GB2256542A - Modular electrical connector assembly. - Google Patents

Abstract

A modular electrical connector assembly (fig. 1) comprises several modules 9 to 18 of the same size but with different configurations of sockets 91. The assembly also comprises two rails 2 and 4, extending along the outside of the assembly, and two end blocks 6 and 8 with guide pins 60 and 80. The modules 9 to 18 may have one projection 94 and 97 on each end and two projections 95 and 96, 98 and 99 along their sides. The rails 2 and 4 have recesses 30 and 50 which receive the projections on the modules and locate the modules along the assembly. The width of the modules 9 to 18 may be twice their length so that different configurations of assembly can be made using the same modules by orienting the modules with their length (fig. 8) or width (fig. 1) extending along the assembly. An additional centre rail (70) may allow the mounting of two lengths of connectors side-by-side. The connector units may be dovetailled to the rails to prevent rails from separating. <IMAGE>

Description

CONNECTOR ASSEMBLIES This invention relates to connector assemblies.

The invention is more particularly concerned with modular connector assemblies or systems.

Electrical connector assemblies of modular configuration are widely available. In these assemblies, the user is able to take a number of standard components and assemble them into a connector to suit his particular requirements. These assemblies commonly comprise a pair of metal rails and end blocks to which the rails are screwed to form a frame. Connector modules are slid into the frame from one end, into abutment with one another, to build up the required configuration of connector. The modules are commonly plastic mouldings within which are supported one or more electrical pins or sockets.

Different modules have different types, sizes or numbers of pins or sockets. The connector assemblies may also include modules which have mechanical couplings or jacking mechanisms by which the complete connector can be coupled to a mating connector. The width of each module in a system, that is the distance between ends which contact the opposite rails, is the same, but the length of modules may vary, one from the other to give modules of different sizes. The length of each module is usually an integral multiple of the length of the shortest module, so that the total length of a complete connector is a multiple of that length, in order to facilitate fitting with the rails and end blocks.

These modular assemblies enable a variety of connector components to be combined together in one connector to suit the user's particular requirements, without incurring the high expense that would be involved in the manufacture of a bespoke connector. The assemblies do, however, suffer from a disadvantage in that, because each module is located in length solely by engagement with adjacent modules, any tolerance in the length of the modules can be magnified by the number of modules so that the total tolerance at the end of the connector exceeds what is acceptable. It will be appreciated that with pin or socket diameters as small as 0.6mm, and connector lengths of up to about 200mm, it is important that the pin or socket elements are accurately positioned.Where the two mating connectors are made together, matching can be improved by the use of shims or spacers, although this is a relatively time-consuming process. However, where only one connector is assembled, for example as a replacement for a damaged connector, it may not be possible to have access to the other connector with which it must mate. In these circumstances it can be very difficult to ensure sufficiently close tolerance to produce a good fit with the existing connector.

Modular connectors also suffer from the disadvantage that connectors of different widths can only be produced by using a different range of modules with that different width.

It is an object of the present invention to provide a modular connector assembly that can be used to alleviate these disadvantages.

According to one aspect of the present invention there is provided a modular connector assembly having a plurality of modules each including at least one coupling element,the modules being of rectangular section and of common width, and first and second retaining rails extending along the length of the connector assembly and being spaced from one another by the width of the 'nodules, each rail having a plurality of surface formations equally spaced from one another along the length of the rails on the side abutting the modules, and each module having a cooperating surface formation on opposite ends thereof arranged to engage with the surface formations on the rails such that engagement of the cooperating surface formations positively locates each module with the rails against movement along the rails. In this way, the modules are located along the connector by engagement with the rails rather than engagement with each other, so that tolerances in the modules do not accumulate.

The surface formations on the modules may be projections and those on the rails be recesses within which the projections are received. The surface formations may be arranged to prevent outward movement of the rails away from the modules. The width of the modules is preferably an integral multiple of their length, such as twice their length. The modules preferably also have surface formations on their sides so that the modules can be fitted in the assembly with their sides against the rails. The modules preferably have two surface formations along their sides.

The coupling element in at least one of the modules is preferably an electrical coupling element. The assembly may include an end block at each end, the end blocks being secured to the rails by screws. The end blocks preferably each have a guide member provided therewith.

