Patent ID: 12212103

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

With reference to the drawings, this section describes various embodiments of an improved electrical connector system, or more specifically, an electrical coax contact system, and its detailed construction and operation. Throughout the specification, reference to “one embodiment,” “an embodiment,” or “some embodiments” means that a particular described feature, structure, or characteristic may be included in at least one embodiment of an electrical coax contact system. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” or “in some embodiments” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the described features, structures, and characteristics may be combined in any suitable manner in one or more embodiments. In view of the disclosure herein, those skilled in the art will recognize that the various embodiments can be practiced without one or more of the specific details or with other methods, components, materials, or the like.

For reference, the following disclosure describes example embodiments of an electrical connector system that may be used for high-power applications, where the electrical connector system is capable of delivering power of 30 amps or more, which may be useful in the aerospace industry and other related applications, such as aircraft electronic systems. In the following description, certain components of the electrical connector system are described in detail, while in some instances, well-known structures, materials, or operations are not shown or not described in detail to avoid obscuring more pertinent aspects of the embodiments. It should be understood that one having ordinary skill in the art understands how to incorporate the features of the electrical connector design described below into a functional electrical connector, even though certain aspects of the electrical connectors are not further described herein.

With general reference to the figures, the following description relates to an electrical connector system having a hybrid power coax pin and socket contact design suitable for high-power applications, where the overall components of the electrical connector system are designed to maintain optimal performance under harsh environmental conditions. As further described in detail below, the socket contact includes a plurality of cantilevered fingers or flanges designed to create multiple contact surfaces between the pin and socket contacts for aiding in aligning the contacts during the mating process, and for minimizing lateral and rotational movement of the contacts after assembly to maintain optimal performance. In addition, the electrical connector system further includes a wire sealing grommet designed to provide a properly sealed environment for the wires of the electrical connector, where the sealing grommet is coupled to a contact housing insert to minimize arcing issues for the electrical connector system.

In some embodiments, the electrical connector system is designed to operate under some or all of the following conditions: Ambient Temperature: 70° C., Internal Heating: 30° C., Resultant Temperature: 100° C., and an Operational Altitude of 51000 ft. The electrical connector is also designed to handle instantaneous peak transient voltage, including under fault conditions. These voltages are: Conductor: 0-540 V; Screen: 0-360 V. In addition, the electrical connector is also designed to handle sustained peak voltages, including under sustained fault conditions. These voltages are: Conductor: 0-320 V; Screen: 0-213 V. In some embodiments, the coax contacts may have rated current and voltage values of 30 A-100 A and 270 V or higher. Additional details, advantages, and features of the electrical connector design are provided below with particular reference to the figures.

FIG.1illustrates an electrical connector system10including a pair of mated electrical connectors12,98in accordance with one embodiment. With reference toFIG.1, the electrical connector system10includes a pin connector12that interfaces and mates with a socket connector98to create an electrical connection between the wires68,162(seeFIGS.4and7) of the respective connectors12,98. As described in further detail below, each connector12,98includes wires covered with appropriate insulating material and terminated at one end by a contact (e.g., a pin contact60or a socket contact150). In some embodiments, the connector system10may be designed and arranged to accommodate size 10 contacts60,150. While the example embodiments described herein are described with reference to size 10 contacts, it should be understood that this particular size and configuration for the electrical connector system10is for illustration purposes. In other embodiments, the contact size may be adjusted without departing from the principles of the claimed subject matter as further described below.

With general reference toFIGS.2-7, the following description focuses on the design and arrangement of the pin connector12and the socket connector98of the electrical connector system10to achieve a connector design capable of handling high-power applications of 30 amps or more, while maintaining appropriate shielding, mechanical shock and vibration resistance, and performance in extreme temperature and pressure changes. The following section provides additional details relating specifically to the features of the pin connector12and the socket connector98. The discussion begins with details relating first to the pin connector12with reference toFIG.2-4, followed by a description of the socket connector98with reference toFIGS.5-7, and concludes with a discussion focusing on how the respective components interact with one another when the connectors12,98are mated.

