Patent Description:
Contemporary aircraft use electric machines, such as electric motors or electric generators for energy conversion. In the aircraft industry, it is common to find an electric motor having a combination of motor and generator modes, where the electric machine, in motor mode, is used to start an aircraft engine, and, depending on the mode, functions as a generator, too, to supply electrical power to the aircraft systems. Electric machines contain electrical components which can in some instances require crimp pin electrical connectors or crimp socket connectors to electrically or communicatively couple separate electrical components. Occasionally, these connections are subject to fluid leakage at the connector, which can contaminate the local electrical components or leak fluid external from a sealed vessel. For crimp pin electrical connectors and crimp socket connectors, the leakage flow path extends from the end of the wire lead insulation, near the crimp barrel, to the inspection hole in the crimp barrel. The end of the wire lead insulation and the inspection hole lie on the external side of a seal, which would otherwise control the fluid leakage. <CIT> discloses an electrical connector with a terminal position assurance (TPA) member. <CIT> discloses an electrical contact with a contact body defining a seat for supporting a sealing element, wherein the sealing element provides an impurity-tight seal between the electrical contact and a contact receiving passage in which it is received.

An invention is set out in the claims. In one aspect, the disclosure relates to a crimp pin electrical connector as defined by claim <NUM>.

In another aspect, the present disclosure relates to a wall of an electrical assembly as defined by claim <NUM>.

A full and enabling disclosure of the present description, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which refers to the appended FIGS. , in which:.

Aspects of the disclosure relate to an improved crimp pin electrical connector that includes a set of crimp pins extending through at least a portion of a first side to a second side of a housing. Avionics including electrical components, as well as other engine components, are constantly challenged with dissipating the heat produced within the increasing thermal production within the aircraft environment, which can require the use of local liquids or fluids for heat dissipation. Fluids can accumulate near the first side or a sump region of the housing for the crimp pin electrical connector.

While the description will generally pertain to an avionics chassis or a Back-up Generator (BUG) within an aircraft, it should be appreciated that the crimp pin electrical connector can be applicable to a myriad of elements or implementations, such as any electronics chassis, electronics components, motors such as those in an aircraft engine or not in an aircraft, or any other electrical assembly utilizing crimp pin electrical connectors, for example. Therefore, the crimp pin electrical connector as described herein will also have applicability in other environments where sealed electrical connections are desirable, such as non-aircraft, terrestrial, or other environments, as well as any other electrical environment.

While "a set of" various elements will be described, it will be understood that "a set" can include any number of the respective elements, including only one element. Additionally, all directional references (e.g., radial, axial, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise) are only used for identification purposes to aid the reader's understanding of the disclosure, and do not create limitations, particularly as to the position, orientation, or use thereof. Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and can include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to each other. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto can vary.

<FIG> schematically illustrates an aircraft <NUM> including a gas turbine engine <NUM>, specifically two gas turbine engines <NUM> disposed on respective sides of the aircraft <NUM>. Each gas turbine engine <NUM> can be a turbofan engine commonly used in modern commercial aviation or it could be a variety of other known gas turbine engines such as a turboprop or turboshaft. Each gas turbine engine <NUM> can include a BUG <NUM>. As illustrated, the aircraft <NUM> can include two BUGs <NUM>, one for each gas turbine engine <NUM>. Each BUG <NUM> can be generally defined as an electric machine such that it can be configured to supply or receive power to various avionic components or systems of the aircraft <NUM>. For example, the BUG <NUM> can supply mechanical power to an Accessory Gear Box (AGB) (not shown) used to drive at least a portion of the gas turbine engine <NUM>. While a BUG <NUM> is shown and described, it will be appreciated that the BUG <NUM>, can be any electric machine including, but not limited to, an electric motor or starter/generator.

The aircraft <NUM> can further include an on-board avionics chassis <NUM> (shown in broken-line) for housing avionics, electronics, electrical components, or avionics components for use in the operation of the aircraft <NUM>. The avionics chassis <NUM> houses a variety of avionics elements and protects them against contaminants, electromagnetic interference (EMI), radio frequency interference (RFI), vibrations, and the like. While illustrated in a commercial airliner, the avionics chassis <NUM> can be used in any type of aircraft as well as any vehicle requiring similar protection. The avionics chassis <NUM> can be located anywhere within the aircraft, not just the nose as illustrated. Furthermore, aspects of the disclosure are not limited only to aircraft aspects, and can be included in other mobile and stationary configurations. Non-limiting example mobile configurations can include ground-based, water-based, or additional air-based vehicles. Further yet, aspects of the disclosure are not limited to that of an avionics chassis, but any portion of the aircraft electrical connections are made or crimp pin electrical connectors are utilized. Further still, the electrical connections can be those made in an oil-wetted cavity, such as within an on-engine electric motor or generator (e.g., the BUG <NUM>), where it is desirable to seal the wetted cavity and permit electrical connection.