The assembly may include two rows of modules and an intermediate rail extending between the two rows.

Several connector module assemblies, according to the present invention will now be described, by way of example with reference to the accompanying drawings, in which: Figure 1 is a plan view of one form of the assembly; Figure 2 is a sectional transverse view along line II-II of Figure 1; Figure 3 is a sectional transverse view along line III-III of Figure 1; Figures 4 to 6 and 8 are plan views of alternative assemblies; Figure 7 is a sectional view along the line VII-VII of Figure 6; Figure 9 is an enlarged sectional transverse view of a part of an alternative assembly; Figure 10 is an enlarged plan view of the part shown in Figure 9; Figure 11 is an enlarged sectional transverse view of a part of an alternative assembly; Figure 12 is an enlarged plan view of the assembly of Figure 11; and Figure 13 is a perspective view of the assembly of Figures 11 and 12.

With reference first to Figures 1 to 3, the connector assembly comprises two rail assemblies 2 and 4 which hold together two end blocks 6 and 8, and ten modules 9 to 18 to make up the connector assembly.

Each rail assembly 2 and 4 is made up of two extruded aluminium rails 20 and 22, and 40 and 42 respectively.

Alternatively, the rails could be moulded from a plastics material. The upper rails 20 and 40 are of T-shape in section, with a horizontal upper limb 24 and 44 respectively and a vertical section 26 and 46. The lower rails 22 and 42 are of generally L-shape in section, with a horizontal foot 27 and 47 and a vertical section 28 and 48 with a step 29 and 49 on which sits the lower end of the vertical section 26 and 46 of the upper rail. The upper end of the vertical section 28 and 48 of the lower rail 22 and 42 extends along the outer side of the vertical section 26 and 46 of the upper rail 20 and 40 and engages the underside of the upper limb 24 and 44 of the upper rail. Along the length of both upper rails 20 and 40, they are provided with a series of equally-spaced surface formations in the form of slots 30 and 50 formed in the underside, or completely through the inner end of the upper limb 24 and 44. The spacing between the slots 30 and 50 is equal to the length 1 of the modules 9 to 18. The slots are formed in the rails by milling or similar mechanical machining techniques, or by punching through.

The end blocks 6 and 8 are identical with one another, being generally rectangular blocks of metal each provided with a guide pin 60 and 80 which serve to align the assembly with a mating assembly. Alternatively, float bushes could be used. The width of the end bushes 6 and 8 is twice their length and, at opposite ends of the bushes, the upper surface is cut away to form ledges 62 and 63 and 82 and 83 which are overlaid by the inner edge of the upper limbs 24 and 44 respectively of the rails 20 and 40. At the ends of the rails, where they extend along the end bushes 6 and 8, the vertical sections 26 and 46 of rails are cut away to form recesses which receive projections 61 from the ends of the end blocks 6 and 8.

Ledges 64 and 65 are also formed along the length of end blocks 6 and 8 on their underside which are overlaid by the horizontal foot 27 and 47 of the rails 22 and 42. The rail assemblies 2 and 4 are secured to the end blocks 6 and 8 by means of screws 66 and 67 and 86 and 87. The screws 66 and 67 extend through apertures in the upper limbs 24 and 44 of the rails 20 and 40 into threaded recesses in the projections 61 and 81 of the end blocks.

Additional screws 68 and 69 extend horizontally through apertures in the vertical sections 28 and 48 of the rails 22 and 42 into threaded recesses in the ends of the blocks.

The modules 9 to 18 are each of the same size but differ from one another in the configuration, number and size of electrical contacts supported by each module. The modules 9 to 18 are of rectangular shape with a width w that is twice as long as the length 1, being about 20mm wide and about 10mum long, that is, the same size as the end blocks 6 and 8. The modules 9 to 18 have a moulded housing 90 of a plastics or similar electrically-insulative material, in which are supported electrical sockets, indicated generally by the numeral 91 in Figure 2. Modules 9 and 18 each support three sockets 91, modules 10 and 17 have thirty-four sockets, modules 11 and 16 each have seven sockets, modules 12 and 15 each have twenty sockets, and modules 13 and 14 each have two sockets each.In use, an electrical wire is secured into each of the sockets 91 at the lower end where the sockets extend below the housing 90, so that each wire makes electrical connection via a socket to a respective pin in the mating connector. By arranging the different types of modules symmetrically along the connector in this way, the insertion forces on the connector are equally distributed.

