Patent ID: 12191596

The foregoing and other features of the present disclosure will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings.

DETAILED DESCRIPTION

In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and made part of this disclosure.

To improve the heating of exhaust gases in aftertreatment systems that use electrical connectors, it may be desirable to use the electrical connector to provide a high electrical current to a heater. However, it can be difficult to conduct a high electrical current without corrosion of the electrical connector over time. As the electrical connector corrodes, the resistance of the electrical connector increases and results in increased temperature at the electrical connector, which can lead to local damage and potential reduction of the ability to deliver thermal energy to the exhaust, which in turn could impact aftertreatment systems and system emissions.

Various embodiments of the electrical connector described herein may provide one or more advantages, including, for example: (1) improved electrical conductivity, improved ability to electrically isolate the electrical connector, and reduced heat generation at the electrical connector through a low resistance connection due to the low resistivity of copper, as compared to using a stainless steel stub with a stainless steel electrical connector; (2) improved temperature resistance and moisture reduction through silicone seals that prevent corrosion; (3) transmitting up to 250 amps while operating at up to 200 degrees Celsius and having sealing of the electrical path; (4) providing robustness for an electrical circuit against the vibration profile experienced with highway trucks; (5) reduced mass, volume, and cost as compared to using a junction box with ring eyelets bolted to buss bars; (6) reduced risk of breaking the conductor pin, increased ease of installation, and facilitation of tightening and undoing for service, through use of a free spinning nut that allows for installing the electrical connector without having to twist the wire or the conductor pin; and (7) lower cost and improved manufacturability and servicing conditions as compared to using a permanent connection between the electrical connector and the conductor pin.

Overview of Exhaust Gas Aftertreatment Systems

FIG.1depicts an aftertreatment system100, according to an embodiment. The aftertreatment system100includes a heater108having a conductor pin260, a heater power source192having a wire250, and an electrical connector200(discussed in further detail herein). The aftertreatment system100is configured to receive exhaust gas (e.g., diesel exhaust gas, etc.) from an engine101(e.g., motor, etc.) and treat constituents (e.g., NOx, CO, CO2, etc.) of the exhaust gas. The aftertreatment system100may also include an inlet conduit102, a first temperature sensor103, an outlet conduit104, a second temperature sensor105, an outlet sensor107, a reductant storage tank110, a gas sensor112, a reductant insertion assembly120, a hydrocarbon insertion assembly122, an oxidation catalyst130, a filter140, a selective catalytic reduction (SCR) system150, a reductant port156, an ammonia oxidation (AMOX) catalyst152, a controller160, a heater control unit (HCU)162, a switched battery194, and/or a fuse196.

The engine101may include, for example, a diesel engine, a gasoline engine, a natural gas engine, a dual fuel engine, a biodiesel engine, an E-85 engine, or any other suitable engine. The engine101combusts fuel and generates an exhaust gas that includes NOx, CO, CO2, and other constituents. The engine101may include other components, for example, a transmission, fuel insertion assemblies, a generator or alternator to convert the mechanical power produced by the engine into electrical power (e.g., to power the heater108, the gas sensor112, the reductant insertion assembly120, the hydrocarbon insertion assembly122, and the controller160, etc.).

The aftertreatment system100may include a housing114(e.g., casing, cover, container, shell, etc.) in which various aftertreatment components of the aftertreatment system100are disposed. The housing114may be formed from a rigid, heat-resistant and corrosion-resistant material, for example stainless steel, iron, aluminum, metals, ceramics, or any other suitable material. The housing114may have any suitable cross-section, for example, circular, square, rectangular, oval, elliptical, polygonal, or any other suitable shape.

The aftertreatment system100may include an inlet conduit102(e.g., channel, duct, pipe, tube, chute, etc.) that is fluidly coupled to an inlet of the housing114and structured to receive exhaust gas from the engine101and communicate the exhaust gas to an internal volume defined by the housing114. Furthermore, an outlet conduit104(e.g., channel, duct, pipe, tube, chute, etc.) may be coupled to an outlet of the housing114and structured to expel treated exhaust gas into the environment (e.g., treated to remove particulate matter such as soot by the filter140and/or reduce constituents of the exhaust gas such as NOx gases, CO, unburnt hydrocarbons, etc. included in the exhaust gas by the SCR system150and the oxidation catalyst130).

