AU706483B3

AU706483B3 - Improved electrical connector

Info

Publication number: AU706483B3
Application number: AU79981/98A
Authority: AU
Inventors: Michael Instance; Cornelis Schaafsma; Philip Timbrell
Original assignee: Tyco Electronics Pty Ltd
Current assignee: Tyco Electronics Pty Ltd
Priority date: 1998-08-13
Filing date: 1998-08-13
Publication date: 1999-06-17
Anticipated expiration: 2004-08-13
Also published as: WO2000010230A1

Description

AUSTRALIA

PATENTS ACT 1990

ORIGINAL

COMPLETE SPECIFICATION PETTY PATENT Invention Title: IMPROVED ELECTRICAL CONNECTOR Name of Applicant: UTILUX PTY LIMITED The following statement is a full description of this invention, including the best method of performing it known to me/us: 2 Improved Electrical Connector The present invention relates to an improved electrical connector and particularly, but not exclusively, to an electrical connector which is arranged to be protected from the external environment.

Electrical connectors are known which are, in use, placed in outdoor environments where they may be exposed to water, or are placed in environments where they are at risk from water. Such connectors are required to be waterproofed to prevent water from reaching the electrical conductors. An example of a connector which is potentially exposed to the environment is an electrical connector used to connect solar panels, on the roof of a house or office building, for example. Such electrical connectors are at risk from rain and stringent standards of waterproofing must be met.

Waterproofing may be achieved by shielding the conductive elements of the electrical connector by an arrangement of interlocking housing portions and sealing gaskets forming a chamber mounting the conductive .elements, which chamber is waterproof. The arrangement is usually such that the interlocking portions are of male and female form. A problem arises in bringing the male and female portions together to make the connection. Because a sealed chamber is formed, as the two portions are brought together and the sealing gasket(s) engage(s), there is an increase in gas pressure within the chamber. This gives rise to two effects: 1. Increase in pressure can sometimes make it difficult to complete the electrical connection.

2. The increase in pressure can give rise to a tactile effect of the connector "bottoming out" which can give the impression that a connection has been made when in fact it has not been made.

These effects can result in connections not being made K:\Speci\300 399\300 349\31990.doc 3 or imperfect connections being made.

In some systems, both halves of an electrical connector may be live it is possible both connector halves can have a voltage creating a safety hazard if both halves are not "finger proof".

To avoid electric shock, it is important that even if a connection is broken, therefore, it is not possible for a person to touch the conductive connector elements in either side of the connector where the connector connects to solar panels, in the side connected to the solar panels or the side of the connector connected to the appliance/consumer.

The present invention provides an electrical connector comprising first and second connector housing portions mounting first and second conductive elements arranged to mate with each other to form an electrical connection, the first and second connector housing portions being arranged to be brought together to form a sealed chamber within which the first and second conductive elements are mated, and valve means arranged to allow for the release of excess gas pressure as the first and second housing portions are brought together, and to maintain the integrity of the sealed chamber once the excess pressure has been released, wherein the valve means comprises a communicating passageway arranged to communicate with the chamber formed by the first and second housing portions, and a closure member which is arranged in a closed position until excess pressure within the chamber forces it open to allow the release of excess pressure via the communicating passageway.

The valve means is preferably arranged to automatically release the excess pressure as the seal is made between the first and second connector housing portions. It is not necessary for the operator to separately manipulate a valve mechanism either before or K:\Speci\300 399\300 349\31990.doc 4 after the seal is made. Gas pressure release is automatic.

Once the excess gas pressure has been released, the closure member preferably closes and seals the communicating passageway.

In the preferred embodiment, the closure member is an ring which sits in a groove in the outer surface of the first connector housing portion. The communicating passageway opens into the base of the groove. On formation of the chamber on the bringing together of the first and second connector housing portions, as gas pressure increases within the chamber, the ring is forced away from the communicating passageway to allow for the release of the excess pressure. Once the excess pressure has been released, the ring returns to close the communicating passageway.

The valve means preferably releases excess pressure one way. It is not a two-way valve.

Each of the first and second connector housing portions are preferably "finger proof". That is, the first and second conductive elements are preferably protected from access by a persons fingers, by way of an arrangement of respective male and female projecting plug and socket portions within each of the first and second connector housing portions.

