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. <CIT> discloses an electrical connector assembly for mating with and in combination with a mating connector assembly according to the preamble of independent claim <NUM>. Other relevant combinations are disclosed in <CIT> and <CIT>.

It would be, therefore, beneficial to provide an electrical connector or connector assembly 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.

The solution is provided by an electrical connector assembly for mating with and in combination with a mating connector assembly according to independent claim <NUM>. Other aspects of the invention are disclosed in the dependent claims.

An embodiment is directed to an electrical connector assembly for mating with a mating connector assembly. The connector assembly includes a housing having a first surface and a second surface. At least one magnet is provided the housing. A mating area extends from the first surface. The mating area has a sloped surface, which is sloped relative to a plane of the first surface of the housing.

An embodiment is directed to an electrical connector assembly for mating with a mating connector assembly. The connector assembly includes a housing having a first surface and a second surface. At least one magnet is provided a magnet receiving cavity of the housing. A mating recess extends from the first surface in a direction toward the second surface. The mating recess has a sloped surface, which is sloped relative to a plane of the first surface of the housing. A resilient member is provided in the mating recess. The resilient member is configured to be resiliently deformable away from a longitudinal axis of the mating recess.

An embodiment is directed to a break away electrical connector assembly having a first connector assembly and a second connector assembly. The first connector assembly includes a first housing with a first magnet provided therein. The first connector assembly has a mating projection with a first sloped surface. The second connector assembly includes a second housing with a second magnet provided therein. The second magnet is configured to provide an attractive force with the first magnet when the first connector assembly and the second connector assembly are mated. The second connector assembly has a mating recess with a second sloped surface. The second sloped surface is configured to cooperate with the first sloped surface.

As shown in <FIG>, an electrical connector assembly <NUM> has a housing <NUM> with 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 first surface <NUM> and the second surface <NUM> have an oval configuration. However, the first surface <NUM> and the second surface <NUM> may have other configurations without departing from the scope of the invention.

As shown in <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 sidewall <NUM> which extends in a direction which is essentially perpendicular to the plane of the first surface <NUM>. The sidewall <NUM> has one or more securing recesses <NUM> provided therein. A keying member <NUM> extends from a portion of the sidewall <NUM>. The keying member <NUM> also extends from the first surface <NUM>.

An angled or sloped surface or wall <NUM> extends from the sidewall <NUM> in a direction away from the first surface <NUM>. The angled or sloped wall <NUM> extends from the sidewall <NUM> to a mating face <NUM>. The mating face <NUM> has contacts <NUM> provided thereon or extending therethrough. In the embodiment shown, the contacts <NUM> are target contacts with concave interfaces <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>, the angled or sloped wall <NUM> is angled approximate <NUM> to <NUM> degrees relative to the mating face <NUM> in the illustrative embodiment shown.

In the illustrative embodiment shown, cross-sections of the mating projection <NUM> have a generally circular configuration. However, other configurations of the mating projection <NUM> may be used.

As shown in <FIG>, a cable or component receiving projection <NUM> extends from the second surface <NUM> in a direction away from the first surface <NUM>. The component receiving projection <NUM> has a sidewall <NUM> which extends in a direction which is essentially perpendicular to the plane of the second surface <NUM>. The sidewall <NUM> has one or more securing shoulders <NUM> provided therein. A wire receiving face <NUM> is provided in the component receiving projection <NUM>.

In the illustrative embodiment shown, cross-sections of the cable or component receiving projection <NUM> have a generally circular configuration. However, other configurations of the cable or component receiving projection <NUM> may be used.

Magnet receiving cavities <NUM> extend in the housing <NUM> from the second surface <NUM> toward the first surface <NUM>. Caps <NUM> are positioned in the magnet receiving cavities <NUM>. The caps <NUM> may be made from various materials, including, but not limited to, rubber. Alternative methods of retaining the magnets in the shell may be used, such as, but not limited to, epoxy or crimping/deforming of the shell after the magnets are properly positioned.

Referring to <FIG>, magnets <NUM> are positioned in the magnet receiving cavities <NUM> and are retained in the magnet receiving cavities <NUM> by the caps <NUM>. The caps <NUM> have projections or a collar <NUM> which extend from sidewalls <NUM> of the caps <NUM>. The projections or a collar <NUM> are positioned in retention recesses <NUM> of the magnet receiving cavities <NUM> when the caps <NUM> are fully inserted into the magnet receiving cavities <NUM>. The cooperation of the projections or a collar <NUM> and the retention recesses <NUM> prevents the unwanted removal of the caps <NUM> and the magnets <NUM> from the magnet receiving cavities <NUM>.