The aftertreatment system100includes a heater108(e.g., ceramic heater, electric heater, etc.) that is disposed upstream of the other aftertreatment components, for example, in the inlet conduit102proximate to an engine exhaust manifold (e.g., at an outlet of a turbo coupled to the engine101). The heater108may be an electrical heater, which may have an input voltage in a range of 36 to 52 V and a heater power in a range of 10 to 100 kW (i.e., the electrical power consumed by the heater108to generate heat). As used herein, a range of X to Y includes X, Y, and values between X and Y. In some embodiments, the heater108is a 48 V, 10 kW electric heater. The heater108is configured to selectively heat the exhaust gas entering the aftertreatment system100, such that heating of the exhaust gas by the heater108causes an increase in a temperature of a heating element of the gas sensor112as the heated exhaust gas flows over the gas sensor112. For example, the heater108can be selectively activated to heat the exhaust gas flowing therethrough towards the gas sensor112and the aftertreatment components, and thereby heat the gas sensor112, as well as downstream aftertreatment components (e.g., heat the oxidation catalyst130to a light-off temperature, heat the SCR system150to its operating temperature, etc.).

The heater108has a conductor pin260(discussed in further detail herein) for connecting to an electrical connector200(discussed in further detail herein). InFIG.2, the heater108has three conductor pins260. InFIG.2, two of the three conductor pins260are supply pins configured to receive electricity to supply the heater108, and one of the three conductor pins260is a ground pin configured to ground the heater108. In other embodiments, the heater108may have more than two supply pins.

The aftertreatment system100includes a heater power source192. The heater power source192has a wire250(discussed in further detail herein) for connecting to the electrical connector200. The heater power source192may have a voltage that is approximately in a range of 36-52 V.

The aftertreatment system100includes an electrical connector200. The electrical connector200is connected to the wire250of the heater power source192. The electrical connector200is connected to the conductor pin260of the heater108.

The aftertreatment system100may include a first temperature sensor103(e.g., detector, indicator, etc.). The first temperature sensor103may be positioned in the inlet conduit102upstream of the heater108. The first temperature sensor103is configured to measure an upstream exhaust gas temperature of the exhaust gas upstream of the heater108. In some embodiments, a second temperature sensor105(e.g., detector, indicator, etc.) is also disposed downstream of the heater108, for example, proximate to an outlet of the heater108and configured to measure a downstream exhaust gas temperature of the exhaust gas downstream of the heater108. In some embodiments, other sensors, for example, pressure sensors, oxygen sensors, and/or any other sensors configured to measure one or more operational parameters of the exhaust gas entering the aftertreatment system100may be disposed in the inlet conduit102. In some embodiments, each of the first temperature sensor103and the second temperature sensor105may be excluded, and instead, the upstream and downstream exhaust gas temperatures may be determined virtually (e.g., by the controller160), using equations, algorithms, or look up tables, for example, based on operating parameters of the engine101exhaust gas flow rate, heater power consumed, etc.

The aftertreatment system100may include an oxidation catalyst130. The oxidation catalyst130is disposed downstream of the heater108in the housing114and configured to decompose unburnt hydrocarbons and/or CO included in the exhaust gas. In some embodiments, the oxidation catalyst130may include a diesel oxidation catalyst. The hydrocarbon insertion assembly122is configured to selectively insert hydrocarbons (e.g., the same fuel that is being consumed by the engine101) upstream of the oxidation catalyst130, for example, into the engine101. When a temperature of the oxidation catalyst130is equal to or above a light-off temperature of the oxidation catalyst130, the oxidation catalyst130catalyzes combustion of the inserted hydrocarbons so as to cause an increase in the temperature of the exhaust gas. In some embodiments, the hydrocarbon insertion assembly122may be selectively activated (e.g., by the controller160) to insert hydrocarbons into the oxidation catalyst130for heating the exhaust gas and thereby, the downstream filter140and SCR system150. In some embodiments, insertion of the hydrocarbons may heat the exhaust gas to a sufficient temperature to regenerate the filter140by burning off particulate matter that may have accumulated on the filter140, and/or regenerate the SCR system150by evaporating reductant deposits deposited on the SCR system150or internal surfaces of the aftertreatment system100.

The aftertreatment system100may include a gas sensor112(e.g., a NOx sensor, detector, indicator, etc.) that is disposed in the housing114downstream of the heater108and upstream of any aftertreatment component that treats the constituents of the exhaust gas. For example, as shown inFIG.1, the gas sensor112is disposed downstream of the heater108and upstream of the oxidation catalyst130.