<FIG> illustrates a housing cover <NUM> or wall of the BUG <NUM> of <FIG>. The housing cover <NUM> can be defined as a portion of the BUG <NUM> which separates a first and a second portion of the BUG <NUM>. The first portion of the BUG <NUM> can be defined as a region which includes one or more components located within a wet portion of the BUG <NUM> such as, but not limited to, circuit boards, wire leads, or other electronic components. As used herein, the term "wet" can refer to any component of the aircraft which is susceptible to be exposed or is exposed to fluids such as, but not limited to, coolants, lubricants, water, gas, oil, or any combination thereof. The first portion of the BUG <NUM> can be defined as a wet region <NUM>. The second region of the BUG <NUM> can be defined as a portion of the BUG <NUM> that is not intended to be in direct contact with fluid. The fluids that a portion of the BUG <NUM> can be exposed to include, but are not limited to, coolants, lubricants, water, oil, gas, or any combination thereof. The second region can be defined as an environment region <NUM>. The environment region <NUM> can be further defined as a location or portion of the BUG <NUM> which is exposed to the environmental conditions surrounding exterior portions of the BUG <NUM>. For example, the environment region <NUM> can be ambient air.

A set of electric pin contacts, specifically a set of crimp pin electrical connectors <NUM>, can extend through the housing cover <NUM> of the BUG <NUM>. The set of crimp pin electrical connectors <NUM> can be configured to establish an electrical connection between a set of electronic components within the BUG <NUM>, specifically the wet region <NUM> of the BUG <NUM>, and a set of external electronic components such as, but not limited to, control systems, health monitoring systems, sensors, generator operations, Full Authority Digital Engine Control (FADEC), or the like. A set of holes extending through the housing cover <NUM> from a first surface corresponding to the wet region <NUM> to a second surface corresponding to the environment region <NUM> can be provided at various locations on the housing cover <NUM> to receive a corresponding crimp pin electrical connector <NUM>. As illustrated, three holes can be provided to receive a total of three crimp pin electrical connectors <NUM>. The set of holes can be configured to circumscribe at least a portion of the crimp pin electrical connector <NUM>.

<FIG> illustrates the avionics chassis <NUM> of <FIG>. according to an aspect of the present disclosure, with a front cover <NUM> removed. The avionics chassis <NUM> includes a chassis housing <NUM> defining an interior <NUM> and exterior <NUM> of the avionics chassis <NUM>. The avionics chassis <NUM> can include a chassis frame <NUM> having a top cover <NUM>, a bottom wall <NUM>, a back wall <NUM>, and opposing sidewalls <NUM>, <NUM>, collectively referred to as a set of walls. The chassis frame <NUM> can further include the aforementioned front cover <NUM> which can be selectively removed, providing access to the interior <NUM> of the avionics chassis <NUM> when removed, and partially restricting access to the interior <NUM> when coupled or mounted with the chassis frame <NUM>. The sidewalls <NUM>, <NUM> can include an interior surface <NUM> and an exterior surface <NUM>. As shown, a set of heat-dissipating elements, such as fins <NUM>, can project from the exterior surface <NUM> of the sidewalls <NUM>, <NUM>. While heat-dissipating fins <NUM> are shown, a number of heat-dissipating elements or heat-dissipating configurations can be utilized by the sidewalls <NUM>, <NUM> to remove or dissipate at least a portion of heat generated by or within the avionics chassis <NUM>, or heat stored by the avionics chassis <NUM>.

