GB2332103A

GB2332103A - Connector with sacrificial parts

Info

Publication number: GB2332103A
Application number: GB9826593A
Authority: GB
Inventors: Jeffrey George Fyffe
Original assignee: WL Gore and Associates UK Ltd; WL Gore and Associates Inc
Current assignee: WL Gore and Associates UK Ltd; WL Gore and Associates Inc
Priority date: 1997-12-05
Filing date: 1998-12-04
Publication date: 1999-06-09
Also published as: GB9725921D0; GB9826593D0; AU1346199A; GB2332103A9; WO1999030389A1

Abstract

A connector assembly 20 provided with sacrificial parts consisting of first and second connectors 22, 24 and a sacrificial connector 28 interposed between connectors 22, 24. The connectors may be generally cylindrical. During repeated use, the connections of sacrificial connector 28 may degrade, and this part be replaced, with minimal damage to permanent connectors 22, 24.

Description

1 CONNECTOR

FIELD OF THE INVENTION

This invention relates to a connector, particular but not exclusively to a cable provided with sacrificial parts.

BACKGROUND OF THE INVENT1 is 2332103 and in connector In certain demanding cable connector applications it is desirable to provide connectors which have the capability to be frequently mated and demated over an extended period: for example, military specifications will often require that certain connectors have the capability to be mated and demated in excess of 10,000 times. Conventionally, such connectors feature a circular or circumferential pin configuration. However, the creation of such a circular connector generally requires a difficult manual soldering or crimping operation in which wires are individually terminated to respective connector pins; as a result of the laborious manufacturing method such connectors tend to be expensive. In view of the high cost of replacing circular connectors, the connectors tend to be constructed such that they are repairable. To facilitate the dismantling and repair of such a connector, loops of wire are left within the connector, which loops are prone to damage when the connector is being Assembled and 1 so further complicate the construction of the connector.

2 Further, the configuration of such connectors does not lend itself to accommodating devices such as f ilters and in circular connectors the requirement to provide filtering is met by providing filter pins, which are relatively expensive.

It is among the objectives of embodiments of the present invention to provide a connector which obviates or mitigates these disadvantages.

is SUMMY OF THE 11MENTION According to the present invention there is provided a connector assembly for forming a demateable connection between first and second signal carriers, the assembly comprising:

first and second connector portions for connection to respective signal carriers; and a sacrificial connector portion for releasable mounting to the first connector portion and for location between the first and second connector portions and forming a connection therebetween.

The invention also relates to a method of forming a connection utilising a sacrificial or replaceable connector portion.

As used herein the term signal carrier is intended to encompass any member or conduit suitable for carrying information or energy, and in the preferred embodiment refers to a conductive metallic wire.

The sacrificial connector portion may contain the 3 elements of the connector which are generally subject to greatest deterioration and wear in use; the sacrificial connector portion may be removed from the first connector portion and replaced when necessary without the requirement to replace either of the first or second connector portions. The first and second connector portions may therefore be less robust than conventional "long-life,, connector portions, and thus will tend to be less expensive to produce and replace.

In certain embodiments two or more sacrificial connector portions may be provided, for example a pair of "back-to-back" sacrificial connector portions may be provided, one for coupling with the first connector portion and the other for coupling with the second connector portion. Alternatively, or in addition, a sacrificial connector portion may be formed of two or more separable parts.

Preferably, the first and second connector portions include one or more planar rows of connecting pins, that is the connector p'ins are in a "flat" or planar pin format. Preferably also, the sacrificial connector portion defines one or more rows of sockets for receiving the pins, and the sockets may be defined by one or more contact housings; in mating and demating operations it is typically the sockets which experience the greatest wear. Such a planar arrangement is generally more easily soldered, or otherwise coupled, than a conventional "long-life,, connector featuring circumferentially arranged peripheral pins, and 4 is facilitates edge mounting to printed circuit boards (PCBs); the soldering or connection operations may be carried out by machine, if desired. One or both of the f irst and second connector portions may be provided in combination with a PCB, and this facilitates the provision of components and devices such as filters and transient suppressors in the connector, as these may be mounted on one of the PCBs. The PCB may be rigid or flexible.

The sacrificial connector portion may define a first connection configuration adapted for connecting to a first connector portion of one configuration and a second connection configuration adapted for connecting to a second connector portion of another configuration, that is the sacrificial connector portion may act as an adapter. In one embodiment, the sacrificial.-connector portion permits a cable having a connector portion having pins in a planar format to be connected to a bulkhead connector portion having pins in a circular or circumferential pin configuration.

Preferably. also, at least one of the connectors is provided in combination with a cable containing a plurality of signal carriers, which will typically be in the form of conductive wires. Most preferably, the wires and pins of the connector are connected via soldered connections.