The aftertreatment system100may include an outlet sensor107(e.g., detector, indicator, etc.). The outlet sensor107may be positioned in the outlet conduit104. The outlet sensor107may comprise a second NOx sensor configured to determine an amount of NOx gases expelled into the environment after passing through the SCR system150. In other embodiments, the outlet sensor107may comprise a particulate matter sensor configured to determine an amount of particulate matter (e.g., soot included in the exhaust gas exiting the filter140) in the exhaust gas being expelled into the environment. In still other embodiments, the outlet sensor107may comprise an ammonia sensor configured to measure an amount of ammonia in the exhaust gas flowing out of the SCR system150, i.e., determine the ammonia slip. The AMOXcatalyst152may be positioned downstream of the SCR system150and formulated to decompose any unreacted ammonia that flows past the SCR system150.

The aftertreatment system100may include a filter140(e.g., mesh, separator, etc.) that is disposed downstream of the oxidation catalyst130and upstream of the SCR system150and configured to remove particulate matter (e.g., soot, debris, inorganic particles, etc.) from the exhaust gas. In some embodiments, the filter140may include a ceramic filter. In some embodiments, the filter140may include a cordierite filter which can, for example, be an asymmetric filter. In yet other embodiments, the filter140may be catalyzed.

The aftertreatment system100may include a SCR system150that is configured to decompose constituents of an exhaust gas flowing therethrough in the presence of a reductant, as described herein. In some embodiments, the SCR system150may include a selective catalytic reduction filter (SCRF). The SCR system150includes a SCR catalyst configured to catalyze decomposition of the NOx gases into its constituents in the presence of a reductant. Any suitable SCR catalyst may be used such as, for example, platinum, palladium, rhodium, cerium, iron, manganese, copper, vanadium based catalyst, any other suitable catalyst, or a combination thereof. The SCR catalyst may be disposed on a suitable substrate such as, for example, a ceramic (e.g., cordierite) or metallic (e.g., kanthal) monolith core that can, for example, define a honeycomb structure. A washcoat can also be used as a carrier material for the SCR catalyst. Such washcoat materials may comprise, for example, aluminum oxide, titanium dioxide, silicon dioxide, any other suitable washcoat material, or a combination thereof.

AlthoughFIG.1shows only the oxidation catalyst130, the filter140, the SCR system150, and the AMOXcatalyst152disposed in the internal volume defined by the housing114, in other embodiments, a plurality of aftertreatment components may be disposed in the internal volume defined by the housing114in addition to, or in place of the oxidation catalyst130, the filter140, the SCR system150, and the AMOXcatalyst152. Such aftertreatment components may include, for example, a two-way catalyst, mixers, baffle plates, secondary filters (e.g., a secondary partial flow or catalyzed filter) and/or any other suitable aftertreatment component.

The aftertreatment system100may include a reductant port156(e.g., opening, outlet, etc.). The reductant port156may be positioned on a sidewall of the housing114and structured to allow insertion of a reductant therethrough into the internal volume defined by the housing114. The reductant port156may be positioned upstream of the SCR system150(e.g., to allow reductant to be inserted into the exhaust gas upstream of the SCR system150) or over the SCR system150(e.g., to allow reductant to be inserted directly on the SCR system150). Mixers, baffles, vanes or other structures may be positioned in the housing114upstream of the SCR system150(e.g., between the filter140and the SCR system150) so as to facilitate mixing of the reductant with the exhaust gas.

The aftertreatment system100may include a reductant storage tank110(e.g., container, reservoir, etc.) that is structured to store a reductant. The reductant is formulated to facilitate decomposition of the constituents of the exhaust gas (e.g., NOx gases included in the exhaust gas). Any suitable reductant may be used. In some embodiments, the exhaust gas comprises a diesel exhaust gas and the reductant comprises a diesel exhaust fluid (DEF). For example, the DEF may comprise urea, an aqueous solution of urea, or any other fluid that comprises ammonia, by-products, or any other diesel exhaust fluid as is known in the arts (e.g., the DEF marketed under the name ADBLUE®). For example, the reductant may comprise an aqueous urea solution having a particular ratio of urea to water. In some embodiments, the reductant can comprise an aqueous urea solution including 32.5% by weight of urea and 67.5% by weight of deionized water, including 40% by weight of urea and 60% by weight of deionized water, or any other suitable ratio of urea to deionized water.