The avionics chassis can further include the electric pin contact, specifically the crimp pin electrical connector <NUM> of <FIG>. As illustrated, the crimp pin electrical connector <NUM> can extend through the sidewall <NUM> from a first surface being the interior surface <NUM> to a second surface being the exterior surface <NUM>. A hole extending from the first surface to the second surface can be included within the sidewall <NUM> and be configured to circumscribe at least a portion of the crimp pin electrical connector <NUM>. It is contemplated that the first surface and the second surface can be any opposing surfaces of a specific wall of the set of walls of the avionics chassis <NUM>. Although illustrated as a singular crimp pin electrical connector <NUM>, it will be appreciated that the crimp pin electrical connector <NUM> can be one of a set of crimp pin electrical connectors <NUM>. The set of crimp pin electrical connectors <NUM> can be placed on any wall of the set of walls.

Each crimp pin electrical connector <NUM> can be operatively coupled to one or more electrical components of the aircraft <NUM>. The avionics chassis <NUM> can be configured to house a set of electronic components used in the operation of the aircraft <NUM>. For example, the interior <NUM> of the avionics chassis <NUM> can hold a set of processors, computers, tablets, an Electronic Flight Bag (EFB), or the like. As such, the avionics chassis <NUM> can be configured to house, support, or include a set of electronic components within the interior <NUM>.

<FIG> illustrates the crimp pin electrical connector <NUM> of <FIG> and <FIG> for use within an electrical assembly included within the aircraft <NUM> of <FIG>. As used herein, it will be appreciated that the electrical assembly can refer to any suitable electrical assembly of the aircraft <NUM> configured to utilize or otherwise receive the crimp pin electrical connector <NUM>. As such, it will be appreciated that as described herein, the crimp pin electrical connector <NUM> can extend through any suitable wall of an electrical assembly. Non-limiting examples of the wall of the electrical assembly that the crimp pin electrical connector <NUM> can extend through can include, but are not limited to, the housing cover <NUM> of the BUG <NUM>, and the sidewall <NUM> of the avionics chassis <NUM>.

The crimp pin electrical connector <NUM> can include a housing <NUM> having a first opening <NUM> and a second opening <NUM> defining a longitudinal axis <NUM> extending between the first opening <NUM> and the second opening <NUM>. As such, the first opening <NUM> and the second opening <NUM> can define an axial path through the housing <NUM>. The housing <NUM> can be any suitable crimp-pin connector body or electrical wire connector, such as any commercial-off-the-shelf or custom connector. A flange <NUM> or a mounting flange can be included as a portion of the housing <NUM>. The flange <NUM> can abut the first surface of the sidewall <NUM> or any other wall of the set of walls facing the interior surface <NUM> of the avionics chassis <NUM>, or any side of the housing cover <NUM> of the BUG <NUM> such that the flange <NUM> can be fastened to the wall or housing cover <NUM> through use of a set of fastener apertures <NUM> provided in the flange <NUM>. Although the flange <NUM> is specifically illustrated as being a <NUM>-bolt mounting flange, it will be appreciated that the flange <NUM> can be any sort of mount for the crimp pin electrical connector <NUM>. Specifically, the crimp pin electrical connector <NUM> can be configured to include the housing <NUM> being any environmentally resistant circular electrical connectors with any sort of flange configured to be mounted to an exterior wall or surface through any suitable mounting style such as, but not limited to, a jam nut, a weld mount, or the like.

A nut <NUM> and a cap <NUM> are provided at the first opening <NUM>, including a set of inlets <NUM> for accepting a set of wires connected to at least a portion of the crimp pin electric connector <NUM>, specifically, a set of crimp contacts as described herein. The nut <NUM> can be made of steel, for example, while other materials are contemplated, such as non-conductive materials such as plastics. The cap <NUM> can be made of dielectric materials due its proximity to the set of wires which can extend through the set of inlets <NUM>. For example, the cap <NUM> can be made of polyamide-imide or the like.

<FIG> illustrates a sectional view of the crimp pin electrical connector <NUM> of <FIG> taken from view V-V of <FIG>, illustrating a shell <NUM> of the housing <NUM>. The shell <NUM> of the housing <NUM> can include an interior <NUM>. The interior <NUM> can include an interfacial seal <NUM>, a dielectric insert <NUM>, a grommet <NUM> including at least a set of seal barriers <NUM>. The interior <NUM> can be split into a first side <NUM> and a second side <NUM>. In the illustrated examples of <FIG> and <FIG>, the first side <NUM> can be in the direction of the exterior surface <NUM> of the avionics chassis <NUM> or the environment region <NUM> of the BUG <NUM>. The second side <NUM> can be in the direction of the interior surface <NUM> of the avionics chassis <NUM> or the wet region <NUM> of the BUG <NUM>. As such, at least a portion of the second side <NUM> can be defined as a region of the crimp pin electrical connector <NUM> in which gas, liquids, or other substances can accumulate. It is further contemplated that the second side <NUM> can be defined as a wet or sump side of the crimp pin electrical connector <NUM> while the first side <NUM> can be defined as an environment side of the crimp pin electrical connector <NUM>.

