Patent Document

FIELD OF THE INVENTION  
       [0001]     The present invention relates to electronics in general, and, more particularly, to electrical connectors.  
       BACKGROUND OF THE INVENTION  
       [0002]     Mobile multi-cell rocket launchers are used by the military to provide firepower during a combat situation. The launcher electronics (e.g., control, power, and targeting systems, etc.) and launch platform necessary to control and fire each rocket are bulky and expensive; therefore, modern multi-cell rocket launchers use modularity to reduce overall system cost and bulkiness.  
         [0003]     A common infrastructure, which includes the launcher electronics and launch platform, is used in conjunction with replaceable canisters, which each contain a rocket. Each canister provides a substantially air-tight environment that reduces the rocket&#39;s exposure to dust, humidity, and other environmental factors. The canisters need to be easily replaced in a combat situation; i.e. it must be possible to quickly remove a spent canister and replace it with a fresh canister to replenish the total firepower of the launcher.  
         [0004]     In the prior art, the loading of a canister into a launch platform requires complicated handling by the crew manning the platform. In particular, in order to connect the electronics contained within the canister to the launcher electronics (i.e., the electronics NOT contained in the canister), the crew must attach the electrical cables associated with the platform to the electrical cables associated with the canister. Furthermore, the crew must ensure that the cables are not severed or damaged while the canisters are loaded.  
         [0005]     Therefore, the need exists for an electrical connection that avoids or mitigates some or all of these problems.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention enables a docking system for a rocket-containing canister and a launch platform that avoids some of the disadvantages for doing so in the prior art. In particular, the illustrative embodiment of the present invention uses mechanical alignment features, spring-loaded electrical contacts, an environmental seal, and an electromagnetic radiation shield to establish and maintain reliable electrical interconnection between the rocket and the launcher electronics.  
         [0007]     The present invention enables a rocket-containing canister to be loaded into a multi-cell rocket launcher while also establishing electrical connection between the rocket and launcher electronics associated with the multi-cell rocket launcher. Once established, the electrical interconnection between the rocket and multi-cell rocket launcher is maintained even in the presence of the vibration associated with a rocket launch, dirt or other airborne contaminants, or external electromagnetic radiation.  
         [0008]     The illustrative embodiment comprises: a spring-loaded electrical contact, a seal for providing an environmental seal, and a shield for providing an electro-magnetic-interference shield, wherein both the environmental seal and the electro-magnetic-interference shield surround the spring-loaded contact so that when the electrical connector is mated, the spring-loaded contact is enclosed in an environment that is substantially isolated from the ambient environment and substantially isolated from external electro-magnetic radiation. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]      FIG. 1  depicts a representational diagram of the salient components of a vehicle-borne multi-cell launcher in accordance with the illustrative embodiment.  
         [0010]      FIG. 2  depicts a perspective view of the salient components of a multi-cell launcher in accordance with the illustrative embodiment of the current invention.  
         [0011]      FIG. 3  depicts a perspective view of the salient components of a representative canister in accordance with the illustrative embodiment of the current invention.  
         [0012]      FIG. 4  depicts an exploded view of the salient components of a canister and a receptacle in accordance with the illustrative embodiment of the current invention.  
         [0013]      FIG. 5  depicts a top-down view of the salient components of a pallet connector and a bottom-up view of a canister connector in accordance with the illustrative embodiment of the current invention.  
         [0014]      FIG. 6  depicts an exploded cross-sectional view of the salient components of a pallet connector and a canister connector in accordance with the illustrative embodiment of the current invention.  
         [0015]      FIG. 7  depicts a cross-sectional view of the salient components of an alternative embodiment of the present invention.  
         [0016]      FIG. 8  depicts a cross-sectional view of the salient components of a resilient contact according to the illustrative embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0017]      FIG. 1  depicts a representational diagram of the salient components of a vehicle-borne multi-cell launcher in accordance with the illustrative embodiment. Although multi-cell launcher  102  is mounted on vehicle  100 , it will be clear to those skilled in the art how to make and use alternative embodiments of the present invention in which multi-cell launcher  102  is mounted on another vehicle, such as a railroad car, warship, submarine, space vehicle, satellite, or stationary ground-based platform.  