The aftertreatment system100may include a reductant insertion assembly120that is fluidly coupled to the reductant storage tank110. The reductant insertion assembly120is configured to selectively insert the reductant into the SCR system150or upstream thereof, or upstream or into a mixer (not shown) positioned upstream of the SCR system150. The reductant insertion assembly120may comprise various structures to facilitate receipt of the reductant from the reductant storage tank110and delivery to the SCR system150, for example, pumps, valves, screens, filters, etc.

The aftertreatment system100may include a reductant injector that is fluidly coupled to the reductant insertion assembly120and configured to insert the reductant (e.g., a combined flow of reductant and compressed air) into the SCR system150. In some embodiments, the reductant injector may include a nozzle having a predetermined diameter. In some embodiments, the reductant injector may be positioned in the reductant port156and structured to deliver a stream or a jet of the reductant into the internal volume of the housing114so as to deliver the reductant to the SCR system150.

The controller160may be operatively coupled to the first temperature sensor103, the second temperature sensor105, the gas sensor112, the heater108, and in some embodiments, the reductant insertion assembly120, the hydrocarbon insertion assembly122, and/or the outlet sensor107. For example, the controller160may be configured to receive an upstream exhaust gas temperature signal from the first temperature sensor103and receive a downstream exhaust gas temperature signal from the second temperature sensor105to determine the upstream exhaust gas temperature and the downstream exhaust gas temperature, respectively. The controller160may also be configured to selectively activate the heater108, and/or a heater module coupled to the heater108so as to heat the exhaust gas flowing through the heater108towards the SCR system150, for heating the SCR system150.

The controller160is configured to determine the upstream exhaust gas temperature upstream of the heater108, for example, based on the exhaust gas temperature signal received from the first temperature sensor103. The upstream exhaust gas temperature corresponds to the temperature of the exhaust gas entering the aftertreatment system100. In response, to the upstream exhaust gas temperature being less than a first threshold, for example, the dew point temperature (e.g., 100 degrees Celsius), the controller160causes activation of the heater108. The controller160may also be configured to determine the downstream exhaust gas temperature downstream of the heater108, for example, based on a signal received from the second temperature sensor105.

The controller160may be operably coupled to the engine101, the first temperature sensor103, the second temperature sensor105, the heater108, the gas sensor112, the outlet sensor107, the reductant insertion assembly120, the hydrocarbon insertion assembly122, and/or various components of the aftertreatment system100using any type and any number of wired or wireless connections. For example, a wired connection may include a serial cable, a fiber optic cable, a CAT5 cable, or any other form of wired connection. Wireless connections may include the Internet, Wi-Fi, cellular, radio, Bluetooth, ZigBee, etc. In one embodiment, a controller area network (CAN) bus provides the exchange of signals, information, and/or data. The CAN bus includes any number of wired and wireless connections. In some embodiments, the controller160includes various circuitries or modules configured to perform the operations of the controller160described herein.

In some embodiments, the aftertreatment system100may include a heater control unit (HCU)162for controlling the heater108, as inFIG.1B. The HCU162has a power connection164, a wake input connection166, a ground connection168, a CAN HI connection170, a CAN LO connection172, a CAN shield connection174, a first high voltage input176, a second high voltage input178, a heater return (RTN) reference180, a first output driver182, and a second output driver184.

The HCU162is connected to the controller160by the CAN HI connection170, CAN LO connection172, and CAN shield connection174of the HCU162. The CAN HI connection170, CAN LO connection172, and CAN shield connection174are configured to allow the exchange of signals between the controller160and the HCU162. When signals are exchanged between the controller160and the HCU162, the voltage of the connection between the controller160and the CAN HI connection170is greater than the voltage of the connection between the controller160and the CAN LO connection172. The CAN shield connection174is configured to surround the links between the controller160and the CAN HI connection170and the CAN LO connection172and to reduce electromagnetic interference.

The aftertreatment system100may include a HCU power source198for providing power to the HCU162. The HCU power source198has a voltage that is approximately in a range of 9-32 V. A first terminal of the HCU power source198is connected to the ground connection168of the HCU162. A second terminal of the HCU power source198is connected and may provide a current both to the power connection164of the HCU162and to the wake input connection166of the HCU162. When the HCU162is in a sleep mode, providing a current to the wake input connection166of the HCU162signals the HCU162to enter an active mode. When the HCU162is in an active mode, the HCU162receives power from the power connection164from the HCU power source198. A fuse196is connected to the second terminal of the HCU power source198and the power connection164of the HCU162. The fuse196may protect the HCU162in the event of the HCU power source198providing an excessive current to the HCU162.