The flange <NUM> can fully circumscribe the exterior of the shell <NUM> and at least partially form a portion of the sump. The flange <NUM> can be positioned and secured such that it forms a seal between the first side <NUM> and the second side <NUM> of the crimp pin electrical connector <NUM> such that liquids cannot leak form one side to the other. For example, in terms of the BUG <NUM>, the flange <NUM> forms a seal on the housing cover <NUM> such that oil, lubricant, or other fluids cannot transfer from the wet region <NUM> to the environment region <NUM> through the set of holes formed within the housing cover <NUM>.

The interfacial seal <NUM> can be on the first side <NUM> of the crimp pin electrical connector and be configured to contact at least a portion of the crimp pin electrical connector <NUM>, specifically, the set of crimp contacts as described herein. The interfacial seal <NUM> can be compressed between the dielectric insert <NUM> and the dielectric insert <NUM> of an exterior connector (not shown). The exterior connector can be defined as a connection which can be electrically coupled to a portion of the crimp pin electrical connector <NUM> through the second opening <NUM>. The interfacial seal <NUM> can be located between the dielectric insert <NUM> and a second opening <NUM> of the shell <NUM>. It is contemplated that the interfacial seal <NUM> can be mated or bonded to the dielectric insert <NUM>. The interfacial seal <NUM> can be formed of any suitable sealing material such as, but not limited to, flurosilicone or the like.

The dielectric insert <NUM> can be provided between the interfacial seal <NUM> and the grommet <NUM>. As illustrated, the dielectric insert <NUM> can span between the first side <NUM> and the second side <NUM> of the crimp pin electrical connector. The dielectric insert <NUM> can define a region of the interior <NUM> of the crimp pin electrical connector <NUM>. It is contemplated, however, that the dielectric insert <NUM> can span along any portion of the interior <NUM> between the interfacial seal <NUM> and the grommet <NUM>. The dielectric insert <NUM> can include any suitable rigid dielectric material such as, but not limited to, a glass filled dielectric material. It will be further appreciated that in some instances the interfacial seal <NUM> can be omitted such that the dielectric insert is retained within the interior <NUM> against the shell <NUM> toward the second opening <NUM>.

A backshell grommet <NUM> is coupled to the shell <NUM>. The grommet <NUM> can be positioned between the backshell grommet <NUM> and the dielectric insert <NUM> on the second side <NUM> of the flange <NUM>, otherwise known as a wet or sump side. The interface between the backshell grommet <NUM> and the grommet <NUM> can be defined by a lower wall <NUM>. The backshell grommet <NUM> can further include or abut against a collar <NUM> circumscribing at least a portion of the backshell grommet <NUM>. The nut <NUM> can be coupled to or otherwise placed over a portion of the collar <NUM>. The nut <NUM> can then be threaded to a portion of the shell <NUM>, specifically to a set of shell threads <NUM>, such that the cap <NUM> is compressively retained against a portion of the collar <NUM>. As such, the collar <NUM> and the cap <NUM> can compressively retain the backshell grommet <NUM> against the grommet <NUM> through the threading of the nut <NUM>.

It will be appreciated that the backshell grommet <NUM> can be included with the grommet <NUM> such that they are integrally formed. Alternatively, the grommet <NUM> and the backshell grommet <NUM> can be formed as two separate pieces. Both the grommet <NUM> and the backshell grommet <NUM> can be made of a compressible, sealing material, such as fluorocarbon or fluorosilicone, while any suitable dielectric compressible material is contemplated, such as rubbers, silicones, carbons, or other materials resistant to leakage and decay.