FIGS.2-4collectively illustrate a hybrid power coax pin connector12of the electrical connector system10. With general reference toFIG.3, the pin connector12includes a shell14having a generally tubular body16, the body16including a front end18, a rear end20, and a cavity22extending along an axial direction through the body16from the front end18to the rear end20. The body16is described herein as being generally tubular, but it should be understood that the body16may have other shapes and configurations in other embodiments. The body16includes a first lip24formed adjacent the rear end20and a second lip26offset from the first lip24, where the lips24,26form the boundaries of a recessed seat28defined therebetween, the seat28spanning around a circumference of an exterior surface of the body16. The shell14further includes a first key feature30formed as a slot or cutaway region along an interior surface of the body16adjacent the front end18, the first key feature30facing inwardly toward the cavity22. The shell14may be formed as a unitary structural member from any suitable material having high electrical conductivity, or formed from a material coated with such a highly conductive material, for improved performance of the electrical connector system10. For example, in some embodiments, the shell14may be formed of a gold-plated brass material.

With reference toFIG.3, the pin connector12further includes a housing insert32having a generally tubular body34, the body34including a front end36, a rear end38, and a contact-receiving cavity40extending along an axial direction through the body34from the front end36to the rear end38. Again, the body34is described herein as being generally tubular, but it should be understood that the body34may have other shapes and configurations in other embodiments, where the shape of the body34of the housing insert32corresponds to the shape of the body16of the shell14. The housing insert32may be formed from any suitable material with desirable electrical insulation and heat resistant properties for improved performance of the electrical connector system10. For example, in some embodiments, the housing insert32may be formed of a ceramic material. In other embodiments, the housing insert32may be made from a thermoset plastic material (such as diallyl phthalate), or a thermoplastic material (such as polyether ether ketone, polyetherimide, or polybutylene terephthalate), or other suitable insulator material.

With reference toFIG.4, within the contact-receiving cavity40, the housing insert32includes an upper shoulder42and a lower shoulder44that collectively form a seat for receiving and supporting a pin contact60as further described below. As illustrated inFIG.4, the housing insert32includes an opening (obscured from view inFIG.4) between the shoulders42,44through which a head66of the pin contact60extends. The shoulders42,44along with rear walls46,48together form a pocket50within the housing insert32for receiving a contact-retaining clip78when the pin contact60is seated within housing insert32as further explained in detail below.

Returning toFIG.3, the housing insert32includes a second key feature52formed as a ridge or bump along the front end36thereof, the second key feature52designed to sit against and mate with the first key feature30formed within the body16of the shell14. When in a mated configuration, the second key feature52and first key feature30cooperate to retain the housing insert32in proper alignment and resist independent rotation of the housing insert32to keep it from freely rotating within the shell14when the pin connector12is assembled. It should be understood that while the figures illustrate the key feature52as a ridge or bump on the housing insert32and the key feature30as a corresponding slot on the shell14, the arrangement of these features could be swapped in other embodiments. For example, the ridge or bump could instead be formed on the shell14and the corresponding slot could be formed on the housing insert32.

Adjacent the key feature52, the housing insert32includes a channel54formed on the body34, the channel54extending around the circumference of the body34. The channel54is formed behind a position of the key feature52relative to the front end36of the housing insert32as illustrated inFIG.3. When the housing insert32is coupled with the shell14, a retaining ring56collapses into the channel54on the housing insert32to retain the housing insert32in position within the shell14and resist separation of the two components. The housing insert32further includes a rubber spring58(or other suitable seal) encircling the body34adjacent the rear end38. With reference toFIG.4, the rubber spring58abuts against an interior surface of the shell14to help address any tolerance issues and ensure a tight fit between the housing insert32and the shell14. In an assembled configuration, the rubber spring58applies a force against the retaining ring56at assembly to ensure the housing insert32and shell14remain firmly mated.

The pin connector12further includes a pin contact60made of any suitable conductive metal or metal alloy such as copper, aluminum, or nickel (or nickel-plated material) designed to carry high current. With reference toFIGS.3and4, the pin contact60includes a body62with a collar64and a head66extending from the collar64toward a front portion of the pin contact60. The pin contact60terminates a size 10 (or other suitable size) wire68received through an opening (obscured from view) formed on a rear end70of the pin contact60. The wire68includes one or more insulation layers72, a shield74, and an outer jacket76encircling the wire68to insulate and protect the wire68from the environment during use. It should be noted that the insulation layers72, shield74, and outer jacket76are shown as only partially surrounding one another in the figures for ease of illustration of the various components. In an assembled configuration, the shield74entirely surrounds the insulation layers72, and the outer jacket76entirely surrounds the shield74.

