GB2537346A

GB2537346A - Electrical connector apparatus, system and method

Info

Publication number: GB2537346A
Application number: GB1503202.2A
Authority: GB
Inventors: Barclay Mair Robin; Simpson Craig
Original assignee: C R ENCAPSULATION Ltd
Current assignee: C R ENCAPSULATION Ltd
Priority date: 2015-02-26
Filing date: 2015-02-26
Publication date: 2016-10-19
Also published as: GB201503202D0

Abstract

An electrical connector system 30, with use in subsea oil and gas pipelines, and marine applications such as underwater remote operated vehicles (ROV), has a socket 36 for mounting first, second and third electrical connectors. A first electrical connector 42 is mounted at socket portion 36a with a seal, and is electrically connectable to a first electrical component. A removable second electrical connector 52 may be mounted at socket portion 36b with a seal, permitting electrical connection to the first electrical connector 42. A third electrical connector 60, part of electrical termination 56, may be mounted at socket portion 36c with a seal, permitting an electrical connection to the second electrical connector 52, and to a second electrical component. The second electrical connector 52 acts as an adaptor between the first 42 and third 60 connectors. Also disclosed is a method for making an electrical connector system and fixing damage.

Description

ELECTRICAL CONNECTOR APPARATUS, SYSTEM AND METHOD

FIELD OF THE INVENTION

The present invention relates to an electrical connector apparatus, system and method.

BACKGROUND

In the marine industry, it is common practice to package electrical components within a water-tight housing or vessel that maintains a dry environment as the vessel is submerged in a marine environment. Heretofore, in order to establish electrical connectivity between the electrical components housed within such a vessel and electrical components that are external to the vessel, two different types of electrical connectors have been employed generally.

According to a first type connector, also referred to in the industry as a bulkhead-type connector, the vessel housing containing the electrical components may be machined to allow a bulkhead to be fitted to the vessel. The bulkhead extends electrical contacts from one or more electrical components housed inside the vessel to the outside of the vessel. A mating connector may then be attached to the bulkhead to enable electrical connection to external electrical components.

According to a second type connector, also referred to in the industry as a penetrator-type connector, cables from the electrical components housed inside the vessel are terminated to a termination assembly positioned within the vessel. The vessel is also machined to permit a connector to enter the vessel to be coupled electrically to the termination assembly. A cable connected to the connector connects the electrical components of the vessel to an external electrical component.

The industry employs bulkhead-type connectors for systems that require frequent change or repositioning because generally these connectors offer the designer of the electrical system greater flexibility and interchangeability for maintenance or upgrade than the penetrator type connectors. The penetrator-type connectors are used more frequently for semi-permanent or permanent applications. Penetrator-type connectors are considered more reliable in preventing water damage to the protected electrical components.

For example, for a bulkhead type connector, failure of the sealing element between the bulkhead/connector interface may damage both components and require that they be replaced. Replacement in the field under harsh environmental conditions may be difficult and may result in lengthy downtime. Or, for example, failure of the sealing element between the bulkhead and the vessel may result in water entering the vessel. This often may result in substantial loss of performance of the electrical components in the vessel and may require that the entire vessel be discarded. Such failures are costly both to the owner of the asset and to the end user as they often may result in extensive downtime while the assets are being repaired or replaced.

SUMMARY OF THE INVENTION

A first aspect of the present invention is directed to an electrical connector system comprising: a connector socket defining a socket; a first electrical connector sealingly mounted within or on the socket, the first electrical connector being electrically connectable to a first electrical component; a second electrical connector sealingly mounted within or on the socket, the second electrical connector being electrically connectable to the first electrical connector; and an electrical connector termination sealingly mounted within or on the socket, the electrical connector termination being electrically connectable to the second electrical connector and to a second electrical component.

In use, the electrical connector system may electrically connect a first electrical component to a second electrical component. The first and/or second electrical components may be housed within a water proof, weatherised housing or vessel.