The set of seal barriers <NUM> can be provided within the grommet <NUM> to provide for sealing within the interior of the crimp pin electrical connector <NUM>. Specifically, the set of seal barriers <NUM> can provide for primary sealing through a set of passages <NUM> and can be located on the sump side, or second side <NUM> fo the flange <NUM>. The set of seal barriers <NUM> can include any suitable sealing material such as, but not limited to, fluorosilicone or other sealing materials. The set of seal barriers <NUM> splits the crimp pin electrical connector into a first side <NUM>, or sump side, of the seal barriers <NUM> and a second side <NUM> of the seal barriers <NUM>. It will be further appreciated, however, that the set of seal barriers <NUM> can be defined as a portion of the grommet <NUM>. As such, the set of seal barriers <NUM> can be integral with the grommet <NUM> and made of the same material as the grommet <NUM>. The set of seal barriers <NUM> can be further defined as a portion within the grommet <NUM> which compressively seals a portion of the crimp pin electrical connector <NUM>, specifically the set of crimp contacts as described herein, such that a barrier is formed to prevent fluids from transferring between the first side <NUM> to the second side <NUM> of the seal barrier <NUM>.

Each passage <NUM> of the set of passages <NUM> can extend from the first opening <NUM> to the second opening <NUM> of the housing <NUM>. The set of passages <NUM> can extend in the direction of the longitudinal axis <NUM> (<FIG>) and be formed within at least the interfacial seal <NUM>, the dielectric insert <NUM>, and the grommet <NUM>. The set of seal barriers <NUM> can inscribe at least a portion of the set of passages <NUM>. Although illustrated as a constant cross-sectional area, it will be appreciated that the set of passages <NUM> can have a varying cross-sectional area along the longitudinal axis <NUM>. For example, the set of passages <NUM> can have a smaller cross-sectional area or contact retaining features, such as protrusions or ribs, in the dielectric insert <NUM>.

A set of inserts or electrical inserts can be provided through the inlets <NUM> and into the passages <NUM>. Each insert of the set of inserts can include a wire lead <NUM>, an electrical insulator <NUM>, and a crimp contact of the set of crimp contacts, specifically a crimp pin <NUM>. Each insert can be defined by a first end <NUM> corresponding to the first opening <NUM> and a second end <NUM> corresponding to the second opening <NUM>. As illustrated, there are two inserts such that two wire leads <NUM>, two electrical insulators <NUM>, and two crimp pins <NUM> are included within the crimp pin electric connector and configured to fit through at least a portion of the set of passages <NUM>. It will be appreciated that the number of inserts can correspond to the number of passages <NUM>. As such, the total number of crimp pins <NUM> can correspond to the total number of passages <NUM>. At least a portion of each insert can extend into the shell <NUM> or the interior <NUM> at the second end <NUM>, and through the cap <NUM>, the collar <NUM> and the nut <NUM> near the first opening <NUM>. It is contemplated that there can be any number of one or more inserts such that there can be any number of one or more wire leads <NUM>, electrical insulators <NUM>, or crimp pins <NUM> passing through a corresponding passage <NUM>.

The set of electrical insulators <NUM> can be located entirely on the second side <NUM> of the flange <NUM>. Specifically, each of the set of electrical insulators can be provided on the first side <NUM> of the seal barrier <NUM>. Each electrical insulator <NUM> of the set of electrical insulators <NUM> can include a wire lead <NUM> or electrical lead having an insulated covering <NUM> extending around at least a portion of the outer circumference of the wire lead <NUM>. The set of electrical insulators <NUM> can extend through at least a portion of a corresponding inlet <NUM> of the set of inlets <NUM>, the cap <NUM>, to a termination point within the backshell grommet <NUM>. The set of wire leads <NUM> can terminate within a portion of the set of crimp pins <NUM> located within a portion of the grommet <NUM>.

At least some of the set of crimp pins <NUM> can include a pin <NUM> and a crimp <NUM>. The crimp pin <NUM> can be configured such that the pin <NUM> is the only portion of the crimp pin <NUM> which extends into the first side <NUM> of the flange <NUM>. As such, the pin <NUM> can extend within the set of passages <NUM> through at least a portion of the grommet <NUM>, the dielectric insert <NUM>, the interfacial seal <NUM> and ultimately into a portion of the shell <NUM>. The pin <NUM> can extend from the first side <NUM> of the flange <NUM> to at least a portion of the second side <NUM> of the flange <NUM>, or to at least a portion of the first side <NUM> of the seal barrier <NUM>. The pin <NUM> can further include a retention shoulder <NUM> defined as a portion of the pin <NUM> which extends into the passage <NUM> from an outer surface of the pin <NUM>. The retention shoulder <NUM> can be configured to fit within a portion of passage <NUM> or the dielectric insert <NUM> to provide for a lock or retention method for the crimp pin <NUM>. Additionally, the passage <NUM> within the dielectric insert <NUM> can have a variable cross-sectional area containing metal contact retention tines or other various contact retaining features for retention of at least a portion of the crimp pin <NUM>, specifically the pin <NUM>.