The aftertreatment system100may include a switched battery194positioned between the wake input connection166and the second terminal of the HCU power source198. The switched battery194with the HCU power source198may provide a greater voltage to the wake input168of the HCU162than the voltage that the HCU power source198alone provides to the power connection164of the HCU162. A fuse196is connected to the switched battery194and the power connection164of the HCU162. The fuse196may protect the HCU162in the event of the HCU power source198and the switched battery194providing an excessive current to the HCU162.

The HCU162is connected to the heater power source192. A first end of the heater power source192is connected to and may provide a current to the first high voltage input176of the HCU162. A fuse196is connected to the first end of the heater power source192and the power connection164of the HCU162. A second end of the heater power source192is connected to and may provide a current to the second high voltage input178of the HCU162. A fuse196is connected to the second end of the heater power source192and the second high voltage input178of the HCU162. The fuses196may protect the HCU162in the event of the heater power source192providing an excessive current to the HCU162. A third end of the heater power source192is connected to the heater RTN reference180of the HCU162and allows a current to be conducted from the HCU162to the heater power source192.

The HCU162is connected to the heater108. The heater108may have a heater HI connection186, a heater LO connection188, and a heater RTN connection190. The heater RTN connection190of the heater108is connected with an electrical connector200to a fourth end of the heater power source192and allows a current to be conducted from the heater108to the heater power source192.

The first output driver182of the HCU162is connected with an electrical connector200to and may provide a current to the heater HI connection186. The second output driver184of the HCU162is connected with an electrical connector200to and may provide a current to the heater LO connection188. When the HCU162provides a current to the heater108using the first output driver182and the second output driver184, the voltage of the connection between the HCU162and the heater HI connection186is greater than the voltage of the connection between the HCU162and the heater LO connection188.

Electrical Connectors

FIG.3-4depict an electrical connector200for conducting high electrical current in a hot environment according to an embodiment. The electrical connector200includes a male connector210having a wire connection portion211configured to be connected to a wire250. The electrical connector200also includes a pin connection portion214having an outer diameter D1less than that of the wire connection portion211. The pin connection portion214is configured to contact a conductor pin260in an electrically conductive manner and has male threads216. The electrical connector200also includes a collar220configured to surround the conductor pin260. The collar220has a collar cylindrical body portion222, and a collar outer flange224. The collar outer flange224has an outer diameter D2larger than that of the collar cylindrical body portion222, a first surface225configured to contact the pin connection portion214of the male connector210, and a second surface226opposite the first surface225. The electrical connector200also includes a nut230configured to surround the pin connection portion214of the male connector210, the collar outer flange224, and part of the collar cylindrical body portion222. The nut230has a nut cylindrical body portion232, and a nut inner flange234. The nut inner flange234has an inner diameter D3less than that of the nut cylindrical body portion232, and has a first surface235that faces the second surface226of the collar outer flange224. The electrical connector200also includes a first seal240that surrounds the collar cylindrical body portion222and is positioned between the second surface226of the collar outer flange224and the first surface235of the nut inner flange234. The electrical connector200also includes a second seal242that surrounds the pin connection portion214of the male connector210and is positioned between an end surface233of the nut cylindrical body portion232and a first surface213of the wire connection portion211that faces the collar220.

The electrical connector200(e.g., conductor, etc.) includes a male connector210(e.g., conductor, plug, etc.). The male connector210may be made of copper, silver, or other suitable materials. The male connector210enables a low-resistance connection to a conductor pin260.

The male connector210includes a wire connection portion211configured to be connected to a wire250(e.g., cable, coil, line, etc.). The wire connection portion211has a first surface213that faces the collar220. The wire connection portion211has a second surface217that faces a lower surface251of the wire250. The wire connection portion211may receive an electrical current from the wire250and may transmit an electrical current to the pin connection portion214of the male connector210.

InFIG.3, the wire connection portion211has a hexagonal cross-sectional shape. In other embodiments, the wire connection portion211may have a cross-sectional shape that is a circle, a circular segment, a circular sector, an oval, a polygon, a rounded polygon, or other geometric shape. The wire connection portion211may have a length that is approximately in a range of 100-150% of the width of the wire connection portion211.