As shown in <FIG>, a mating electrical connector assembly <NUM> has a housing <NUM> with 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 first surface <NUM> and the second surface <NUM> have an oval configuration. However, the first surface <NUM> and the second surface <NUM> may have other configurations without departing from the scope of the invention.

As shown in <FIG>, a mating recess <NUM> extends from the first surface <NUM> in a direction toward the second surface <NUM>. The mating recess <NUM> has a sidewall <NUM> which has a receiving portion <NUM> which extends in a direction which is essentially perpendicular to the plane of the first surface <NUM>. A keying recess <NUM> extends from the sidewall <NUM>. The keying recess <NUM> also extends from the first surface <NUM>. The keying recess <NUM> is configured to allow the keying member <NUM> to be inserted therein.

An angled or sloped surface or portion <NUM> of the sidewall <NUM> extends from the receiving portion <NUM> in a direction away from the first surface <NUM>. The angled or sloped portion <NUM> extends from the receiving portion <NUM> to a mating face <NUM>. The angled or sloped portion <NUM> is angled relative to the first surface <NUM> and the mating face <NUM>. While the angle may vary depending upon the depth of the mating recess <NUM>, the angled or sloped portion <NUM> is angled approximate <NUM> to <NUM> degrees relative to the mating face <NUM> in the illustrative embodiment shown. 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 the embodiment shown, the contacts <NUM> are spring probes or resilient pins with concave interfaces <NUM> at a free end thereof.

In the illustrative embodiment shown, cross-sections of the mating recess <NUM> have a generally circular configuration. However, other configurations of the mating recess <NUM> may be used.

As shown in <FIG>, <FIG> and <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 portion <NUM> is angled relative to the mating face <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>. 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.

Magnet receiving cavities <NUM> extend in the housing <NUM> from the second surface <NUM> toward the first surface <NUM>. Caps <NUM> are positioned in the magnet receiving cavities <NUM>. The caps <NUM> may be made from various materials, including, but not limited to, rubber.

In use, the cable or component receiving projection <NUM> of the mating connector assembly <NUM> is mounted or secured to a cable or device (not shown). The cable or component receiving projection <NUM> of the connector assembly <NUM> is mounted or secured to a cable or device (not shown). When desired, the connector assembly <NUM> and mating connector assembly <NUM> are mated together to form a mechanical and electrical connection therebetween, as shown in <FIG> and <FIG>.

As mating occurs, the magnets <NUM> and magnets <NUM> are configured to exert an attractive force between the magnets <NUM> an the magnets <NUM>. In the illustrative embodiment shown, the magnets <NUM>, <NUM> are polarized magnets to allow mating of the connector assembly <NUM> and mating connector assembly <NUM> without the user needing to line up the keying member <NUM> to the keying recess. The magnets are powerful enough that if the connector assembly <NUM> and mating connector assembly <NUM> are placed in proximity to each other they get properly oriented to each other by themselves.

In order to maintain the proper orientation of the connector assembly <NUM> to the mating connector assembly <NUM> as insertion occurs and after mating, the keying member <NUM> is positioned in the keying recess <NUM> to prevent the rotation of the connector assembly <NUM> to the mating connector assembly <NUM>. In addition, the alignment of the keying member <NUM> and the keying recess <NUM> can facilitate the mechanical polarization of the connector assembly <NUM> and the mating connector assembly <NUM>.

As insertion continues, the angled or sloped wall <NUM> of the connector assembly <NUM> engages the seal <NUM> positioned in 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>.

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 magnetic attraction or force of the connector assembly <NUM> coupled to the mating connector assembly <NUM> can be configured for a particular implementation and a particular force as desired. In various embodiments, the magnet attraction is configured to be small, in the range of, but not limited to, between <NUM>-<NUM> lbs. , , 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 magnet attraction is configured to be large, in the range of, but not limited to, 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>. The magnetic field produced by the magnetic attraction between the magnets <NUM> and the magnets <NUM> is controlled to prevent the magnetic field from interfering with the signal transmission between the connector assembly <NUM> and the mating connector assembly <NUM>.

Similarly, 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. 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. , 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>.

As shown in <FIG>, <FIG> and <FIG>, an alternate electrical connector assembly <NUM> has a first surface <NUM> and an oppositely facing second surface <NUM>. As many of the components of connector assembly <NUM> are identical to the connector assembly <NUM>, those components are incorporated by reference.