The crimp <NUM> is located entirely within the second side <NUM> of the flange <NUM>. Specifically, the crimp <NUM> is located entirely within the first side <NUM> of the seal barrier <NUM>. As such, the crimp <NUM> can extend along at least a portion of the crimp pin <NUM> on the first side <NUM> of the seal barrier <NUM>. The crimp <NUM> can be configured to deform at least a portion of a barrel <NUM> positioned entirely on the second side <NUM> of the flange <NUM> or entirely on the first side <NUM> of the seal barrier <NUM>. Specifically, the barrel <NUM> or the crimp <NUM> can be located at least partially within the grommet <NUM> and the backshell grommet <NUM>. Specifically, it is contemplated that at least a portion of the crimp <NUM> is received within a portion of a corresponding passage <NUM> that extends through the grommet <NUM>. The barrel <NUM> can be configured such that it can circumscribe at least a portion of the wire leads <NUM>.

The barrel <NUM> can further include an inspection hole <NUM> which can extend through one or both walls of the crimp pin <NUM> at the barrel <NUM>. The inspection hole <NUM> can be formed as a circular hole or any other hole such as, but not limited to, a slot or a slit. The inspection hole <NUM> can be located entirely on the second side <NUM> of the flange <NUM>, specifically, on the first side <NUM> of the seal barrier <NUM>. It will be further appreciated that each barrel <NUM> can include a set of inspections holes <NUM>. As such, there can be any number of one or more inspection holes <NUM> included on the barrel <NUM>.

The crimp <NUM> can be further defined as a portion of the crimp pins <NUM> which can compressively retain at least a portion of the wire lead <NUM>. The crimp <NUM> can decrease a local cross-sectional area of the barrel <NUM> such that the barrel <NUM> presses up against the wire lead <NUM> and compressively retains the wire leads <NUM>. As such, the crimp can operatively couple the crimp pin <NUM> to the electrical insulator <NUM>. It is contemplated that the crimp <NUM> can additionally be located around another portion of the electric insulator <NUM> such as the insulated cover <NUM>. Additionally, or alternatively, it is contemplated that the crimp <NUM> be one of a set of crimps <NUM> located at various suitable locations along the crimp pin <NUM>. For example, there can be a first crimp <NUM> located around the wire lead <NUM> as illustrated and a second crimp <NUM> located around a portion of the insulated cover <NUM>.

The crimp pin electrical connector or crimp contact as described herein provides for an improved environmental seal compared to conventional crimp pin electrical contacts. For example, in terms of the BUG during operation, internal pressure and fluids can be exerted on the crimp pin electrical connector. In conventional crimp pin electrical connectors liquid, gas, or other substances can leak along a portion of stranded wire of the wire lead exposed to the fluids, and within the insulated covering around the wire lead. A space can be present between the end of the contact and the insulated covering of the wire lead such that fluids can leak into portions of the contact or crimp pin electrical connector. Additionally, the open end of the barrel and inspection hole in conventional crimp pin electrical connectors can provide for a fluid leakage path. As the termination of the insulated covering, crimp, inspection hole and any other leakage paths described herein in conventional crimp pin electrical connectors is located on the second side of the seal barriers, any leaking fluid will egress around the pins of the crimp pins and into regions of the crimp pin electrical connector on the first side of the flange or environment. The crimp pin electrical connector is extended as described herein, such that it eliminates the leaking caused by a pressure vent across the connector by establishing the , the crimp, inspection hole, and the termination of the insulated covering of the crimp pin electrical connector on the second side of the flange, specifically, the first side of the seal barriers. Pressure and fluid, like that generated from BUG operation, can remain entirely within the first side of the seal barriers on the second side of the flange. As such, internal pressure and fluids remain sealed within the pressure vessel by eliminating leak paths unaddressed by standard contacts in the crimp pin electrical connector or crimp pin electrical contact. Further, any fluid wicking along stranded wire leads feeding into the connector, despite the lack of a pressure vent across the connector, will be constrained internal to the sump where the fluid is already expected.