         [0018]      FIG. 2  depicts a perspective view of the salient components of multi-cell launcher  102 . Launcher  102  comprises eight canisters  206   1,1  through  206   2,4 , and launch pallet  216 . Launch pallet  216  comprises eight canister receptacles  217   1,1  through  217   2,4 , and pallet connectors  218   1,1  through  218   2,4  (for clarity, only receptacles  217   1,4  and  217   2,4  and pallet connectors  218   1,4  and  218   2,4  are shown). Although multi-cell launcher  102  comprises eight canisters and eight canister receptacles, it will be clear to those skilled in the art, after reading this disclosure, how to make and use embodiments of the present invention that comprise any number of canisters and canister receptacles.  
         [0019]     Multi-cell launcher  102  is a system that has the capability of launching a plurality of rockets from its launch platform. Launch pallet  216  accepts and holds rocket-containing canisters  204   i,j  in canister receptacle  206   i,j  wherein i is a positive integer in the set {1, . . . 2}, and j is a positive integer in the set {1, . . . 4}. After a rocket is launched from canister  204   i,j , the spent canister can be replaced by an unused canister to replenish the fire power of multi-cell launcher  102 .  
         [0020]     Launch pallet  216  comprises canister receptacles  206   1,1  through  206   2,4 , which provide mechanical structure to which canisters  204   1,1  through  204   2,4  are mounted. In addition, each canister receptacle  206   i,j  includes pallet connector  208   i,j , which provides an electrical interface between canister  206   i,j  and fire control.  
         [0021]      FIG. 3  depicts a perspective view of the salient components of canister  204   i,j . Canister  204   i,j , comprises rocket  310   i,j , housing  312   i,j , connector plate  314   i,j , canister connector  316   i,j , canister-to-rocket umbilical  318   i,j , rear legs  320 , and front legs  322 .  
         [0022]     Housing  312   i,j , fly-through cover  313   i,j , and connector plate  314   i,j  are sheet metal that form a substantially weather-proof and dust-proof environment for rocket  310   i,j , such that rocket  310   i,j  does not suffer from environmental conditions (e.g., dust, rain, dirt, etc.).  
         [0023]     Connector plate  314   i,j  comprises canister connector  316   i,j , rear legs  320 , and front legs  322 . Canister connector  316   i,j  mates with pallet connector  208   i,j  when rear legs  320  and front legs  322  are engaged with their respective alignment holes, rear slots  424  and front slots  426  (which are depicted in  FIG. 4 ). When canister  204   i,j  is inserted into receptacle  206   i,j , rear legs  320  and front legs  322  engage rear slots  424  and front slots  426  in a single orientation, and, as a consequence, canister connector  316   i,j  is properly aligned with pallet connector  208   i,j  to ensure the interconnection of their appropriate contacts.  
         [0024]      FIG. 4  depicts an exploded view of the salient components of canister  204   2,4  and receptacle  206   2,4  in accordance with the illustrative embodiment of the current invention. Canister  204   2,4  includes connector plate  314   2,4 , which comprises canister connector  314   2,4 , rear legs  320 , and front legs  322 . Receptacle  206   2,4  comprises pallet connector  208   2,4 , rear slots  424 , and front slots  426 . Further, and as depicted in more detail in  FIG. 5 , canister connector  316   2,4  comprises canister annulus  432  and canister contacts  434 , and pallet connector  208   2,4  comprises pallet annulus  428  and pallet contacts  430 .  
         [0025]     As canister  204   2,4  engages receptacle  206   2,4 , rear legs  320  engage rear slots  424  such that canister  204   2,4  can only seat in receptacle  206   2,4  in a single orientation. Once rear legs  320  have engaged rear slots  424 , canister  204   2,4  rotates into position above receptacle  206   2,4  enabling front legs  322  to be inserted into front slots  426 . The insertion of rear legs  320  and front legs  322  into slots  424  and  426  aligns canister connector  316   2,4  and pallet connector  208   2,4 .  