With particular reference toFIG.4, the following describes an example assembly of the pin contact60and the housing insert32. In an assembled configuration, the pin contact60and the size 10 wire68are arranged within the contact-receiving cavity40of the housing insert32, with the collar64of the pin contact60positioned adjacent the shoulders42,44, and the head66extending through the opening between the shoulders42,44and toward the front end36of the housing insert32to form the mating interface of the pin connector12. The pin connector12further includes a contact-retaining clip78encircling a portion of the pin contact60, the contact-retaining clip78seated within the pocket50formed within the housing insert32. With the contact-retaining clip78in the pocket50, the contact-retaining clip78abuts the shoulders42,44and the walls46,48of the pocket50to ensure the contact60is securely retained in position within the housing insert32.

With reference toFIGS.3-4, the pin connector12includes a wire sealing grommet80having a body82, the body82including a front end84, a rear end86, and a cavity88extending along an axial direction through the body82from the front end84to the rear end86. The wire sealing grommet80may be made from any suitable material, such as silicone or rubber. Within the cavity88, the wire sealing grommet80includes a plurality of ripple features90(seeFIG.4) designed to create a tight seal around the size 10 wire68to protect against the intrusion of dust, debris, and moisture. The front end84of the body82may include a recessed region92with a diameter and mating features corresponding to those of the rear end38of the housing insert32. With particular reference toFIG.4, the rear end38of the housing insert32is received within the recessed region92of the wire sealing grommet80, with the two components bonded to one another to seal the pin contact60and the wire68. In some embodiments, the rear end38of the housing insert32and the recessed region92of the wire sealing grommet80may include threading or other mating features to help ensure a tight fit and seal between the components. Coupling the wire sealing grommet80directly with the housing insert32instead of the shell14optimizes the dielectric potential of the shielding components of the pin connector12and helps avoid arcing between the shell14and the shielding components. As illustrated inFIG.4, with the components mated, the wire68extends through the contact-receiving cavity40of the housing insert32, through the front end84and the ripple features90within the cavity88of the wire sealing grommet80, and exiting out the rear end86of the wire sealing grommet80.

The pin connector12further includes a second shield94encircling the wire sealing grommet80and a portion of the shell14to help further insulate the pin connector12. With reference toFIGS.3and4, a portion of the second shield94extends over the rear end20and the lip24of the shell14and is disposed along the seat28formed between the lips24,26of the shell14. A shield banding strap96is positioned around the seat28, the shield banding strap96encircling the portion of the second shield94disposed along the seat28to retain the second shield94in place against the body16of the shell14.

FIGS.5-7collectively illustrate a hybrid power coax socket connector98of the electrical connector system10. For reference purposes, the socket connector98includes many of the same components arranged in the same manner as the pin connector12described with reference toFIGS.2-4. With general reference toFIG.6, the socket connector98includes a shell100having a generally tubular body102, the body102including a front end104, a rear end106, and a cavity108extending along an axial direction through the body102from the front end104to the rear end106. The body102is described herein as being generally tubular, but it should be understood that the body102may have other shapes and configurations in other embodiments. The body102includes a first lip110formed adjacent the rear end106and a second lip112offset from the first lip110, where the lips110,112form the boundaries of a recessed seat114defined therebetween, the seat114spanning around a circumference of an exterior surface of the body102. The shell100further includes a first key feature116formed as a slot or cutaway region along an interior surface of the body102adjacent the front end104, the first key feature116facing inwardly toward the cavity108.

Along the front end104of the body102, the shell100further includes a plurality of cantilevered fingers118arranged generally parallel relative to a central longitudinal axis extending through the cavity108of the shell100. The fingers118are formed as integral components of the body102, the fingers118having a free end along the front end104of the body102. The cantilevered fingers118are separated from one another via a small gap or slot120that is preferably of equal size between all the fingers118to ensure that the fingers118are distributed evenly along the body102of the shell100. The shell100may be formed as a unitary structural member from any suitable material having high electrical conductivity, or formed from a material coated with such a highly conductive material, for improved performance of the electrical connector system10. For example, in some embodiments, the shell100may be formed of a gold-plated brass material.