In one preferred embodiment, the second housing portion includes a receptacle cover portion arranged to receive within it a complimentary projecting portion mounted on the first connector housing portion, in a relatively tight fit, preferably waterproof. The gasket may be provided about the complimentary projecting portion to facilitate waterproofing.

The receptacle cover portion and complimentary projecting portion are preferably hollow and preferably mount within them the conductive elements. The conductive elements are preferably mounted within slots in projecting K:\Speci\300 399\300 349\31990.doc 5 plug bodies which have adjacent to them complimentary socket bodies, dimension so that the conductive elements cannot be accessed by anybodies fingers.

Features and advantages of the present invention will become apparent from the following description of an embodiment thereof, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a partially cut away perspective view from above and one side of a connector in accordance with an embodiment of the present invention, with first and second portions of the connector shown separated; Figure 2 is a partial cut-away perspective view of the embodiment of figure 1 showing the two portions of the connector joined; Figure 3 is a detail on X of figure 2; Figure 4 is a view from above the connector of figure 1 showing the connector portions joined; Figure 5 is a view from above the connector of figure 4 showing the connector portions separated; Figure 6 is a view from one side of the connector of figure 1 showing the connector portions joined; Figure 7 is a view from one side of the connector of figure 1 showing the connector portions separated; Figure 9 is a view from above of a part of a first connector portion of the connector of figure 1; Figure 10 is a view from the side of the part of Figure 9; Figure 11 is a view from the front of the first connector portion; Figure 12 is a section on line A-A of figure Figure 13 is a view from the side of the part of Figure 13; Figure 14 is a view from above of the part of Figure 13; Figure 15 is a view from the front of the second K:\Speci\300 399\300 349\31990.doc 6 connector portion, and Figure 16 is a sectional view on line B-B of figure 13.

Referring to the drawings, the electrical connector in accordance with an embodiment of the present invention is designated generally by reference numeral i. The connector 1 comprises a first connector housing portion 2 and a second connector housing portion 3. In this example the connector housing portion 2 comprises a complimentary projecting portion in the form of substantially cylindrical connecting portion 4 and a portion 5 which tapers towards a cable 6 carrying an electrical conductor (not shown).

Similarly, the second connector housing portion 3 comprises a receptacle cover portion further cylindrical portion 7 and a rearwardly extending tapered portion 8 tapering towards a cable 50 carrying an electrical conductor (not shown).

The first and second connector housing portions 2 and 3 mount respective first 9, 10 and second 11ii, 12 conductive elements.

When the first 2 and second 3 connector housing portions are brought together and joined (figure 2) the first 9, 10 and second 11, 12 conductive elements mate with each other to form an electrical connection. Further, the first 2 and second 3 connector housing portions are arranged to mate together as shown in figure 2 to form a sealed chamber 13, within which the conductive elements 9, 11, 12 are retained. The chamber 13 is preferably waterproof. As shown in detail in figure 3, a valve means 14, 15, in this case comprising an ring 14 and a passageway 15 in one wall 16 of the cylindrical connecting portion 4 of the first connector housing portion 2. On bringing together of the first 2 and second 3 conenctor housing portions, the valve means 14, 15 operates to release excess pressure within the chamber 13, whereby K:\Speci\300 399\300 349\31990.doc 7 allowing the connector housing portions to be brought together without undue resistance to ensure that a good electrical connection is made between the conductive elements 9, 10, 11, 12.

In more detail, the cylindrical connecting portion 4 forms a male mating portion which is arranged to fit within a corresponding female mating portion formed by the cylindrical portion 7 of the second connector housing portion 3. Lugs 22, 23 are formed on the portion 4. The lugs 22, 23 are arranged to fit into corresponding recesses 24, 25 formed in the portion 7 of the second connector housing portion 3. Portion 7 is formed of suitably resilient material, such as plastics, so that it can be deformed to fit over the lugs 22, 23, and the lugs 22, 23 will snap fit into the recesses 24, 25 to retain the first 2 and second 3 connector housing portions together. The female portion 7 can be deformed by pressing on areas 26 (a similar corrugated area on the opposite side of the connector housing portion 3 is formed but is not shown in the drawings), to release the recesses 24, 25 from the lugs and enable the first 2 and second 3 connector housing portions to be pulled apart.

The portion 4 of the first connector housing portion 2 has two circumferential grooves 27, 28 formed in its outer surface. The first groove 27 retains a sealing ring 29. The second groove 28 retains the ring 14 which forms part of the valve means 14, 15. The rings 14 and 29 are of suitable resilient material, such as rubber or suitable plastics.