         [0026]      FIG. 5  depicts a top-down view of the salient components of pallet connector  208   i,j  and a bottom-up view of canister connector  316   i,j  in accordance with the illustrative embodiment of the current invention. Canister connector  316   i,j  comprises canister annulus  432 , shield seat  544 , seal seat  546 , contacts  434   1,1  through  434   2,2  (collectively, contacts  434 ), canister connector face  539 , and canister key  538 .  
         [0027]     Pallet connector  208   i,j  comprises pallet annulus  428 , shield seat  540 , seal seat  542 , contacts  430   1,1  through  430   2,2  (collectively, contacts  430 ), pallet connector face  537 , and pallet key  536 .  
         [0028]     Canister connector  316   i,j  and pallet connector  208   i,j  include pallet key  536  and canister key  538 , respectively, and are designed to mate in a single orientation that ensures proper interconnection of contacts  434 , which depend from canister connector face  539 , with contacts  430 , which depend from pallet connector face  537 , (i.e., contact  434   1,1  interconnected to  430   1,1 , . . . ,  434   2,2  interconnected to  430   2,2 ). Additionally, correct alignment of pallet connector  208   i,j  and canister connector  316   i,j  ensures that shield seat  540  aligns with shield seat  544 , and seal seat  542  aligns with seal seat  546  such that when seat  648  and shield  650  are present (as depicted in  FIGS. 6 and 7 ), shield  650  is located in shield seats  540  and  544 , and seal  648  is located in seal seats  542  and  546 .  
         [0029]      FIG. 6  depicts an cross-sectional view of the salient components of pallet connector  208   i,j  and canister connector  316   i,j , as taken through line a-a of  FIG. 5 , in accordance with the illustrative embodiment of the current invention. Pallet connector  208   i,j  comprises circuit board  652 , pallet annulus  428  that includes shield seat  540  and seal seat  542 , resilient contacts  430   1,1  and  430   1,2 , pallet key  536 , shield  650 , and seal  648 . Canister connector  316   i,j  comprises printed circuit board  654 , canister annulus  432  that includes shield seat  544  and seal seat  546 , resilient contacts  434   1,1  and  434   1,2 , and pallet key  538 .  
         [0030]     Circuit board  652  provides connection between resilient contacts  430   1,1  and  430   1,2  to the launcher electronics associated with multi-cell launcher  102 . Pallet annulus  428  and canister annulus  432  provide structure to hold shield  650  and seat  648  such that when pallet connector  208   i,j  is mated to canister connector  316   i,j , resilient contacts  430  and  434  are enclosed in an environment that is substantially free of externally-generated electro-magnetic radiation and substantially isolated from the external ambient environment. Pallet key  536  and canister key  538  ensure proper alignment of pallet annulus  428  to canister annulus  432  and resilient contacts  430  to resilient contacts  434 .  
         [0031]     Resilient contacts  430   1,1 ,  430   1,2 ,  434   1,1 , and  434   1,2  are flexible, spring-loaded electrical contacts. When pallet connector  208   i,j  and canister connector  316   i,j  are mated, resilient contacts  430   1,1  and  434   1,1  are compressed against each other, and resilient contacts  430   1,2  and  434   1,2  are compressed against each other, and at least one contact in each compressed pair deforms. During a rocket launch, although vibration causes canister  204   i,j  and receptacle  206   i,j  to move with respect to one another, the resiliency of resilient contacts  430  and  434  ensures that positive electrical contact is maintained.  
         [0032]      FIG. 7  depicts a cross-sectional view, as taken through the line a-a of  FIG. 5 , of the salient components of an alternative embodiment of the present invention. Referring to  FIG. 7 , pallet connector  208   i,j  comprises circuit board  652 , pallet annulus  428  that includes shield seat  540  and seal seat  542 , rigid contacts  756   1,1  and  756   1,2 , pallet key  536 , shield  650 , and seal  648 . Canister connector  316   i,j  comprises printed circuit board  654 , canister annulus  432  that includes shield seat  544  and seal seat  546 , resilient contacts  434   1,1  and  434   1,2 , and pallet key  538 .  