In some embodiments, the wire connection portion211has a protruding portion212, as inFIG.3. The protruding portion212has a lateral surface218that faces the lateral surface252of the wire250. InFIG.4, the lateral surface218of the protruding portion212is flat. In other embodiments, the lateral surface218of the protruding portion212may have a surface that is convex, concave, rough, or has other surface geometry. InFIG.3, the protruding portion212of the wire connection portion211has a circular segment cross-sectional shape. The protruding portion212of the wire connection portion211may have a cross-sectional shape that is a circle, a circular segment, a circular sector, an oval, a polygon, a rounded polygon, or other geometric shape.

The protruding portion212of the wire connection portion211may have a maximum cross-sectional width (e.g., a diameter where the cross-sectional shape is circular) that is approximately in a range of 100-150% of the width of the wire250. In some embodiments, the protruding portion212of the wire connection portion211may have a uniform cross-sectional width. In other embodiments, the protruding portion212of the wire connection portion211may have a cross-sectional width that varies over the length of the protruding portion212. InFIG.3, the end of the protruding portion212of the wire connection portion211is rounded. In other embodiments, the end of the protruding portion212of the wire connection portion211may be beveled, chamfered, flat, pointed, or have another shape. The protruding portion212of the wire connection portion211may have a length that is approximately 100-150% of the width of wire250.

The wire250has a lower surface251that faces the second surface217of the wire connection portion211. The wire250has a lateral surface252that faces the lateral surface218of the protruding portion212. InFIG.4, the lateral surface252of the wire250is flat. In other embodiments, the lateral surface252of the wire250may have a surface that is convex, concave, rough, or has other surface geometry. The wire250may be connected to the wire connection portion211of the male connector210by ultrasonic welding, laser welding, brazing, soldering, or other suitable connecting processes. Preferably, ultrasonic welding or laser welding is used. Connecting the wire250to the wire connection portion211of the male connector includes connecting the lateral surface252of the wire250to the lateral surface218of the protruding portion212of the wire connection portion211and connecting the lower surface251of the wire250to the second surface217of the wire connection portion211.

The wire250may be made of copper, aluminum, or other suitable materials. In some embodiments, the wire250may be a multi-strand wire. In other embodiments, the wire250may be a single-strand wire. The wire250may have a minimum cross-sectional area that is approximately in a range of 25-50 mm2.

In some embodiments, a wire insulation shield258surrounds the wire250. The wire insulation shield258insulates the wire250from the hot environment that the wire250and the electrical connector200may be operating in and may improve conduction of electrical current from the wire250to the electrical connector200. The wire insulation shield258may be made of suitable insulating materials.

The male connector210also includes a pin connection portion214configured to contact a conductor pin260(e.g., cold pin, heater conductor, etc.) in an electrically conductive manner (e.g., permitting an electrical current to be transmitted). The pin connection portion214may receive an electrical current from the wire connection portion211of the male connector210and may transmit an electrical current to the conductor pin260. The conductor pin260may be made of nickel-clad copper or other suitable materials.

The pin connection portion214has a circular cross-sectional shape. The pin connection portion214has an outer diameter D1that is less than that of the wire connection portion211. The pin connection portion214may have a length that is approximately in a range of 0.09-0.125 in. (approximately 2.2-3.2 mm).

The pin connection portion214has male threads216(e.g., external threads) configured to connect to a nut230. InFIG.3, the male threads216are positioned with a uniform spacing between each of the male threads216. In other embodiments, the male threads216may be positioned with spacing that varies between the male threads216. The male threads216may have a spacing (e.g., thread pitch) that is approximately in a range of 1-1.5 mm between each of the male threads. InFIG.3, the male threads216have a diameter that is uniform over the length of the pin connection portion214. The male threads216may have a rotational orientation that is clockwise or counter-clockwise. The male threads216may be tapered threads.

The electrical connector200also includes a collar220. The collar220is configured to surround the conductor pin260. The collar220may be made of copper, nickel-plated copper, silver, or other suitable materials.

The collar220includes a collar cylindrical body portion222. The collar cylindrical body portion222may be connected to the conductor pin260by crimping or by other suitable connecting processes.

The collar cylindrical body portion222has a maximum outer diameter that is approximately in a range of ⅙-¼ in. (4.2-6.4 mm). The wall of the collar cylindrical body portion222may have a maximum width that is approximately in a range of 0.06-0.09 in. (approximately 1.5-2.3 mm).