The second ring 29 forms a seal between an inner surface 30 of the portion 7 and the groove 27. The inner surface 30 of the portion 7 is shaped to conform to the outer surface of the ring 29. The seal extends all the way around the circumference of the portion 7. This seal 29 keeps the chamber 13, containing the conductive elements K:\Speci\300 399\300 349\31990.doc 8 9, 10, 11, 12, waterproof.

The ring 14 does not operate to seal the chamber, but in fact only operates as part of the valve means 14, As the female portion 7 is being pushed over the male portion 4 towards the ring 29, gas pressure build up occurs in the chamber 13. If this excess pressure is not released, it can cause difficulties in making an electrical connection between the conductive elements 9, 10, 11, 12, as discussed above. In this embodiment, however, excess pressure from the chamber 13 in the passageway 15 forces the ring 14 away from the passageway 15 so that gas flows through the passageway 15 to the outside, releasing the excess pressure. On release of the excess pressure, the ring 14 falls back to cover the hole 15 to maintain the waterproof integrity of the chamber 13.

The valve means 14, 15 is one-way only. There can be a reduction in pressure in the chamber when releasing the connector housing portions 2 and 3 from each other. This reduction in pressure is not communicated to the chamber '13, however, as the valve means 14, 15 remains in place, nor is it critical that any release in pressure be communicated on release of the connector halves 2, 3, however.

The conductive element 9 comprises a forwardly extending portion 35 and a rearwardly extending portion 36.

The rearwardly extending portion 36 includes a crimp bucket 37 which is crimped to a conductive lead (not shown). The forwardly extending portion 35 comprises a projecting portion 38 which is arranged to interlock with a complimentary projecting portion 39 on conductive element 11 mounted in second connector housing portion 3. The conductive element 11 also has a forwardly extending portion 40 and a rearwardly extending portion 41 which mounts a crimp connector (not shown). The other conductive elements 10, 11 are of a similar structure.

K:\Speci\300 399\300 349\31990.doc '0 K:\speci\300 399\300 349\31990.doc 9 In the first connector housing portion 2, the conductive elements 9, 10 are seated in slots 42, 43 within an insulating projecting plug 44. The insulating plug 44 is arranged to fit within a corresponding socket 45 formed in the second connector housing portion 3. Further, the conductive elements, 11ii, 12 in the second connector housing portion 3 are mounted within slots 50 51 in a further insulating projecting plug 52 in the second connector housing portion 3. In turn, this further projecting plug 52 is arranged to fit within a socket 53 formed in the first connector housing portion 2. The respective sockets and 53 are designed to be too narrow to allow access by a persons fingers. In other words, they are "finger proof". If any of the conductive elements have the potential to be "live" when the connector halves 2 and 3 are separated, then this finger proofing will reduce the chances of electric shock.

The electrical connector which is illustrated in the figures is particularly suited for connecting solar panels to the electrical grid/building circuitry. The electrical connector of this invention may have many other applications, however, particularly outdoors. It could also be of many other forms. For example, the portions and 21, do not have to be cylindrical although it is preferred.

The pressure release valve of the illustrated embodiment is formed by an ring seated in a groove sealing a communicating passageway. The sealing means could take other forms. For example, a resilient substantially flat member, rather than an ring, could seal a communicating passageway.

In the illustrated embodiment, there are two pairs of contacts (conductive portions). It will be appreciated that the invention is not limited to two pairs of contacts.

7 L There may be one or any number of (multiple) contacts.

C)K:\peci\300 -399\300 -349\31990.dc N NIK:\Speci\300 -399\300 -349\31990.doc 10 It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

K:\Speci\300 399\300 349\31990.doc

Claims

2. An electrical connector in accordance with claim 1, wherein the closure member is an ring which normally sits over an outer opening of the communicating passageway, and is arranged to be forced away from the outer opening on the occurrence of sufficient excess pressure within chamber. K:\Speci\300 399\300 349\31990.doc 12
3. An electrical connector in accordance with claim 1 or claim 2, wherein the first and second conductive elements are shielded by insulating members from access by a persons fingers when the first and second connector housing portions are separated. Dated this 15th day of April, 1999 UTILUX PTY LIMITED By their Patent Attorney GRIFFITH HACK K:\Speci\300 399\300 349\31990.doc F-