With reference toFIG.6, the socket connector98further includes a housing insert122having a generally tubular body124, the body124including a front end126, a rear end128, and a contact-receiving cavity130extending along an axial direction through the body124from the front end126to the rear end128. Again, the body124is described herein as being generally tubular, but it should be understood that the body124may have other shapes and configurations in other embodiments, where the shape of the body124of the housing insert122corresponds to the shape of the body102of the shell100. The housing insert122may be formed from any suitable material with desirable electrical insulation and heat resistant properties for improved performance of the electrical connector system10. For example, in some embodiments, the housing insert122may be formed of a ceramic material. In other embodiments, the housing insert122may be made from a thermoset plastic material (such as diallyl phthalate), or a thermoplastic material (such as polyether ether ketone, polyetherimide, or polybutylene terephthalate), or other suitable insulator material.

With reference toFIG.7, within the contact-receiving cavity130, the housing insert122includes an upper shoulder132and a lower shoulder134that collectively form a seat for receiving and supporting a socket contact150as further described below. As illustrated inFIG.7, the housing insert122includes an opening (obscured from view inFIG.7) between the shoulders132,134through which a plurality of fingers156of the socket contact150extend. The shoulders132,134along with rear walls136,138together form a pocket140within the housing insert122for receiving a contact-retaining clip172when the socket contact150is seated within housing insert122as further explained in detail below.

Returning toFIG.6, the housing insert122includes a second key feature (obscured from view, but similar to key feature52of the pin connector12shown inFIG.3) formed as a ridge or bump along a collar142adjacent the front end126thereof, the second key feature designed to sit against and mate with the first key feature116formed within the body102of the shell100. When in a mated configuration, the first key feature116and second key feature cooperate to retain the housing insert122in proper alignment and resist independent rotation of the housing insert122to keep it from freely rotating within the shell100when the socket connector98is assembled. It should be understood that while the second key feature is described as a ridge or bump on the housing insert122and the key feature116as a corresponding slot on the shell100, the arrangement of these features could be swapped in other embodiments. For example, the ridge or bump could instead be formed on the shell100and the corresponding slot could be formed on the housing insert122.

Adjacent the collar142, the housing insert122includes a channel144formed on the body124, the channel144extending around the circumference of the body124. The channel144is formed behind a position of the collar142relative to the front end126of the housing insert122as illustrated inFIG.6. When the housing insert122is coupled with the shell100, a retaining ring146collapses into the channel144on the housing insert122to retain the housing insert122in position within the shell100and resist separation of the two components. The housing insert122further includes a rubber spring148(or other suitable seal) encircling the body124adjacent the rear end128. With reference toFIG.7, the rubber spring148abuts against an interior surface of the shell100to help address any tolerance issues and ensure a tight fit between the housing insert122and the shell100. In an assembled configuration, the rubber spring148applies a force against the retaining ring146at assembly to ensure the housing insert122and shell100remain firmly mated.

The socket connector12further includes a socket contact150made of any suitable conductive metal or metal alloy such as copper, aluminum, or nickel (or nickel-plated material) designed to carry high current. With reference toFIGS.6and7, the socket contact150includes a body152with a collar154and a plurality of cantilevered fingers156extending from the collar154toward a front portion of the socket contact150, the fingers156being arranged generally parallel relative to a central longitudinal axis traversing the body152of the socket contact150. As mentioned above, the socket contact150is formed of a material with high conductivity, but many such materials lack suitable elastic properties to allow the cantilevered fingers156to have desired spring force properties when mating with the pin contact60as further described below. Accordingly, along an exterior surface of each of the cantilevered fingers156is formed a slot158sized and dimensioned for receiving a napkin ring160encircling the cantilevered fingers156, where the napkin ring160provides the necessary spring force to ensure a secure connection between the pin contact60and socket contact150.