The external configuration of each module is identical, having a ledge 92 around the periphery of the upper surface; a similar ledge 93 extends around the periphery of the lower surface of the modules. The ledges 92 and 93 at the ends of the modules are overlaid by the upper and lower surfaces by the upper limbs 24 and 44 of the rails 20 and 40 and by the feet 27 and 47 of the lower rails 22 and 42. The upper ledge 92 is interrupted by surface formations in the form of vertical, arcuate locating pips 94 to 99. Two of the pips 94 and 97 are located at opposite ends of the modules, midway along their length.

A further two of the pips 95 and 96 are located along one side of the module, being positioned at locations one third and two thirds the width of the module. The remaining two pips 98 and 99 are located directly opposite the pips 96 and 95 respectively on the opposite side of the module. Thus the spacing between pips 95 and 96 is equal to that between the pip 94 and the corresponding pip on an adjacent module.

The width of the modules 9 to 18 and the spacing of the slots 30 and 50 is such that the pips 94 and 97 align with the slots in the rails 20 and 40 when the modules are arranged side-by-side in the connector, with the modules being spaced from one another by a small clearance (not visible on the drawings) just sufficient to accommodate variations in length of the modules caused by manufacturing tolerances. The size of the slots 30 and 50 is closely matched to that of the pips 94 to 99 so that the pips are a close fit within the slots and do not enable any significant movement of the modules along the length of the connector. The cooperating surface formations on the modules and the rails ensure that the modules are positively and accurately located, regardless of the length of the connector.This is in contrast with previous modular connectors where the modules are located by contact with one another, thereby leading to the possible accummulation of manufacturing tolerances.

The connector assembly can be assembled by first securing both the lower rails 22 and 42 to the two end blocks 6 and 8 by means of the screws 68 and 69. The modules 9 to 18 are then placed on the lower rails, side-by-side. The upper rails 20 and 40 are then placed across the ends of the end blocks 6 and 8 and modules 9 to 18, so that the pips 94 on the modules locate in the slots 30 and 50 in the rails 20 and 40. The rail assembly is then screwed to the end blocks 6 and 8 using screws 66 and 67 and 86 and 87 to retain all the components together.

Instead of assembling the modules width-wise across the connector, it is possible to assemble them so that their width extends along the length of the connector in the fashion shown in Figure 4. In this configuration, the connector system has five modules 11, 10, 9, 17, and 16 which are identical to the modules of the same numbers in the arrangement shown in Figure 1. The end blocks 6' and 8' are different from those in the other arrangement in that they are only half the width. The modules, in this orientation, are located by engagement of the pips 95 and 96 in the slots 30 in the rail 20 and by engagement of the pips 98 and 99 in the slots 50 in the rail 40. It will be appreciated that the spacing between the pips 95 and 96, and between pips 98 and 99, is the same as the spacing between adjacent ones of the slots 30 and 50. In this way, it is possible to assemble a connector that is half the width of the other connector but using all the same components except for the end blocks.

It is not necessary for the modules to have sockets, instead they could have pins or other contact elements.

Not all of the modules need have contact elements, or indeed, any form of electrical component. Instead, one or some of the modules could have some other form of coupling such as a mechanical coupling, for example, a jack screw 50 as shown in Figure 5. In this example the jack screw module 50 is square in shape, so that its length is half that of the other modules arranged lengthwise as shown.

Many other configurations are possible by using intermediate rail assemblies, as shown in Figures 6 to 8.

The arrangement shown in Figures 6 and 7 is similar to that of Figure 1 in that the modules are oriented with their width extending across the width of the connector.

The connector system, however, differs in that it includes two rows of ten modules each extending parallel to each other along the connector. The two rows of modules 9 to 18 and 9' to 18' are separated from one another by an intermediate rail assembly 70 of I-shape in section, formed by two T-shape rails 71 and 72, one inverted beneath the other . The horizontal limb of the upper rail 71 is provided with slots 73 on one side which locate with pips 97 of the modules in the top row; slots 74 are also formed along the opposite side of the rail 71 which locate with the pips 94 on the modules in the bottom row.