Further benefits of the crimp pin electrical connector as described herein include an increased stabilization of the crimp pin. The increased stabilization is due in part to the extended design of the crimp pin when compared to conventional crimp pins. For example, conventional crimp pin deigns can extend only partially onto the second side of the flange and terminate fully within the second side of the seal barriers. The wire lead, crimped to the crimp pin, is left relatively unsupported through the seal barriers when compared to the crimp pin of the present disclosure. In the event that the insert or the crimp pin electrical connector is put under external loads which can create a side loading, the fluids can bypass the seal between the wire lead and the seal barriers. Additionally, if there is no wire lead connected to a crimp pin of a conventional crimp pin electrical connector, then the seal barriers will not be engaged and fluids will leak around the conventional crimp pin to the external environment. The crimp pin as described herein extends fully through the passage on the second side of the flange, the first side of the seal barrier, through the grommet, and into the backshell grommet. As such, the grommet and additionally the backshell grommet can act as a constraint to better stabilize the crimp pin when compared to conventional crimp pin designs. The increased stability of the extended crimp pin as described herein ensures that the extended crimp pin remains engaged with the seal barriers through side loading of the wire leads, insert, or crimp pin electrical connector.

It is further contemplated that the crimp pin electrical connector as described herein can allow for improved installation and removal of crimp pins than when compared to conventional electrical connectors, specifically hermetic electrical connectors. For example, hermetic electrical connectors can require soldering between the crimp pin and the wire lead. This can add another layer of difficulty for manufacturing when connecting a hermetic connector to an assembly as soldering can require skilled and certified operators. The crimp pin electrical connector as described herein, however, is configured such that it can be repeatedly installed and removed from the crimp pin electrical connector without soldering. As such, the extended crimp pin can be installed and removed from a crimp pin electrical connector using the same tools and in the same manner as a conventional crimp pin.

Many other possible configurations in addition to that shown in the above figures are contemplated by the present disclosure. To the extent not already described, the different features and structures of the various aspects can be used in combination with others as desired. That one feature cannot be illustrated in all of the aspects is not meant to be construed that it cannot be, but is done for brevity of description. Thus, the various features of the different aspects can be mixed and matched as desired to form new aspects, whether or not the new aspects are expressly described. Combinations or permutations of features described herein are covered by this disclosure.

Claim 1:
A crimp pin electrical connector (<NUM>) comprising:
a shell (<NUM>) defining an interior (<NUM>) with a first opening (<NUM>) and a second opening (<NUM>) to define an axial path through the shell (<NUM>) between the first opening (<NUM>) and the second opening (<NUM>);
a flange (<NUM>) circumscribing an exterior of the shell (<NUM>); and
an insert located within the interior (<NUM>) and comprising a first end (<NUM>) corresponding to the first opening (<NUM>), a second end (<NUM>) corresponding to the second opening (<NUM>), and at least one passage (<NUM>) extending between the first end (<NUM>) and the second end (<NUM>), the insert comprising:
at least one crimp pin (<NUM>) corresponding to the at least one passage, with at least some of the at least one crimp pins (<NUM>) comprising a pin (<NUM>) and a crimp (<NUM>); and
a seal barrier (<NUM>) forming a portion of the passage and being configured to compressively seal at least a portion of the at least one crimp pin (<NUM>); wherein
the at least one crimp pin (<NUM>) is located within the at least one passage (<NUM>) such that a portion of the at least one crimp pin (<NUM>) is located on a first side (<NUM>) of the flange (<NUM>) and the crimp (<NUM>) lies on a second side (<NUM>), opposite the first side (<NUM>), of the flange (<NUM>); and
the seal barrier (<NUM>) defines a first side (<NUM>) and a second side (<NUM>) of the seal barrier (<NUM>); the crimp (<NUM>) is located entirely on the first side (<NUM>) of the seal barrier (<NUM>); characterized in that
the at least one passage (<NUM>) extends through a grommet (<NUM>) and at least a portion of the crimp (<NUM>) is received within a portion of the at least one passage (<NUM>) extending through the grommet (<NUM>);
and
the crimp (<NUM>) is further located at least partially within a backshell grommet (<NUM>), the backshell grommet (<NUM>) having an interface with the grommet (<NUM>).