Patent Description:
Integrating electrical connectors into product designs or units is often complicated and costly, particularly for outdoor applications where environmental sealing and ruggedness is required. The cables of these connectors are typically pre-terminated to a connector component instead of being field installable. That is particularly cumbersome and costly when dealing with long and heavy cables which are large and expensive to ship to site.

Therefore, a need exists for a connector terminal that can be easily integrated into a unit and allows field installation of the cables at a reduced cost while also providing ruggedness and environmental sealing for outdoor applications.

Further prior art in this technical field is disclosed in the documents <CIT>, <CIT>, <CIT> and <CIT>.

Accordingly, the present invention provides a connector terminal as defined by claim <NUM>. Said connector terminal comprises a unit-mountable connector including a connector body that has an adapter engagement end and a unit engagement end opposite the adapter engagement end, and a mounting member therebetween for mounting the connector body to a unit. An insert extends through the connector body. The insert has an inner bore that extends between a cable interface end and a unit interface end opposite the cable interface end. A connector body interface portion is between the cable interface and unit interface ends. At least one double-sided contact is received in the inner bore of the insert. The double-sided contact has one end that is a cable termination end configured to terminate to at least one conductor of a cable and an opposite end that is a unit termination end configured to terminate at least one conductor of the unit. In a preferred embodiment, the cable termination end and the unit termination end are different types of termination. In a preferred embodiment, the double-sided contact is a one-piece member.

The connector terminal as defined by claim <NUM> comprises a cable sealing adapter mateable with the unit-mountable connector. The cable sealing adapter includes a housing that has a mating end configured to engage the adapter engagement end of the connector body and receive the cable interface end of the insert and a cable securing end opposite the mating end. The cable securing end is configured to terminate a cable. The cable sealing adapter is devoid of any contacts. The double-sided contact of the unit-mountable connector has one end that is a cable termination end configured to terminate to at least one conductor of the cable supported by the cable sealing adapter and an opposite end that is a unit termination end configured to terminate at least one conductor of the unit. In a preferred embodiment, the connector terminal is a power terminal and the cable is a power cable. In a preferred embodiment, the double-sided contact is a one-piece member.

The present invention further provides a method according to claim <NUM> of assembling a connector terminal to a unit, the connector terminal including a unit-mountable connector and a cable sealing adapter, comprising the steps of: terminating at least one conductor of the unit to a unit interface end of a double-sided contact of the unit-mountable connector; mounting a connector body of the unit-mountable connector to the unit; installing a connector cable by terminating at least one conductor of the connector cable to a cable interface end of the double-sided contact of the unit-mountable connector opposite the unit interface end of the double-sided contact; and assembling the cable sealing adapter on the connector cable after the step of installing the connector cable and mating an end of the cable sealing adapter with the connector body of the unit-mountable connector such that a cable interface end of the unit-mountable connector is received in the cable sealing adapter.

A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawing figures:.

Referring to <FIG>, the present invention relates to a connector terminal <NUM>, such as a power terminal, and a method of assembling the same, particularly on a unit, such as a telecom radio unit. The connector terminal of the present invention is designed to have field-installable capability which allows termination of a cable, such as a power cable, to be done on site rather than requiring the use of a pre-terminated cable assembly or wire harness. That is particularly beneficial when dealing with long and heavy cables which are large and expensive to ship to site. The present invention eliminates the workspace and electrical connections required to terminate a cable outside of the unit's enclosure, thereby allowing reduced sizing and increased connector ruggedness. This design also allows the use of standard tools for conductor termination instead of specialty tools. Although the connector terminal of the present invention is preferably used for power applications, the connector terminal <NUM> may also be used for other applications, such as signal.

Connector terminal <NUM> includes a unit-mountable connector <NUM> that mates with a cable sealing adapter <NUM>. Unit-mountable connector <NUM> is configured to mount to an enclosure or panel <NUM> (<FIG>) of a unit. Cable sealing adapter <NUM> terminates and environmentally seals a cable C (<FIG>). When unit-mountable connector <NUM> and cable sealing adapter <NUM> are mated, an electrical and a mechanical connection is provided between the unit and the cable C.