The socket contact150terminates a size 10 (or other suitable size) wire162received through an opening (obscured from view) formed on a rear end164of the socket contact150. The wire162includes one or more insulation layers166, a shield168, and an outer jacket170encircling the wire162to insulate and protect the wire162from the environment during use. It should be noted that the insulation layers166, shield168, and outer jacket170are shown as only partially surrounding one another in the figures for ease of illustration of the various components. In an assembled configuration, the shield168entirely surrounds the insulation layers166and the outer jacket170entirely surrounds the shield168.

With particular reference toFIG.7, the following describes an example assembly of the socket contact150and the housing insert122. In an assembled configuration, the socket contact150and the size 10 wire162are arranged within the contact-receiving cavity130of the housing insert122, with the collar154of the socket contact150positioned adjacent the shoulders132,134, and the fingers156extending through the opening between the shoulders132,134and toward the front end126of the housing insert122to form the mating interface of the socket connector98. The socket connector98further includes a contact-retaining clip172encircling a portion of the socket contact150, the contact-retaining clip172seated within the pocket140formed within the housing insert122. With the contact-retaining clip172in the pocket140, the contact-retaining clip172abuts the shoulders132,134and the walls136,138of the pocket140to ensure the contact150is securely retained in position within the housing insert122.

With reference toFIGS.6-7, the socket connector98includes a wire sealing grommet174having a body176, the body176including a front end178, a rear end180, and a cavity182extending along an axial direction through the body176from the front end178to the rear end180. The wire sealing grommet174may be made from any suitable material, such as silicone or rubber. Within the cavity182, the wire sealing grommet174includes a plurality of ripple features184designed to create a tight seal around the size 10 wire162to protect against the intrusion of dust, debris, and moisture. The front end178of the body176may include a recessed region186with a diameter and mating features corresponding to those of the rear end128of the housing insert122. With particular reference toFIG.7, the rear end128of the housing insert122is received within the recessed region186of the wire sealing grommet174, with the two components bonded to one another to seal the socket contact150and the wire162. In some embodiments, the rear end128of the housing insert122and the recessed region186of the wire sealing grommet174may include threading or other mating features to help ensure a tight fit and seal between the components. Coupling the wire sealing grommet174directly with the housing insert122instead of to the shell100optimizes the dielectric potential of the shielding components of the socket connector98and helps avoid arcing between the shell100and the shielding components. As illustrated inFIG.7, with the components mated, the wire162extends through the contact-receiving cavity130of the housing insert122, through the front end178and the ripple features184within the cavity182of the wire sealing grommet174, and exiting out the rear end180of the wire sealing grommet174.

The socket connector98further includes a second shield188encircling the wire sealing grommet174and a portion of the shell100to help further insulate the socket connector98. With reference toFIGS.6and7, a portion of the second shield188extends over the rear end106and the lip110of the shell100and is disposed along the seat114formed between the lips110,112of the shell100. A shield banding strap190is positioned around the seat114, the shield banding strap190encircling the portion of the second shield188disposed along the seat114to retain the second shield188in place against the body102of the shell100.

With collective reference toFIGS.1-7, the following briefly describes a mated configuration of the electrical connector system10including the pin connector12and the socket connector98. In an example mating process, the pin connector12and the socket connector98are arranged such that front end18of the shell14of the pin connector12faces the corresponding front end104of the shell100of the socket connector98. In this arrangement, the connectors12,98are brought together until the head66of the pin contact60is received within the opening between the plurality of cantilevered fingers156of the socket contact150. As the connectors12,98are pushed together, the head66spreads the plurality of cantilevered fingers156apart slightly, with the napkin ring160providing sufficient spring force to ensure that the plurality of cantilevered fingers156of the socket contact150remain tightly wrap around the head66of the pin contact60to ensure optimal performance of the electrical connector system10.

Although the description above contains certain details, these details should not be construed as limiting the scope of the invention, but as merely providing illustrations of some embodiments of the invention. It should be understood that subject matter disclosed in one portion herein can be combined with the subject matter of one or more of other portions herein as long as such combinations are not mutually exclusive or inoperable. The terms and descriptions used above are set forth by way of illustration only and are not meant as limitations. It will be obvious to those having skill in the art that many changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention. Those having skill in the art should understand that other embodiments than those described herein are possible.