The electrical connector system may protect the first and/or second electrical components from water damage.

The term electrical component is used herein broadly to include both electrical and electronic components of any type. An electrical component may be of any type, including but not limited to active electronic components, passive electronic components, electromechanical components and the like. Examples of active electronic components may include but are not limited to diodes, integrated circuits, optoelectronic devices, display technologies, transistors, and power sources. Examples of passive electronic components may include but are not limited to capacitors, magnetic electrical devices, resistors, RC circuits, LC circuits, transducers, sensors, detectors, antennas, oscillators, liquid display devices and the like.

Electromechanical components may include but are not limited to piezoelectric devices, power cables, connectors, terminals, switches, circuit breakers, heat sinks, printed circuit boards and the like.

The electrical connector system may comprise a modular design. The modular design may provide enhanced water protection to the electrical connectors and components of the system. Moreover, in the event of a failure of one of the electrical connectors or components the modularity of the system may still allow keeping the remaining connectors or components dry. For example, in the event of water damage to the electrical connector termination and/or to the second electrical connector, the first electrical connector and the first electrical component may be kept dry.

The modular design may allow any damaged electrical connectors or components to be replaced without having to replace the non-damaged connectors or components.

For example, in the event of damage to the second electrical connector, this connector may be repaired or replaced without having to replace the first electrical component or the first electrical connector.

The electrical connector system may provide improved flexibility and inter-changeability to the designer of the system. For instance, the second electrical connector may be readily adapted or replaced to fit with any suitable electrical connector termination.

The electrical connector system may allow for faster repair and less downtime in the event of water or other damage. For example, in the event of water or other damage to the electrical connector termination and/or to the second electrical connector, the electrical connector system may be readily redressed with a new second electrical connector and/or electrical connector termination while keeping the first electrical component protected. The damaged components may be replaced without having to replace the first electrical connector or risking damage to the first electrical component.

The electrical connector system may be made of or comprise any suitable material. For example, the non-electrical parts of the electrical connector system may be made of or comprise light materials such as plastic materials.

The electrical connector system may be used in any application requiring electrical connectivity under conditions posing risk of exposure to water.

The electrical connector system may be used in land or air applications requiring protection from water damage..

The electrical connector system may be used in marine applications.

The electrical connector system may be used in subsea applications.

The electrical connector system may be used in subsea oil and gas applications.

The connector socket may be sealingly mountable to a housing containing a first electrical component.

The connector socket may be an integral part of a housing containing a first electronic component.

The connector socket may form part of a housing containing a first electrical component.

According to an embodiment, the connector socket may be defined within a wall of a housing containing a first electrical component. For example, the socket may comprise a bore defined within a wall of the housing. The bore may be made by any suitable method including but not limited to machining...

According to an embodiment, the connector socket may form part of an end cap of a housing. For example, the socket may comprise a bore defined within an end cap of a housing. The bore may be made by any suitable method including but not limited to machining. The end cap may be sealingly mounted by any suitable means on the housing.

The connector socket may be or comprise an insert adapted to be sealingly mounted to a mating receptacle of a housing.

The connector socket may be of any suitable shape and size. The shape and size of the connector socket may be adapted depending on the application. For example, the connector socket may have a generally cylindrical or rectangular shape.

The connector socket may comprise a body defining a socket or bore therein.

The body of the connector socket may be of any suitable shape including but not limited to cylindrical, or rectangular.

The socket of the connector socket may be of any suitable shape and size. The shape and size of the socket may be adapted to sealingly receive the first and second electrical connectors and at least a part of the electrical connector termination. According to an embodiment, the socket may be substantially cylindrical with a substantially constant diameter along the entire length of the socket.

According to an embodiment, the socket may be substantially cylindrical with three distinct sections, each section having a different diameter adapted to sealingly receive a mating profile electrical connector. For example, a first section may be of a first diameter adapted to sealingly receive the first electrical connector, a second section may be of a second diameter adapted to sealingly receive the second electrical connector and a third section may be of a third diameter adapted to receive the third electrical connector.