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 sidewall <NUM> which extends in a direction which is essentially perpendicular to the plane of the first surface <NUM>. The sidewall <NUM> has one or more securing recesses <NUM> provided therein. Keying openings <NUM> extend from the first surface <NUM> toward the second surface <NUM>.

An angled or sloped wall <NUM> extends from the sidewall <NUM> in a direction away from the first surface <NUM>. The angled or sloped wall <NUM> extends from the sidewall <NUM> to a mating face <NUM>. The mating face <NUM> has contacts <NUM> provided thereon or extending therethrough. In the embodiment shown, the contacts <NUM> are surface mounted contacts. 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>, the angled or sloped wall <NUM> is angled approximate <NUM> to <NUM> degrees relative to the mating face <NUM> in the illustrative embodiment shown.

Magnet receiving cavities <NUM> extend in the housing <NUM> from the second surface <NUM> toward the first surface <NUM>. Caps <NUM> are positioned in the magnet receiving cavities <NUM>. Referring to <FIG>, magnets <NUM> are positioned in the magnet receiving cavities <NUM> and are retained in the magnet receiving cavities <NUM> by the caps <NUM>.

As shown in <FIG> and <FIG>, a mating electrical connector assembly <NUM> has a first surface <NUM> and an oppositely facing second surface <NUM>. As many of the components of connector assembly <NUM> are identical to the connector assembly <NUM>, those components are incorporated by reference.

A mating recess <NUM> extends from the first surface <NUM> in a direction toward the second surface <NUM>. The mating recess <NUM> has a sidewall <NUM> which has a receiving portion <NUM> which extends in a direction which is essentially perpendicular to the plane of the first surface <NUM>. Keying projections <NUM> extends from the first surface <NUM>. The keying projections <NUM> are configured to be positioned in the keying openings <NUM>.

An angled or sloped portion <NUM> of the sidewall <NUM> extends from the receiving portion <NUM> in a direction away from the first surface <NUM>. The angled or sloped portion <NUM> extends from the receiving portion <NUM> to a mating face <NUM>. The angled or sloped portion <NUM> is angled relative to the first surface <NUM> and the mating face <NUM>. While the angle may vary depending upon the depth of the mating recess <NUM>, the angled or sloped portion <NUM> is angled approximate <NUM> to <NUM> degrees relative to the mating face <NUM> in the illustrative embodiment shown. 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 the embodiment shown, the contacts <NUM> are surface mounted contacts.

The angled or sloped portion <NUM> has a circumferential seal receiving recess <NUM>. An O-ring seal <NUM> is positioned in the seal receiving recess <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>. 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>.

Magnet receiving cavities <NUM> extend in the housing <NUM> from the second surface <NUM> toward the first surface <NUM>. In this illustrative embodiment, the housing <NUM> has two pieces which form the magnet receiving cavities <NUM> and retain the magnets <NUM> in the magnet receiving cavities <NUM>.

The use and operation of the connector assembly <NUM> and mating connector assembly <NUM> are similar to that previously described with respect to connector assembly <NUM> and mating connector assembly <NUM>.

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

Claim 1:
An electrical connector assembly (<NUM>) for mating with and in combination with a mating connector assembly (<NUM>), each connector assembly (<NUM>, <NUM>) comprising:
a housing (<NUM>, <NUM>) having a first surface (<NUM>, <NUM>) and a second surface (<NUM>, <NUM>);
at least one magnet (<NUM>, <NUM>) provided in the housing (<NUM>, <NUM>);
a mating area extending from the first surface (<NUM>, <NUM>), the mating area having a sloped surface (<NUM>, <NUM>), which is sloped relative to a plane of the first surface (<NUM>, <NUM>) of the housing (<NUM>, <NUM>),
wherein the mating area of the mating connector assembly (<NUM>) is a mating recess (<NUM>) which extends from the first surface (<NUM>) of the housing (<NUM>) in a direction toward the second surface (<NUM>),
wherein the mating recess (<NUM>) has a sidewall (<NUM>) with a receiving portion (<NUM>) which extends in a direction which is essentially perpendicular to the plane of the first surface (<NUM>),
characterized in that
a U-shaped resilient securing member (<NUM>) with legs (<NUM>) is provided in the mating recess (<NUM>), the resilient member (<NUM>) configured to be resiliently deformable away from a longitudinal axis of the mating recess (<NUM>).