> is attracted toward the magnets <NUM> to help align and mate the connector assembly <NUM> with the connector assembly <NUM>.

As the mating occurs, the mating sections <NUM> of the contacts <NUM> positioned in openings 182a engage the engagement sections <NUM> of the contacts <NUM> prior to the mating sections <NUM> of the contacts <NUM> positioned in openings 182b engage the engagement sections <NUM> of the contacts <NUM>. This allow the mating sections <NUM> of the contacts <NUM> positioned in openings 182a to make electrical engagement with respective engagement sections <NUM> of the contacts <NUM> prior to the mating sections <NUM> of the contacts <NUM> positioned in openings 182b making electrical engagement with other respective engagement sections <NUM> of the contacts <NUM>.

With the mating projection <NUM> fully inserted into the mating recess <NUM>, the magnetic force between the magnets <NUM> and the magnetic member <NUM> allows the assembly <NUM> and the assembly <NUM> to be retained in mechanical engagement, and the contacts <NUM> and contacts <NUM> to be retained in mechanical and electrical engagement. In one illustrative embodiment, the magnetic force applied by the magnets <NUM> is between approximately <NUM> to <NUM> lbs. (approximately <NUM> to <NUM> N), and preferably approximately <NUM> lbs. (approximately <NUM> N), providing a minimum retention force to disconnect assembly <NUM> from assembly <NUM> of approximate <NUM> to <NUM> lbs. (approximately <NUM> to <NUM> N).

In various other embodiments, the retention force is configured to be small, in the range of between <NUM>-<NUM> lbs. (approximately <NUM>,<NUM> to <NUM>,<NUM> N) to allow the connector assembly <NUM> to be easily removed from the mating connector assembly <NUM> when a force is applied to either the connector assembly <NUM> or the mating connector assembly <NUM>. In other embodiments, the retention force is configured to be large, in the range of between <NUM>-<NUM> Ibs. , to prevent the connector assembly <NUM> from being easily removed from the mating connector assembly <NUM> when a force is applied to either the connector assembly <NUM> or the mating connector assembly <NUM>.

In various environments, it is important that the connector assembly <NUM> be allowed to be mated from any direction and be removed or break away from the mating connector assembly <NUM> when a designated amount of force is applied from any direction to the connector assembly <NUM> or the mating connector assembly <NUM>. To allow the connector assembly <NUM> and mating connector assembly <NUM> to be properly released in different directions, the retention force of the securing member <NUM> and the angles of the angled or sloped wall <NUM> and the angled or sloped portion <NUM> must be controlled.

Accordingly, the electrical connector or connector assembly, as described herein, can be mounted from any direction, without the need for pre-alignment, and can be easily broken away from the mating connector, connector assembly upon the application of designated force, regardless of the direction the force is applied to the connector or connector assembly. The ability to mate and release in different directions allows the connector assembly to be used in many applications or environments to prevent damage to the equipment and prevent harm to the user.

As shown in <FIG>, an alternate illustrative electrical connector assembly <NUM> has a housing <NUM> with a cable receiving portion <NUM> and a mating portion <NUM>. The housing <NUM> has a first surface <NUM> and an oppositely facing second surface <NUM>. Sidewalls <NUM> extend between the first surface <NUM> and the second surface <NUM>.

In the illustrative embodiment shown, the mating portion <NUM> have a circular configuration. However, the mating portion <NUM> may have other configurations without departing from the scope of the invention as defined in the claims.

The angled or sloped wall <NUM> is angled relative to the first surface <NUM> and the mating face <NUM>. While the angle may vary depending upon the length of the mating projection <NUM>, in the illustrative embodiment shown, the angled or sloped wall <NUM> is angled approximate <NUM> to <NUM> degrees relative to the mating face <NUM>.

A securing or clip-receiving recess <NUM> is provided on an outside surface of the angled or sloped wall <NUM>. The securing or clip-receiving recess <NUM> extends about the outside circumference of the angled or sloped wall <NUM>. In the illustrative embodiment shown, the securing or clip-receiving recess <NUM> is provide proximate or adjacent to the first surface <NUM>.

With the contacts <NUM> properly terminated and the board or substrate <NUM> properly positioned electrical connector assembly <NUM>, an epoxy <NUM> is provide in an interior cavity <NUM> of the electrical connector assembly <NUM> to properly maintain the substrate <NUM> in position and to seal the interior cavity2 <NUM> to prevent moisture or debris from interfering with the connection between the termination sections <NUM> of the contacts <NUM> and the wires (not shown).

As shown in <FIG>, an alternate illustrative mating electrical connector assembly <NUM> has a housing <NUM> with a cable receiving portion <NUM> and a mating portion <NUM>. The housing <NUM> has a first surface <NUM> and an oppositely facing second surface <NUM>. Sidewalls <NUM> extend between the first surface <NUM> and the second surface <NUM>.

An angled or sloped surface or portion <NUM> of the sidewall <NUM> extends from the mating surface <NUM> to a mating face <NUM>. The angled or sloped portion <NUM> is angled relative to the mating surface <NUM> and the mating face <NUM>. While the angle may vary depending upon the depth of the mating recess <NUM>, in the illustrative embodiment shown, the angled or sloped portion <NUM> is angled approximate <NUM> to <NUM> degrees relative to the mating face <NUM>. The angle of the angled or sloped portion <NUM> is configured to be approximately equal to the angle of the angled or sloped wall <NUM> of the mating projection <NUM> of the connector assembly <NUM>.