According to an embodiment, the third section of the socket may have a larger diameter than the second section which in turn may have a larger diameter than the first section of the socket The connector socket may be made of any suitable material. For example, the connector socket may be made of a non-conductive material. The connector socket may be made of a core conductive material and coated or covered with a non-conductive material. Suitable non-conductive materials may include but are not limited to plastic or rubber materials.

According to an embodiment the connector socket may comprise a generally cylindrical body defining a socket therein having a first end portion for mounting the connector socket to housing and a second end portion for mounting the connector termination thereto. The first end portion of the connector socket may be or comprise a flanged connector for attaching the connector socket to a housing. One or more seals may be disposed between the flanged connector and the housing. The seals may be, for example 0-rings placed in a groove formed on the flanged connector. The first end portion may be or comprise a protruding end connector for securing the connector socket within a mating cavity of the housing. One or more seals may be disposed between the protruding connector and the cavity of the housing such as an 0-ring placed within a groove formed on an external surface of the protruding connector. 15 The first electrical connector may be permanently mounted within or on the socket of the connector socket. Such a configuration may reduce the risk of water damage. For example, according to an embodiment of the electrical connector system, the first electrical connector may be mounted within the socket and then, in order to permanently secure the first electrical connector inside the socket, an adhesive coating may be applied. According to another embodiment an adhesive coating may be applied on the first electrical connector, prior to inserting it within the socket of the connector socket. Setting of the adhesive may secure the first electrical connector within the socket. The adhesive coating may be any suitable material such as a polymeric material. The polymeric material may be an epoxy resin.

The first electrical connector may be removably mounted within or on the socket of the connector socket. For example, the first electrical connector may be an insert adapted to be sealingly mounted within or on the socket of the connector socket. Such a configuration may facilitate replacement of the first electrical connector.

The first electrical connector may be an integral part of the connector socket. For example the first electrical connector may be manufactured as an integral part of the connector socket. Such a configuration may reduce or eliminate the need for providing any seals between the first electrical connector and the socket of the connector socket thus reducing the risk of water damage.

The first electrical connector may be an integral part of an end cap of a housing.

Such a configuration may reduce or eliminate the need for any seals between the first electrical connector and the socket of the connector socket.

The first electrical connector may comprise a first seal arrangement for sealing the area between the first electrical connector and the socket of the connector socket.

The first seal arrangement may comprise at least one seal for sealing the area between the first electrical connector and the socket of the connector socket.

The first seal arrangement may comprise at least two seals for sealing the area between the first electrical connector and the socket of the connector socket.

One or more of the seals of the first sealing arrangement may be or comprise an 0-ring seal, however, any other suitable seals may be used.

The first seal arrangement may be or comprise a coating that may be applied in the area between the first electrical connector and the socket of the connector socket in order to seal this area. The coating may be any suitable coating and may include a polymeric material such as an epoxy resin. The coating may be an adhesive coating used also for securing the first electrical connector inside the socket. The coating may be applied by any suitable means and or methods. For example the first electrical connector may be inserted within an adhesive bath just prior to inserting the first electrical connector within the socket of the connector socket. Care may be exercised to coat only part of the first electrical connector and leave uncovered certain areas such as, for example, at least a part of any electrical contacts. For example, a removable mask may be applied to the areas of the electrical connector not to be covered by the coating prior to applying the coating.

The first electrical connector may comprise a first electrical contact arrangement for operably connecting the first electrical connector with the electrical component.

The first electrical contact arrangement may comprise one or more electrical contacts. The electrical contacts may be of any suitable type, shape and or configuration. For example, the electrical contacts may be arranged in a symmetrical configuration allowing electrical connection to be achieved with the second electrical connector once both the first and second electrical connectors are mounted within or on the socket of the connector socket regardless of the orientation of the second electrical connector.