Preferably also, connections between one or both of the first and second connector portions and the associated signal carriers are potted, that is the connections are surrounded by a settable material during manufacture of the is connector portion, which settable material then solidifies. This improves the mechanical reliability of the connections and may also provide an environmental seal.

one or both of the first and second connector portions may be fixed, for example to an item of equipment or a bulkhead, or may be free mounted to a cable and the like. In the preferred embodiment, the first connector portion is adapted to be fixed and the second connector portion is mounted on a cable.

Preferably also, the sacrificial connector portion is attached to the first connector portion by one or more screws, or other releasable means.

Preferably also, the first and second connector portions include circular cross-section housings. This facilitates provision of seals, which may be o-rings, on the connector components, and also allows threads to be provided on the connector components to, for example, locate a jam nut on the first connector portion. In other embodiments the connector portion housings may be rectangular, square, or indeed of any appropriate form.

Preferably also, the sacrificial connector portion is adapted to releasably engage with the second connector portion. Most preferably, the second connector portion is a push fit with the sacrificial connector portion and a pull or "snatch" disconnect.

Preferably also, the sacrificial connector includes RFI seals.

Preferably also, the second connector portions and the 6 sacrificial connector portion include means for ensuring proper contact alignment therebetween, such as an offset contact housing, offset pins, or offset studs.

Preferably also, one or both of the connector portions includes a moulded boot. Grips may be formed in the outer surface of the boot. The boot may surround a back shell and secure the shell to a signal carrier. The shell may define a cavity which is filled during the boot moulding process.

A cable storage clamp or clip may be mounted on one of the connector portions.

A protective cap may be mounted on one or both of the first and second connector portions.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:

Figure 1 is a perspective exploded view of a connector assembly in accordance with a preferred embodiment of the present invention; Figure 2 is an enlarged sectional view of connector assembly of Figure 1; Figure 3 is an enlarged sectional view of the connector assembly of Figure 1, and illustrating the sacrificial connector portion fixed to the first connector portion; Figure 4 is a sectional view of the connector assembly the 7 is of Figure 1, showing the portions of the connector in mated configuration; Figure 5 is an end view of the connector assembly of Figure 4; Figure 6 is a perspective view from the rear of the sacrificial connector portion of Figure 1; Figure 7 is an exploded view of the sacrificial connector portion of Figure 6; Figure 8 is a perspective view from the front of the sacrificial connector portion of Figure 6, fixed to the first connector portion; Figure 9 is a perspective view of a cable storage clamp for use with the assembly of the present invention (on same sheet as Figure 1); Figure 10 is a perspective view of a protective cap for use with the connector assembly of the present invention (on same sheet as Figure 1); and Figures 11 and 12 are perspective views of the connector assembly of the preferred embodiment of the pr esent invention provided with the storage clip and protective cap of Figures 9 and 10.

DETAILED DESCRIPTION OF THE DRAWINGS

Reference is first made to Figures 1 to 5 of the drawings, which illustrate a connector assembly 20 in accordance with a preferred embodiment of the present invention. The assembly 20 comprises a first connector 22 which is adapted to be f ixed to an item of equipment, a 8 bulkhead or the like, a second connector in the form of a free connector 24 mounted on the end of a cable 26, and a replaceable sacrificial connector 28. As will be described in greater detail below, the sacrificial connector 28 is adapted to be secured to the fixed connector 22 (see Figure 3) and the free connector 24 mated with the fixed connector 24 via the sacrificial connector 28.

As evident from Figure 1, the connectors 22, 24, 28 are generally circular or cylindrical in form and are arranged to provide a flat pin type connection. In particular, the fixed and free connectors 22, 24 each feature two parallel planar rows of connecting pins 30, 32 and the sacrificial connector 28 includes contact housings 34, 35 defining corresponding rows of scoop proof sockets 36.

The fixed connector 22 includes a generally cylindrical body 38 and a disc 40 (see Figures 2 - 4) for mounting -the connecting pins 30 in the body. The rear portions of the pins 30 extend rearwards from the connector 22 and may be soldered or otherwise connected to appropriate wiring or components. The outer rear surface of the connector body 38 is formed to define a screw thread 42 so that a jam nut 44 may be used to secure the connector 22 in an appropriately sized hole in a bulkhead or the like. For engaging with a front face of the bulkhead the connector body 38 defines an annular extension 46 which carries an facial O-ring seal 48.

The front face of the connector body 38 defines a pair is 9 of threaded bores 50 for receiving screws 52 (see Figures 1, 6 and 7) for securing the sacrificial connector 28 to the fixed connector 22.