Legs <NUM> of a resilient securing member <NUM> are provided in the mating recess <NUM>. The legs <NUM> are a portion of a U-shaped resilient securing member <NUM> (<FIG>). The legs <NUM> are resiliently deformable away from a longitudinal axis of the mating recess <NUM> as the mating projection <NUM> of connector assembly <NUM> is positioned in the mating recess <NUM> of mating connector assembly <NUM>, as will be more fully described.

In the illustrative embodiment shown, the connector assembly <NUM> has a first contact receiving member <NUM> and a second contact receiving member <NUM> which are used to properly position and retain the contacts <NUM> in position. A surface of the first contact receiving member <NUM> is the mating face <NUM>.

The first contact receiving member <NUM> has openings 382a, 382b which extend therethrough and which are configured to receive the mating sections <NUM> of the contacts <NUM> therein. Openings 382a have a smaller projection 384a which cooperates with the transition portions <NUM> of the contacts <NUM> to allow the transition portions <NUM> to be positioned essentially parallel to the mating face <NUM>. This allows the resilient mating sections <NUM> of the contacts <NUM> in openings 382b to extend a height H3 above the mating face <NUM>. Openings 382b have a larger projection 384b which cooperates with the transition portions <NUM> of the contacts <NUM> to allow the transition portions <NUM> to be positioned at an angle relative to the mating face <NUM>. This allows the mating sections <NUM> of the contacts <NUM> in openings 382a to extend a height H4 above the mating face <NUM>.

A cover <NUM> is provided on the second surface <NUM> of the connector assembly <NUM>. When assembled the cover <NUM> defines a cable receiving interior cavity <NUM> which accommodates the ends of individual wires of the cable (not shown).

As the connector assembly <NUM> is moved into engagement with the connector assembly <NUM>, the angled or sloped wall <NUM> of the connector assembly <NUM> engages the seal <NUM> positioned on the angled or sloped portion <NUM> of the mating connector assembly <NUM>. The legs <NUM> of the resilient securing member <NUM> are moved outward as the mating projection <NUM> is inserted into the mating recess <NUM>.

As the mating occurs, the mating sections <NUM> of the contacts <NUM> positioned in openings 382a engage the engagement sections <NUM> of the contacts <NUM> prior to the mating sections <NUM> of the contacts <NUM> positioned in openings 382b engage the engagement sections <NUM> of the contacts <NUM>. This allow the mating sections <NUM> of the contacts <NUM> positioned in openings 382a to make electrical engagement with respective engagement sections <NUM> of the contacts <NUM> prior to the mating sections <NUM> of the contacts <NUM> positioned in openings 382b making electrical engagement with other respective engagement sections <NUM> of the contacts <NUM>.

With the mating projection <NUM> fully inserted into the mating recess <NUM>, the legs <NUM> enter the securing recess <NUM> positioned in the sidewall <NUM> of the mating projection <NUM> of the connector assembly <NUM>. As this occurs, the legs <NUM> move back toward their unstressed position, thereby exerting a retention force on the securing recess <NUM> and the mating projection <NUM> to retain the mating projection <NUM> in the mating recess <NUM>, allowing the contacts <NUM> and contacts <NUM> to be retained in mechanical and electrical engagement.

The legs <NUM> of the resilient securing member <NUM> can be configured to allow the retention force to be configured for a particular implementation and a particular force as desired. In various embodiments, the retention force is configured to be small, in the range of between <NUM>-<NUM> lbs. (approximately <NUM> to <NUM> N) to allow the connector assembly <NUM> to be easily removed from the mating connector assembly <NUM> when a force is applied to either the connector assembly <NUM> or the mating connector assembly <NUM>. In other embodiments, the retention force is configured to be large, in the range of between <NUM>-<NUM> lbs. (approximately <NUM> to <NUM> N), to prevent the connector assembly <NUM> from being easily removed from the mating connector assembly <NUM> when a force is applied to either the connector assembly <NUM> or the mating connector assembly <NUM>.

Claim 1:
An electrical connector assembly (<NUM>) for mating with a mating connector assembly (<NUM>), the connector assembly (<NUM>) comprising:
a housing (<NUM>) having a cable receiving portion (<NUM>) and a mating portion (<NUM>), the housing having a first surface (<NUM>) and an oppositely facing second surface (<NUM>);
the mating portion (<NUM>) having a mating projection (<NUM>) extending from the first surface (<NUM>) in a direction away from the second surface (<NUM>), the mating projection (<NUM>) having a circular cross-sectional configuration, the mating projection (<NUM>) having an angled wall (<NUM>) which extends from the first surface (<NUM>) to a mating face (<NUM>), the angled wall (<NUM>) being angled relative to a plane of the first surface (<NUM>) and a plane of the mating face (<NUM>);
the mating face (<NUM>) having contacts (<NUM>) extending therethrough, the contacts having circular engagement sections (<NUM>) arranged concentrically about a center of the mating face;
characterized in that
the mating portion (<NUM>) has one or more metallic members (<NUM>) provided on the first surface (<NUM>) of the housing, positioned about at least a portion of the circumference of the outside surface of the angled wall (<NUM>), and which are made of material able to provide a magnetic attraction to magnets provided in the mating electrical connector assembly (<NUM>);
and in that the electrical connector assembly (<NUM>) further comprises a nonconductive coating (<NUM>) applied to the angled wall (<NUM>).