The electrical contacts may comprise elongated, metal pins having a mating profile to corresponding electrical contacts of the first electrical component and of the second electrical connector. For example, according to an embodiment, the electrical contacts may comprise elongated, hollow metal pins at a first end thereof adapted to receive mating prongs or end cables of the first electrical component. The electrical contacts may comprise elongated solid metal pins at a second end thereof adapted to be inserted in mating electrical contacts of the second electrical connector. In yet another embodiment, the electrical contacts may comprise elongated receptacles at a first end thereof such as holes defined within the body of the first electrical connector or hollow metal pins adapted to receive mating prongs or end cables of the first electrical component.

The first electrical connector may be designed to withstand any operating pressure.

The first electrical connector may be designed to withstand the same differential pressure as the housing.

The first electrical connector may comprise a coating. The coating may cover all or part of the first electrical connector. The coating may enhance sealing between the first electrical connector and the socket. The coating may hold the first electrical connector securely mounted within the socket. The coating may insulate a non-contacting part of the electrical contacts.

The coating may be any suitable material. The coating may be or comprise a polymeric material.

The coating may be or comprise an epoxy resin.

The second electrical connector may be permanently or removably mounted within or on the socket of the connector socket.

The second electrical connector may be removably mounted within or on the socket of the connector socket. For example, the second electrical connector may be or comprise an insert adapted to be sealingly mounted within or on the socket of the connector socket. Such a configuration may allow for ready replacement of the second electrical connector and may therefore be preferred.

The second electrical connector may comprise a second seal arrangement for sealing the area between the second electrical connector and the socket of the connector socket. The second seal arrangement may comprise at least one seal for sealing the area between the second electrical connector and the socket of the connector socket. The second seal arrangement may comprise at least two seals for sealing the area between the second electrical connector and the socket of the connector socket. One or more of the seals of the second sealing arrangement may be or comprise an 0-ring seal, however, any other suitable seals may be used.

The second electrical connector may comprise a second electrical contact arrangement for operably connecting the second electrical connector with the first electrical connector.

The second electrical contact arrangement may comprise one or more electrical contacts. The electrical contacts may be of ant suitable type, shape and or configuration. For example, the electrical contacts may be arranged in a symmetrical configuration allowing an electrical connection to be achieved once the second electrical connector is mounted within or on the socket regardless of the orientation of the second electrical connector.

Also for example, the electrical contacts may be of any shape, for example, the electrical contacts may be elongated, metal pins having a mating profile to corresponding electrical contacts of the first electrical arrangement and of the third electrical connector.

The second electrical connector may be capable of supporting the same differential pressure as the housing. For example the second connector may independently seal the housing if necessary and keep water pressure away from the first electrical component.

The second electrical connector may comprise a coating. The coating may cover all or part of the second electrical connector. The coating may provide sealing between the second electrical connector and the socket.

The coating may insulate the non-contacting parts of the electrical contacts.

The coating may be any suitable material. The coating may be a polymeric material.

The coating may be the same or different to the coating that may be employed for the first electrical connector.

According to an embodiment, the first electrical connector may be permanently mounted within or on the socket of the connector socket, while the second electrical connector may be removably mounted within or on the socket of the connector socket.

This embodiment may reduce the risk of water damage to the first electrical component and at the same time allow ready replacement of the second electrical connector in the event of damage to the second electrical connector.

A suitable electrical connector termination may comprise a body having a third electrical connector for electrically connecting to the second electrical connector at one end thereof and a fourth electrical connector for connecting to a second electrical component at a second end thereof.

The third electrical connector may have any of the features of the first and/or second electrical connectors. For example, the third electrical connector may comprise a third electrical arrangement having a plurality of electrical contacts for effecting an electrical connection with the second electrical connector at one end thereof and with a fourth electrical connector at a second end thereof.