The arrangement shown in Figure 8 has two rows of five modules 11, 10, 9, 17 and 16 and 11',10', 9', 17' and 16' but these are arranged so that their width extends along the length of the connector, as in the arrangement shown in Figure 4. An identical intermediate rail 70 is used to that shown in Figures 6 and 7.

The surface formations on the modules and rails could take various forms, as shown, for example in Figures 9 to 13.

In the arrangement illustrated in Figures 9 and 10, the surface formations on the modules take the form of cones 100 that project upwardly from the ledge 92 around the module. The surface formations on the rails 101 take the form of circular, cylindrical apertures 102 through the horizontal upper limbs 124 and 144, the diameter of the apertures being slightly less than the diameter of the cones at their base so that the cones self-centre in the apertures.

In the arrangement shown in Figures 11 to 13, the surface formations on the module are dovetail-shape projections 200 that extend upwards from the ledge 92. The dovetails 200 taper both outwardly and top to bottom, being narrower closer to the module and towards its upper surface. The upper surface of each dovetail 200 also slopes downwardly towards its outer edge. The surface formations on the rails 201 are slots 202 formed in the underside of the upper limb 224 and having the same shape as the dovetails 200. The shape of the dovetails 200 is such that they both self-centre in the slots 202 and they lock with the rails, preventing the rails being deformed outwardly. This enables relatively thin rails to be used with long connector assemblies.

It will be appreciated that many different configurations of connector assembly are possible. By use of additional intermediate rails it is possible to provide connectors with three or more rows of modules.

The modules will generally have electrically-insulative bodies but in. some applications, where earthing is required, the modules might have metal bodies so that earthing currents are carried to the rails. Added strength can be given to connector assemblies by the use of blank metal modules secured to opposite rail assemblies such as by means of screws.

The connector assembly could include fibre-optic couplings instead of or in addition to electrical couplings.

Claims (18)

1. A modular connector assembly having a plurality of modules each including at least one coupling element, wherein the modules are of rectangular section and of common width, wherein first and second retaining rails extend along the length of the connector assembly and are spaced from one another by the width of the modules, wherein each rail has a plurality of surfaces formations equally spaced from one another along the length of the rails on the side abutting the modules, and wherein each module has a cooperating surface formation on opposite ends thereof arranged to engage with the surface formations on the rails such that engagement of the cooperating surface formations positively locates each module with the rails against movement along the rails.

2. An assembly according to Claim 1, wherein the surface formations on the modules are projections, and wherein the surface formations on the rails are recesses within which the projections are received.

3. An assembly according to Claim 1 or 2, wherein the surface formations are arranged to prevent outward movement of the rails away from the modules.

4. An assembly according to Claim 3, wherein the surface formations are of dovetail shape.

5. An assembly according to any one of the preceding Claim, wherein the width of the modules is an integral multiple of their length.

6. An assembly according to Claim 5, wherein the width of the modules is twice their length.

7. An assembly according to Claim 5 or 6, wherein the modules also have surface formations on their sides so that the modules can be fitted in the assembly with their sides against the rails.

8. An assembly according to Claims 6 and 7, wherein the modules have two surface formations along their sides.

9. An assembly according to any one of the preceding claims, wherein the coupling element in at least one of the modules is an electrical coupling element.

10. An assembly according to any one of the preceding claims, wherein the assembly includes an end block at each end, and wherein the end blocks are secured to the rails by screws.

11. An assembly according to Claim 10, wherein the end blocks each have a guide member provided therewith.

12. An assembly according to any one of the preceding claims including two rows of modules and an intermediate rail extending between the two rows.

13. An assembly substantially as hereinbefore described with reference to Figures 1 to 3 of the accompanying drawings.

14. An assembly substantially as herebefore described with reference to Figures 1 to 3 as modified by Figures 4 or 5 of the accompanying drawings.

15. An assembly substantially as hereinbefore described with reference to Figures 1 to 3 as modified by Figures 6 and 7 of the accompanying drawings.

16. An assembly substantially as hereinbefore described with reference to Figures 1 to 3 as modified by Figure 8 of the accompanying drawings.

17. An assembly substantially as hereinbefore described with reference to Figures 1 to 3 as modified by Figures 9 and 10 or Figures 11 to 13 of the accompanying drawings.

18. Any novel feature or combination of features as hereinbefore described.