The sacrificial connector 28 also has a generally cylindrical body 54, the rear end of the body defining a female portion 56 for sealing location over the front portion of the fixed connector body 38. The sacrificial connector body portion 56 carries a peripheral O-ring seal 58. A web 60 extends across the sacrificial connector body 54, defining two countersunk bores 62 for receiving the screws 52, and a stepped rectangular aperture 64 which accommodates a board 66 on which the oppositely directed contact housings 34, 35 are mounted. Located within the sacrificial connector 54 are two annular RFI seals 73 (see Figures 6 - 8), retained by appropriate rings.

The front part of the sacrificial connector body 54 is profiled 70 to provide a pull or "snatch" release connection with the free connector 24. A portion of the free connector 24 extends inside the sacrificial connector body 54 on mating, and is engaged by a peripheral O-ring seal 72 carried within the front portion of the body 54.

The free connector 24 includes a back shell 76 contained within a moulded boot 74 formed on the end of the cable 26. Although not illustrated in the Figures, the material used in forming the boot 74 also flows into the back shell 76 during forming, to "pot" the internal soldered connections within the free connector 24. The cable 26 is shielded, and the cable shielding 78 is clamped to the back shell 76. Also, a strain relief cord 80 passes through the cable 26 and is fixed to the back shell 76.

The outer protective cover of the cable is stripped from the cable 26 within the connector 24 and the individual insulated wires 82 of the cable extend through the back shell 76. The insulation is removed from the ends of the wires and the exposed wires are soldered to one of two PCBs 84, 85. The connection pins 32 are mounted to the other side of the PCBs 84, 85 and extend into a rectangular pin surround 86 adapted to extend into the front of the sacrificial connector body 54. The surround 86 is located within a cylindrical collar 88 profiled to engage with the sacrificial connector body profile 70.

To ensure correct alignment, the contact housing 35 and the connecting pins 32 of the sacrificial connector 28 and the free connector 24 are offset in the respective connector bodies.

The use of flat pin configurations, particular in the free connector 24, facilitates formation of soldered connections between the wires 82 and the associated connecting pins 32. In the illustrated embodiment, the connection is made via the PCBs 84, 85, and may be carried out in an automated soldering operation. Also, the use of the flat pin configuration facilitates the inclusion of the PCBs 84, 85 in the connector 24 and if desired various devices, such as filters or other signal processing devices, may be mounted on the PCBs 84, 85, for filtering the outputs or inputs from particular wires 82.

is 11 The connector assembly 20 may be provided in combination with various accessories, as illustrated in Figures 9 through 12 of the drawings. In particular, a cable storage clamp 92 may be mounted on the fixed connector 22, the clamp 92 comprising an annular loop 94 for location over the connector body 38 and a cable clamp 96 mounted on an arm 98 extending from the loop 94 such that, as illustrated in Figure 11, the cable 26 extending from the free connector 24 may be held by the clamp 96.

Figure 10 illustrates a protective cap arrangement 100, including a loop 102 which is mounted over the fixed connector body 38 and provides mounting for a cap 104 via an arm 108. When the free connector 24 is demated from the sacrificial connector 28 the cap 104 may be fitted into the open end of the sacrificial connector body 54.

From the above -description it will be apparent that the connector assembly 20 may be produced relatively inexpensively, by "mass production" processes if desired, and in particular that the individual connections between the wires 82 of the cable 26 and the connecting pins 32 of the free connector 24 may be formed using standard edge connection techniques. Further, the connector pin arrangement facilitates provision of PCBs within the free connector, such that filtering, transient suppression or other facilities or functions may be readily provided within the connector body.

The connector assembly connector 20 as described above is intended for use in demanding applications, where the is 12 assembly 20 will be expected to withstand in excess of 10,000 mating and demating operations. However, during the life of the assembly 20, it is expected that the sacrificial connector 28 will be replaced from time- to-time (typically after 300 500 matings), as the sacrificial connector 28 contains the elements of the assembly 20 which are likely to experience greatest wear, namely the sockets 36, 37 within the contact housings 34. However, even accounting for the provision of perhaps twenty or thirty sacrificial connectors 28 during the life of the connector assembly 20, the cost of the connector 20 is still likely to be substantially less than costs associated with a conventional circumferential pin configuration connector.

The ability to pot the connections within the free connector 24 improves the reliability of the connections and also provides environmental protection for the connections, reducing or obviating the risk of failure through corrosion or shorting between connections in damp conditions. Even if the fixed or free connectors 22, 24 are subject to unexpected damage or failure and have to be replaced before the end of their normal lifespan, replacement connectors are relatively inexpensive.

It will also be clear to those of skill in the art that the abovedescribed embodiment is merely exemplary of the present invention, and that various modifications and improvements may be made thereto, without departing from the scope of the invention.