The third electrical connector may be sized and profiled so that it can be readily mounted within a third section of the socket to effect electrical connection between the second electrical connector and the electrical connector termination.

The third electrical connector may comprise a key adapted to co-operate with a respective mating keyway formed within the internal wall of a respective section of the socket that is adapted to receive the third electrical connector. The key/keyway combination may allow the third electrical connector to be guided and positioned within the socket in a suitable orientation that ensures that electrical contact is established between the second and third electrical connectors via their respective electrical contacts.

The first, second and third electrical connectors may be of any suitable size, shape and configuration. The size, shape and configuration of each electrical connector may be adapted to match the size, shape and/or configuration of a mating socket portion wherein each electrical connector may be sealingly mounted.

The first, second and third connectors may have the same size.

The first, second and third connectors may have different size.

According to an embodiment, the first, second, and third electrical connectors may be of different size whereas the second electrical connector may be larger in diameter than the first electrical connector, and the third electrical connector may be larger in diameter than the second electrical connector. Such a configuration, may improve the reliability of the first, second and third sealing arrangements.

The fourth electrical connector may be any suitable electrical connector. The fourth electrical connector may be or comprise, for example a cable, or a cable assembly.

The electrical contacts of the first, second, third and fourth electrical connectors may be made or comprise any suitable material such as silver, silver alloys The housing may be a water-tight housing. The housing may be designed to withstand and/or contain any operating pressure. The housing may be designed to withstand and/or contain a slight pressure. The housing may be designed to withstand and/or contain an atmospheric pressure. The housing may be designed to withstand deep water pressures such as the ones encountered in deep water oil and gas subsea operations.

The housing may be of any suitable shape and size and may contain one or more electrical components.

The housing may be made of any suitable material.

The housing may be part of a larger device or system. The housing may, for example, be a part of a subsea device.

According to an embodiment, the housing may be or comprise a control box, or a communications box of a subsea device or system.

The housing may be a control box of a subsea remote operated vehicle (ROV). A second aspect of the present invention is directed to the use of an electrical connector system having one or more of the aforementioned features for making an electrical connection to be used under any environmental conditions as described above.

According to an embodiment the electrical connector system may be used in a marine environment such as a subsea environment.

Yet another aspect of the present invention is directed to a method for making an electrical connection the method comprising: providing an electrical connector system according to a first aspect of the present invention; and coupling the electrical connector system to a first electrical component via a first electrical connector.

Yet another aspect of the present invention relates to a method for redressing a damaged electrical connector system according to a first aspect of the invention, the method comprising decoupling a damaged component and replacing it with a new or redressed component.

According to an embodiment, a method for redressing a damaged electrical connector system according to a first aspect of the invention comprises removing an electrical connector termination from a connector socket, removing a second electrical connector from the connector socket; and inserting a new or redressed second electrical connector into the connector socket.

The second electrical connector may be removed using any suitable tool such as for example a tool having a first end having a profile designed to engage a matching profile of the second electrical connector. According to an embodiment, the tool may be or comprise a T-bar having a protruding prong at a first end thereof that is sized and shaped to engage a matching slot of the second electrical connector. Many variations of a suitable tool and/or tool profile may be readily envisioned by the skilled person in this art after having read the present description.

Another aspect of the invention is directed to an electrical connector system comprising: a connector socket defining a socket the socket being adapted to receive first, second and third electrical connectors; a first electrical connector sealingly mounted within or on the socket, the first electrical connector being electrically connectable to a first electrical component; wherein said third electrical connector forms part of an electrical connector termination and said second and third electrical connectors are sealingly mountable within or on the socket to thereby establish electrical connection between said first, second and third electrical connectors.

The first electrical connector may be permanently mounted within or on the socket.

The second and third electrical connectors may be removably mounted within or on the connector socket.

According to an embodiment of the electrical connector system the first electrical connector may be permanently mounted within or on the connector socket whereas the second and/or third electrical connectors are removably mounted within or on the socket.