         [0033]     As in the illustrative embodiment, when pallet connector  208   i,j  is mated to canister connector  316   i,j , printed circuit boards  652  and  654 , pallet annulus  428 , canister annulus  432 , shield  650  and seal  648  together enclose rigid contacts  756  and resilient contacts  434  in an environment that is substantially free of externally-generated electro-magnetic radiation and substantially isolated from the external ambient environment. Additionally, as in the illustrative embodiment, pallet key  536  and canister key  538  ensure that pallet connector  208   i,j  mates properly to canister connector  316   i,j .  
         [0034]     When pallet connector  208   i,j  and canister connector  316   i,j  are mated, resilient contact  430   1,1  is compressed against rigid contact  756   1,1 , and resilient contact  430   1,2  is compressed against rigid contact  756   1,2  such that resilient contacts  430   1,1  and  430   1,2  deform. During a rocket launch, although vibration causes canister  204   i,j  and receptacle  206   i,j  to move with respect to one another, the resiliency of resilient contacts  430   1,1  and  430   1,2  ensures that positive electrical contact with rigid contacts  756   1,1  and  756   1,2  is maintained.  
         [0035]      FIG. 8  depicts a cross-sectional view of the salient components of resilient contact  434   i,j  in accordance with to the illustrative embodiment of the present invention. Resilient contact  434   i,j  comprises spring  858   i,j  that includes free-end  864   i,j , and hold down  860   i,j .  
         [0036]     Spring  858   i,j  is formed from an electrically-conductive, resilient material, such as copper, gold-alloy, bronze, or aluminum, as is well-known by those skilled in the art. At one end, spring  858   i,j  is fixidly-attached by hold down  860   i,j  to via pad  862   i,j  on printed circuit board  654 . At the other end, spring  858   i,j  is left unattached in order to allow for flexibility and resiliency when mated to another contact.  
         [0037]     Although the illustrative embodiment comprises two alignment features (i.e., (1) legs  320  and  322  and slots  424  and  426 , and (2) keys  536  and  538 ), it will be clear to those skilled in the art, however, after reading this specification, how to make and use alternative embodiments of the present invention that comprise any number of alignment features, alternative alignment features, or embodiments that rely on shield  650 , seal  648 , or both shield  650  and seal  648  to ensure the alignment of canister  204   i,j  to receptacle  206   i,j .  
         [0038]     Furthermore, it will be clear to those skilled in the art how to make and use alternative embodiments of the present invention in which shield  650  is located in shield seat  544 , or seal  648  is located in seal seat  546 , or shield  650  is located in shield seat  544  and seal  648  is located in seal seat  546 .  
         [0039]     Moreover, it will be clear to those skilled in the art how to make and use alternative embodiments of the present invention in which resilient contacts are formed using spring-loaded shaft-type contacts, leaf-spring contacts, button contacts, etc.  
         [0040]     It is to be understood that the above-described embodiments are merely illustrative of the present invention and that many variations of the above-described embodiments can be devised by those skilled in the art without departing from the scope of the invention. For example, in this Specification, numerous specific details are provided in order to provide a thorough description and understanding of the illustrative embodiments of the present invention. Those skilled in the art will recognize, however, that the invention can be practiced without one or more of those details, or with other methods, materials, components, etc.  
         [0041]     Furthermore, in some instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the illustrative embodiments. It is understood that the various embodiments shown in the Figures are illustrative, and are not necessarily drawn to scale. Reference throughout the specification to “one embodiment” or “an embodiment” or “some embodiments” means that a particular feature, structure, material, or characteristic described in connection with the embodiment(s) is included in at least one embodiment of the present invention, but not necessarily all embodiments. Consequently, the appearances of the phrase “in one embodiment,” “in an embodiment,” or “in some embodiments” in various places throughout the Specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, materials, or characteristics can be combined in any suitable manner in one or more embodiments. It is therefore intended that such variations be included within the scope of the following claims and their equivalents.

Technology Category: 2