As seen in <FIG>, unit-mountable connector <NUM> generally includes a connector body <NUM>, an insert <NUM> received in connector body <NUM>, and one or more double-sided contacts <NUM> received in insert <NUM>. Connector body <NUM> may include an adapter engagement end <NUM> that interfaces with cable sealing adapter <NUM>, an opposite unit mountable end <NUM> that interfaces with the unit, and a mounting member <NUM> therebetween. Connector body <NUM> may be generally cylindrical in shape, except for mounting member <NUM>. Adapter engagement end <NUM> preferably includes outer threads <NUM> for engaging cable sealing adapter <NUM>. Although threads are preferred, adapter engagement end <NUM> may include any known type of attachment, such as a bayonet engagement.

Mounting member <NUM> is preferably an outwardly extending flange, as best seen in <FIG>. One or more mounting holes <NUM> may be provided in mounting member <NUM> for receiving a fastener to mount connector body <NUM> to the panel or enclosure <NUM> of the unit. Mounting member <NUM> may be any shape, such as substantially square, as long as one or more of the mounting holes <NUM> are provided. Mounting member <NUM> includes a mounting surface <NUM> that faces the unit mountable end <NUM> for abutting the unit's panel or enclosure <NUM> when unit- mountable connector <NUM> is mounted thereon. In a preferred embodiment, mounting surface <NUM> of mounting member <NUM> includes an annular groove <NUM> that receives a sealing member <NUM>, such as an O-ring or gasket.

<FIG> illustrates an alternative design for a connector body <NUM>' of unit-mountable connector <NUM>. Connector body <NUM>' is similar to connector body <NUM> of the embodiment above, except that connector body <NUM>' is threadably mounted to the unit and not bolted to the unit. Like connector body <NUM> of the embodiment above, connector body <NUM>' includes adapter engagement end <NUM> with outer threads for engaging cable sealing adapter <NUM>. Unlike connector body <NUM> of the embodiment above, the unit engagement end <NUM>' of connector body <NUM>' also includes outer threads <NUM> for threadably engaging the panel or enclosure <NUM> of the unit. Connector body <NUM>' includes a mounting member <NUM>' that is an outwardly extending flange like the mounting member <NUM> of the embodiment above. Mounting member <NUM>' preferably includes a number of gripping faces <NUM> for facilitating rotation and application of torque to connector body <NUM>' when mounting connector body <NUM>' to the unit's panel or enclosure <NUM> via threads <NUM>.

Insert <NUM> is received in and extends through connector body <NUM>. Insert <NUM> generally includes a cable interface end <NUM>, an opposite unit interface end <NUM>, and a connector body interface portion <NUM> therebetween. Cable interface end <NUM> extends through and beyond adapter engagement end <NUM> of connector body <NUM>, unit interface end <NUM> extends through and beyond unit engagement end <NUM> of connector body <NUM>, and connector body interface portion <NUM> is received inside of connector body <NUM>. An inner bore <NUM> of insert <NUM> extends between those ends and supports double-sided contacts <NUM>. As seen in <FIG> and <FIG>, cable interface end <NUM> of insert <NUM> includes one or more holes <NUM> located outside of connector body <NUM> allowing access to double-sided contacts <NUM>. An end face <NUM> of cable interface end <NUM> may include one or more openings <NUM> (<FIG>) also providing access to double-sided contacts <NUM>.

Inner bore <NUM> of insert <NUM> is preferably substantially cylindrical and may include one or more dividers <NUM> to divide inner bore <NUM> into a plurality of compartments where each compartment supports an individual double-sided contact <NUM>, as seen in <FIG>.

Each double-sided contact <NUM> includes opposite termination ends, one end being a cable termination end <NUM> and the other end being a unit termination end <NUM>. Each double- sided contact <NUM> is preferably one-piece or integrally formed. Cable termination end <NUM> is configured to electrically and mechanically connect to and terminate a conductor of a cable C and unit termination end <NUM> is configured to electrically and mechanically connect to and terminate a conductor of the unit. In a preferred embodiment, cable termination end <NUM> and unit termination end <NUM> are different types of termination mechanisms. For example, cable termination end <NUM> may be a clamp termination where end <NUM> is clamped, via either a spring clamp or clamp fastener, such as screw <NUM>, onto the conductor of the cable C and unit termination end <NUM> may be a crimp termination where end <NUM> is crimped onto the conductor of the unit. Alternatively, cable termination end <NUM> and unit termination end <NUM> may be the same type of termination mechanism. Where cable termination end <NUM> uses clamp fastener like screw <NUM>, screw <NUM> may be easily inserted from outside of unit-mountable connector <NUM> through the hole <NUM> into the insert's inner bore <NUM> through a corresponding hole <NUM> (<FIG>) in double- sided contact <NUM> to clamp cable termination end <NUM> of double-sided contact <NUM> onto the conductor of the cable C.