Another aspect of the electrical connector system is directed to a method for making an electrical connector system, the method comprising: providing a connector socket having a socket defined therein, the socket being adapted for receiving a first, second and third electrical connectors the third electrical connector being part of an electrical connector termination; providing a first electrical connector, the first electrical connector being electrically connectable to a first electrical component; and sealingly mounting the first electrical connector within or on the socket.

Mounting of the first electrical connector may include orienting the first electrical connector in a desired orientation using a key/keway combination.

The key may be part of the first electrical connector.

The key may be part of a guiding jig that replicates the second and third electrical connectors.

The keyway may be part of the socket.

The key/keyway combination may ensure that the first electrical connector is mounted within or on the socket in a desired orientation to ensure ready alignment of the first, second and third electrical connectors.

Mounting of the first electrical connector within or on the socket may include first positioning the first electrical connector to a guiding jig. The guiding jig may comprise replicate the shape and configuration of the second and/or third electrical connectors and may include a key for orienting the first electrical connector in a desired orientation within or on the connector socket in cooperation with a mating keyway formed on the socket.

The method may comprise sealingly mounting a second electrical connector within or on the socket, the second electrical connector being electrically coupled to the first electrical connector.

The method may comprise sealingly mounting third electrical connector within or on the socket, the third electrical connector being part of an electrical connector termination, the electrical connector termination being electrically connectable to a second electrical component.

The second and/or third electrical connectors may be removably mounted within or on the socket connector.

According to an embodiment the first electrical connector is mounted permanently within or on the socket whereas the second and third electrical connectors are removably mounted within or on the socket.

The first electrical connector may be provided by first making a body of a first electrical connector in a desired size and shape. The method may comprise making one or more cavities extending the entire length of the body of the first electrical connector.

The method may comprise fitting one or more electrical contacts in said one or more cavities. Proper fitting of the one or more electrical contacts may include positioning the first electrical connector to a jig prior to the fitting step.

The jig may comprise a replica of the shape and configuration of the second electrical component including the electrical arrangement of the second electrical component so that the one or more electrical contacts of the first electrical component are properly fitted within the one or more cavities.

The body of the first electrical connector may be made of any suitable material such an epoxy resin.

An adhesive such as an epoxy resin may be added to fix the one or more electrical contacts in place within the one or more cavities and to seal the area between the one or more electrical contacts and the one or more cavities.

Cables may be connected to one end of the one or more electrical contacts by soldering, crimping or any other suitable technique. The cables may be loose cables that can be used form an electrical connection with a first electrical component when needed. The cables may be cables already connected to a first electrical component positioned within a vessel.

According to a preferred embodiment, a first electrical connector may be formed using a suitable material such as an epoxy resin to form the body of the first electrical connector in the desired shape. For example, a billet made of epoxy may be formed having a generally cylindrical or rectangular shape. The billet may be pre-cured and pre-shrunk. The body may be machined to the desired size.

A plurality of cavities extending through the whole length of the body of the first electrical connector may also be formed.

The cavities may be formed by machining.

The cavities may be formed by any other suitable techniques.

The cavities may be adapted for receiving a plurality of mating electrical contacts therein.

A suitable material such as an epoxy resin may be applied to securely fix the electrical contacts to the body and also to seal the area between the electrical contacts and the cavities. Then loose cables may be soldered to one end of the electrical contacts.

The first electrical connector may be then guided within a socket in a suitable orientation. This may be achieved by attaching the first electrical connector to a guiding member that replicates the size and external shape of the second and/or third electrical connectors and employs a key/keway combination. For example a key may be formed on the external surface of a third electrical connector that is part of the electrical connector termination. A mating keyway may be part of the internal wall of the socket. This way, using the key of the guide member, the first electrical connector may be guided within the socket in an orientation that ensures proper alignment of the first electrical connector.