The collar220also includes a collar outer flange224. The collar outer flange224is positioned such that a first surface225of the collar outer flange224is configured to contact the pin connection portion214of the male connector210. The collar outer flange224has a second surface226that is opposite the first surface225. The collar outer flange224may be connected to the conductor pin260by welding, brazing, soldering or by other suitable connecting processes. In some embodiments, when the collar outer flange224is brazed to the conductor pin260, silver brazing is used.

InFIG.4, the collar outer flange224has an annular cross-sectional shape. The collar outer flange224has an outer diameter D2that is larger than that of the collar cylindrical body portion222. The collar outer flange224may have a maximum outer diameter D2that is approximately in a range of 0.23-0.50 in. (5.84-12.7 mm). The collar outer flange224may have a length that is approximately in a range of 1/16-¼ in. (approximately 1.5-6.4 mm).

The electrical connector200also includes a nut230. The nut230is configured to surround the pin connection portion214of the male connector210, the collar outer flange224, and part of the collar cylindrical body portion222. The nut230is capable of spinning freely (e.g., independently) of the wire250, male connector210, collar220, and the conductor pin260. The nut230may be made of brass or other suitable materials. InFIG.3, the nut230has a hexagonal outer surface238. In other embodiments, the nut230may be a square nut, wing nut, or knurled nut.

The nut230includes a nut cylindrical body portion232. The nut cylindrical body portion232has an end surface233that faces the first surface213of the wire connection portion211. The nut cylindrical body portion232has female threads (e.g., internal threads) that are configured to connect to the male threads216of the pin connection portion214of the male connector210. The nut230may have an undercut236(e.g., recess, groove, cavity) that allows for machining of the female threads of the nut cylindrical body portion232. The female threads are configured to engage with the male threads216of the pin connection portion214of the male connector210.

The nut cylindrical body portion232may have a maximum width that is approximately in a range of ⅜-1 in. (approximately 9.5-25.4 mm. The nut cylindrical body portion232may have a length that is approximately in a range of 100-150% of the width of the nut cylindrical body portion232.

The nut230also includes a nut inner flange234. The nut inner flange234has a first surface235that faces the second surface226of the collar outer flange224. The nut inner flange234has an inner diameter D3that is less than that of the nut cylindrical body portion232.

The electrical connector200also includes a first seal240. The first seal240surrounds the collar cylindrical body portion222and is positioned between the second surface226of the collar outer flange224and the first surface235of the nut inner flange234. When the nut230is tightened, the first seal240functions as a barrier between collar220and the nut230that prevents moisture from collecting on and/or near, and prevents corroding, the pin connection portion214of the male connector210, the collar outer flange224, a portion of the conductor pin260, and the connection between the pin connection portion214of the male connector210, the collar outer flange224, and the conductor pin260.

InFIG.4, the first seal240has an annular cross-sectional shape. The first seal240may be made of silicone or other suitable materials (e.g., materials capable of withstanding a temperature of approximately 180 degrees Celsius). The first seal240may have a thickness (e.g., a length) that is approximately in a range of 0.5-2 mm. The first seal240may have a width (e.g., a difference between an inner diameter and the outer diameter) that is approximately in a range of 0.5-2 mm.

The electrical connector200also includes a second seal242. The second seal242surrounds the pin connection portion214of the male connector210and is positioned between the end surface233of the nut cylindrical body portion232and the first surface213of the wire connection portion211. When the nut230is tightened, the second seal242functions as a barrier between the nut230and the wire connection portion211of the male connector210that prevents moisture from collecting on and/or near, and prevents corroding, the pin connection portion214of the male connector210, the collar outer flange224, a portion of the conductor pin260, and the connection between the pin connection portion214of the male connector210, the collar outer flange224, and the conductor pin260.

InFIG.4, the second seal242has an annular cross-sectional shape. The second seal242may be made of silicone or other suitable materials (e.g., materials capable of withstanding a temperature of approximately 180 degrees Celsius). In some embodiments, both the first seal240is made of silicone and the second seal242is made of silicone.

In some embodiments, an electrical isolation cover surrounds a portion of the wire insulation shield258, a portion of the wire250, the male connector210, the collar220, the nut230, the first seal240, the second seal242, and a portion of the conductor pin260. The electrical isolation cover may have a cross-sectional shape that is a circle, a circular segment, a circular sector, an oval, a polygon, a rounded polygon, or other geometric shape. In some embodiments, the electrical isolation cover has a length of 55 mm.