As seen in <FIG>, cable sealing adapter <NUM> generally includes a housing <NUM>, a main sealing member <NUM> for sealing the cable C, such as a wide cable sealing gasket, a secondary sealing member <NUM>, such as an O-ring or gasket, received in housing <NUM>, and a compression nut <NUM>. Cable sealing adapter <NUM> may also include a cable gasket compressor <NUM>, a cable shielding ring <NUM>, and a cable reducer <NUM>. Housing <NUM> may be generally cylindrical with a mating end <NUM> that is configured to engage adapter engagement end <NUM> of connector body <NUM> and receive cable interface end <NUM> of insert <NUM>. In a preferred embodiment, inner threads <NUM> of mating end <NUM> engage outer threads <NUM> of connector body <NUM>. Opposite mating end <NUM> is a cable securing end <NUM> that is configured to terminate the cable C. Cable securing end <NUM> may include outer threads <NUM> that engage corresponding threads <NUM> (<FIG>) of compression nut <NUM> to facilitate the advancement of compression nut <NUM> onto housing <NUM> for compressing main sealing member <NUM> and cable gasket compressor <NUM> to terminate a prepared end of the cable C. Any known attachment other than threads may be used to advance nut <NUM> onto housing <NUM>, such as a bayonet attachment.

Connector terminal <NUM> may be assembled by first electrically and mechanically connecting unit engagement end <NUM><NUM> of unit-mountable connector <NUM> to the unit's panel or enclosure <NUM>. To do so, the one or more conductors of the unit are terminated, such as by crimping, to the unit interface end <NUM> of each double-sided contact <NUM> of unit-mountable connector <NUM>. This step preferably occurs inside of the unit. Unit engagement end <NUM> of connector body <NUM> is sized to be received in and extend through an opening in the unit's panel or enclosure, as seen in <FIG>. Then connector body <NUM> of unit-mountable connector <NUM> may be mounted to the unit. Fasteners, such as bolts, may be extended through mounting holes <NUM> in mounting flange <NUM> and into the unit's panel or enclosure <NUM> to complete the mounting of unit- mountable connector <NUM>. Alternatively, the connector body may be threadably mounted to the unit's panel or enclosure <NUM> via threads <NUM> (<FIG>). When mounted, the mounting surface <NUM> of mounting member <NUM> along with sealing member <NUM> abut or nearly abut the unit's panel or enclosure <NUM>.

Once unit-mountable connector <NUM> is mounted on the unit, the cable C may be terminated thereto by terminating, such as by clamping via a screw or spring clamp, each of the conductors of the cable C to cable interface end <NUM> of each double-sided contact <NUM> of the unit- mountable connector <NUM>. Because unit-mountable connector <NUM> includes contacts <NUM> that are double-sided for termination, no corresponding contacts are required for cable sealing adapter <NUM>. Thus, cable sealing adapter <NUM> is devoid of any contacts. The step of installing the cable C preferably occurs outside the unit.

Cable sealing adapter <NUM> may then be assembled onto the cable C and mated to cable engagement end <NUM> of unit-mountable connector <NUM>. Compression nut <NUM> is advanced onto housing <NUM> of cable sealing adapter <NUM> to terminate and seal the prepared end of the cable C. And the mating end <NUM> connects with cable engagement <NUM> of connector body <NUM> of unit- mountable connector <NUM> such that cable interface end <NUM> of insert <NUM> of unit-mountable connector <NUM> is received in mating end <NUM>, to secure cable sealing adapter <NUM> to unit- mountable connector <NUM>.