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Claims

CLAIMS is 1. A connector assembly for forming a demateable connection

between first and second signal carriers, the assembly comprising: first and second connector portions for connection to respective first and second signal carriers; and a sacrificial connector portion for releasable mounting to the first connector portion and for location between the first and second connector portions and forming a connection therebetween.
2. The connector assembly of claim 1, wherein a plurality of sacrificial connector portions are provided for location between the first connector and the second connector portion.
3. The connector assembly of claim 2, wherein two sacrificial connector portions are provided, one for releasable mounting to the first connector portion and the other for releasable mounting to the second connector portion.
4. The connector assembly of claim 1, 2 or 3, wherein at least one of the first and second connector portions include at least one planar row of connecting pins.

14
5. The connector assembly of claim 4, wherein the sacrificial connector portion defines at least one row of sockets for receiving the pins.
6. The connector assembly of claim 5, wherein the sockets are defined by a contact housing.

is
7. The connector assembly of any of the preceding claims. wherein the sacrificial connector portion defines a first connection configuration adapted for connecting to a connector portion of one configuration and a second connection configuration adapted for connecting to a connector portion of another configuration.
8. The connector assembly of claim 7, wherein the first connection configuration is adapted for connection to a connector portion having connecting pins in a circular configuration and the second connection configuration is adapted for connection to a connector portion having connecting pins in a planar configuration.
9. The connector assembly of any of the preceding claims, wherein at least one of the first and second connector portions is provided in combination with a printed circuit board (PCB)
10. The connector assembly of claim 9, wherein the PCB carries at least one filtering device.
11. The connector assembly of claim 9 or 10, wherein the PCB carries at least transient suppression device.
12. The connector assembly of any of the preceding claims, wherein at least one of the connectors is provided in combination with a cable containing a plurality of wires connected to pins of the connector via soldered connections.

is
13. The connector assembly of any of the preceding claims, wherein connections between at least one of the first and second connector portions and the associated signal carriers are potted.
14. The connector assembly of any of the preceding claims wherein one of the first and second connector portions is adapted to be fixed in position.
15. The connector assembly of any of the preceding claims, wherein one of the first and second connector portions is free mounted to a cable.
16. The connector assembly of claim 14 or 15, wherein the f irst connector portion is adapted to be fixed and the second connector portion is mounted on a cable.
17. The connector assembly of any of the preceding claims, wherein the sacrificial connector portion is attached to 16 the first connector portion by one or more screws.
18. The connector assembly of any of the preceding claims, wherein the first and second connector portions include circular cross-section housings.
19. The connector assembly of any of the preceding claims, wherein the sacrificial connector portion is adapted to releasably engage with the second connector portion.

is
20. The connector assembly of claim 19, wherein the second connector portion is a push fit with the sacrificial connector portion and a pull or ',snatch" disconnect.
21. The connector assembly of any of the preceding claims, wherein the sacrificial connector includes radio frequency interference (RFI) seals.
22. The connector assembly of any of the preceding claims wherein the second connector portions and the sacrificial connector include means for ensuring proper contact alignment therebetween.
23. The connector assembly of any of the preceding claims, wherein at least one of the connector portions includes a moulded boot.
24. The connector assembly of claim 23, wherein the boot 17 surrounds a back shell and.secures the shell to a signal carrier.
25. The connector assembly of claim 24, wherein the shell defines a cavity which is at least partially filled with material during the boot moulding process.
26. The connector assembly of any of the preceding claims, wherein a cable storage clamp or clip is mounted on one of the connector portions.
27. The connector assembly of any of the preceding claims, wherein a protective cap is mounted on at least one of the first and second connector portions.
28. A method of forming a connection between first and second signal carriers, the method comprising the steps: connecting a first connector portion to a first signal carrier; connecting a second connector portion to a second signal carrier; mounting a sacrificial connector portion to the first connector portion; and mating the first and second connector portions with the sacrificial connector portion therebetween.

28. A method of forming a connection between first and second signal carriers, the method comprising the steps: connecting a first connector portion to a first signal carrier; connecting a second connector portion to a second signal carrier; mounting a sacrificial connector portion to the first connector portion; and mating the first and second connector portions with the sacrificial connector portion therebetween.

surrounds a back shell and secures the shell to a signal carrier.

io 25. The connector assembly of claim 24, wherein the shell defines a cavity which is at least partially f illed with. material during the boot moulding process.

26. The connector assembly of any of the preceding claims, wherein a cable storage clamp or clip is mounted on one pf the connector portions.

27. The connector assembly of any of the preceding claims, wherein a protective cap is mounted on at least one of the first and second connector portions.