Methods of Making an Electrical Connection

An example method for making an electrical connection includes providing an electrical connector200. The method also includes inserting the conductor pin260into the collar220so that the conductor pin260contacts the pin connection portion214of the male connector210. The method also includes crimping the collar cylindrical body portion222to the conductor pin260. The method also includes attaching the collar outer flange224to the conductor pin260. The method also includes attaching the wire250to the wire connection portion211of the male connector210. The method also includes tightening the nut230to connect the pin connection portion214of the male connector210, the collar220, the conductor pin260, the first seal240, and the second seal242. In some embodiments, attaching the collar outer flange224to the conductor pin260includes welding or brazing the collar outer flange224to the conductor pin260. In some embodiments, attaching the wire250to the wire connection portion211of the male connector210includes ultrasonically welding the wire250to the wire connection portion211.

The method includes providing an electrical connector200. The electrical connector200includes a male connector210having a wire connection portion211configured to be connected to a wire250. The electrical connector200also includes a pin connection portion214having an outer diameter D1less than that of the wire connection portion211. The pin connection portion214is configured to contact a conductor pin260in an electrically conductive manner and has male threads216. The electrical connector200also includes a collar220configured to surround the conductor pin260. The collar220has a collar cylindrical body portion222, and a collar outer flange224. The collar outer flange224has an outer diameter D2larger than that of the collar cylindrical body portion222, a first surface225configured to contact the pin connection portion214of the male connector210, and a second surface226opposite the first surface225. The electrical connector200also includes a nut230configured to surround the pin connection portion214of the male connector210, the collar outer flange224, and part of the collar cylindrical body portion222. The nut230has a nut cylindrical body portion232, and a nut inner flange234. The nut inner flange234has an inner diameter D3less than that of the nut cylindrical body portion232, and has a first surface235that faces the second surface226of the collar outer flange224. The electrical connector200also includes a first seal240that surrounds the collar cylindrical body portion222and is positioned between the second surface226of the collar outer flange224and the first surface235of the nut inner flange234. The electrical connector200also includes a second seal242that surrounds the pin connection portion214of the male connector210and is positioned between an end surface233of the nut cylindrical body portion232and a first surface213of the wire connection portion211that faces the collar220. While the method is described with respect to the electrical connector200, it should be appreciated that the operations of the method are equally applicable to any other electrical connector that includes components analogous to those described therein.

The method includes inserting the conductor pin260into the collar220so that the conductor pin260contacts the pin connection portion214of the male connector210. The pin connection portion214of the male connector210contacts the conductor pin260in an electrically conductive manner.

The method includes crimping the collar cylindrical body portion222to the conductor pin260.

The method includes attaching the collar outer flange224to the conductor pin260. In some embodiments, the collar outer flange224is welded or brazed to the conductor pin260.

The method includes attaching the wire250to the wire connection portion211of the male connector210. In some embodiments, the wire250is ultrasonically welded to the wire connection portion211of the male connector210. In other embodiments, the wire250is laser welded to the wire connection portion211of the male connector210.

The method includes tightening the nut230to connect the pin connection portion214of the male connector210, the collar220, the conductor pin260, the first seal240, and the second seal242. Tightening the nut230allows the first seal240and the second seal242to prevent moisture from collecting on and/or near, and prevent corroding, the pin connection portion214of the male connector210, the collar outer flange224, a portion of the conductor pin260, and the connection between the pin connection portion214of the male connector210, the collar outer flange224, and the conductor pin260.

CONSTRUCTION OF EXAMPLE EMBODIMENTS

It should be noted that the term “example” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

The terms “coupled,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

It is important to note that the construction and arrangement of the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Additionally, it should be understood that features from one embodiment disclosed herein may be combined with features of other embodiments disclosed herein as one of ordinary skill in the art would understand. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular implementations of particular inventions. Certain features described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

As utilized herein, the terms “substantially,” “generally,” “approximately,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the appended claims.

Also, the term “or” is used, in the context of a list of elements, in its inclusive sense (and not in its exclusive sense) so that when used to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, Z, X and Y, X and Z, Y and Z, or X, Y, and Z (i.e., any combination of X, Y, and Z). Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present, unless otherwise indicated.

Additionally, the use of ranges of values (e.g., W1to W2, etc.) herein are inclusive of their maximum values and minimum values (e.g., W1to W2includes W1and includes W2, etc.), unless otherwise indicated. Furthermore, a range of values (e.g., W1to W2, etc.) does not necessarily require the inclusion of intermediate values within the range of values (e.g., W1to W2can include only W1and W2, etc.), unless otherwise indicated.