While particular embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims. For example, the above mentioned connector terminal may comprise in a preferred embodiment one of the following features:
said cable termination end of said double-sided contact is different than said unit termination end and preferably said cable termination end is a clamp termination and said unit termination end is a crimp termination and further preferably said cable interface end of said insert includes at least one hole that receives a clamp fastener, and said clamp fastener engages said clamp termination of said double-sided contact.

Moreover, in an embodiment of the invention, said mounting member is an outwardly extending flange it is preferred that said flange includes at least one mounting hole for receiving a fastener or said flange includes gripping faces for facilitating application of torque to said flange.

In another preferred embodiment of the invention, said inner bore includes a divider dividing said inner bore into a plurality of compartments, and said double-sided contact is received in one of said plurality of compartments; and another double-sided contact that has one end that is a cable termination end configured to terminate to at least one conductor of the cable and an opposite end that is a unit termination end configured to terminate at least one conductor of the unit, is received in another of said plurality of compartments, wherein said inner bore of said insert is preferably substantially cylindrical.

In another preferred embodiment of the invention, said adapter engagement end of said connector body includes outer threads for engaging corresponding threads of an adapter; and said unit engagement end of said connector body is sized for extending through an opening in the unit and wherein preferably said unit engagement end includes outer threads for engaging corresponding threads of the unit.

In another preferred embodiment of the invention, said cable termination end of said double-sided contact is different than said unit termination end and wherein said cable termination end is a clamp termination and said unit termination end is a crimp termination and more preferably wherein said cable interface end of said insert includes at least one hole that receives a clamp fastener, and said clamp fastener engages said clamp termination of said double-sided contact. In another preferred embodiment of the invention, said adapter engagement end of said connector body includes outer threads for engaging corresponding threads of an adapter; and said unit engagement end of said connector body is sized for extending through an opening in the unit. In another preferred embodiment of the invention, said double-sided contact is a one-piece member.

Claim 1:
A connector terminal, comprising
a unit-mountable connector (<NUM>), including,
a connector body (<NUM>, <NUM>') having an adapter engagement end (<NUM>) and a unit engagement end (<NUM>, <NUM>') opposite said adapter engagement end,
a mounting member (<NUM>, <NUM>') between the adapter and unit engagement ends for mounting the connector body (<NUM>, <NUM>') to a unit (<NUM>);
an insert (<NUM>) extending through said connector body (<NUM>, <NUM>'), said insert having (<NUM>) an inner bore (<NUM>) extending between a cable interface end (<NUM>) and a unit interface end opposite (<NUM>) said cable interface end (<NUM>), and a connector body interface portion (<NUM>) between said cable interface and unit interface ends; and
at least one double-sided contact (<NUM>) received in said inner bore (<NUM>) of said insert (<NUM>),
wherein said cable interface end (<NUM>) of said insert (<NUM>) extends through and beyond said adapter engagement end (<NUM>) of said connector body (<NUM>, <NUM>'); and said unit interface end (<NUM>) of said insert (<NUM>) extends through and beyond said unit engagement end (<NUM>, <NUM>') of said connector body (<NUM>, <NUM>');
said double-sided contact (<NUM>) having one end and an opposite end that is a unit termination end (<NUM>) configured to terminate at least one conductor of the unit (<NUM>);
characterized in that
said one end of said double-sided contact (<NUM>) is a cable termination end (<NUM>) configured to terminate to at least one conductor of a cable (C), and
the connector terminal comprising a cable sealing adapter (<NUM>) mateable with said unit-mountable connector (<NUM>), said cable sealing adapter (<NUM>) including a housing (<NUM>) having a mating end (<NUM>) configured to engage said adapter engagement end (<NUM>) of said connector body (<NUM>, <NUM>') and receive said cable interface end (<NUM>) of said insert (<NUM>) and a cable securing end (<NUM>) opposite said mating end, said cable securing end being configured to terminate a cable (C), and said cable sealing adapter (<NUM>) being devoid of any contacts, wherein said double-sided contact (<NUM>) of said unit-mountable connector (<NUM>) having one end that is a cable termination end (<NUM>) configured to terminate to at least one conductor of the cable (C) supported by said cable sealing adapter (<NUM>) and an opposite end that is a unit termination end (<NUM>) configured to terminate at least one conductor of the unit (<NUM>).