Upon positioning of the first electrical connector within the socket at the correct position and orientation, a suitable material such as an epoxy resin may then be used for sealing the area between the cables and the socket and for affixing permanently the first electrical connector to the socket.

The second electrical connector may then be inserted inside a second area of the socket using a suitable tool to effect an electrical connection with the first electrical connector via their respective electrical contacts.

By employing a symmetrical and matching configuration for the electrical contacts of the first and second electrical connectors, electrical connection may be established between the first and second electrical connectors regardless of the orientation of the second electrical connector.

The electrical connector termination may also then be mounted within or on the socket.

According to an embodiment the electrical connector termination may be guided within the socket using a key/keway combination. The key may form part of the external surface of a third electrical connector forming part of the electrical connector termination. The keyway may form part of the internal wall of the socket area within which the third electrical connector is mounted.

It should be understood that any features described in relation to any aspect of the present invention may be employed with any other aspect of the invention in a similar manner. For example the coating described in relation to the first aspect of the invention may be used to permanently mount the first electrical connector within or on the connector socket according to an embodiment of the method of making the electrical connector system. Or a T-Bar tool as the one described in relation to the method of redressing the electrical connector system may also be used in mounting the first and or second electrical connectors within or on the socket.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a subsea ROV.

Figure 2 is an enlarged perspective view of the circled area A of Figure 1, showing an electrical connector system, according to an embodiment of the invention.

Figure 3 is a side partial cross-sectional view of an electrical connector system, according to an embodiment of the invention.

Figure 4 is a side partial cross-sectional view of the electrical connector system of Figure 3 in an assembled state.

Figures 5A and 58 show in a diagrammatic form the mounting of a second electrical connector within a socket of an electrical connector system, according to an embodiment of the invention.

Figure 6A is a side view of an electrical connector system, according to another embodiment of the invention.

Figure 68 is a partial cross-sectional view of the electrical connector system of Figure 6A.

Figures 7A and 78 show in a diagrammatic form the mounting of a second electrical connector within a socket of a connector socket, according to an embodiment of the invention.

DETAILED DESCRIPTON OF THE DRAWINGS

Figure 1 shows a remotely operated vehicle (ROV) generally designated with numeral 1. The ROV 1 is of the type commonly employed in subsea operations and has a control box 5 upon which an electrical connector system 10 is mounted, according to an embodiment of the invention. Figure 2 shows an enlarged perspective view of the control box 5 with the electrical connector system 10. Although the electrical connector system 10 is described in use with a subsea vessel such as the ROV 1, it will be appreciated that the electrical connector system 10 could equally be used with any other suitable system that requires a water tight electrical connection. For example, control box 5 may be the housing of any device or system used in subsea applications for containing one or more electrical components.

It should also be understood that although the present invention is described herein in the context of a subsea application, the present invention is not limited to subsea applications. In fact, it may be used in any application requiring a water tight electrical connection.

An electrical connector system 30 is shown in more detail in Figure 3 in a non-fully assembled configuration, according to an embodiment of the invention. Accordingly, electrical connector system 30 comprises a housing 32 defining a chamber 33 containing one or more electrical components (not shown). The electrical components have a plurality of electrical terminal contacts in the form of cables 34. However, it should be understood that electrical components having a different type terminal connection, other than cables 34, may also be used without departing from the scope of the invention. For example, the cables 34 may be terminated in a terminal connection comprising a plurality of elongated electrical contacts such as metal pins (not shown).

The housing 32 has an end cap 35 defining a bore or socket 36. Socket 36 comprises three distinct socket sections 36a, 36b, and 36c having different diameter cross-sections adapted to receive first, second and third electrical connectors 42, 52, and 60 respectively. The end cap 35 is removably secured on the housing via a plurality of fasteners 38. Any type of fasteners may be used. Two seals 40 are disposed on the periphery of the end cap 35 to seal the area between the end cap 35 and the housing 32. The seals 40 may be 0-ring seals or any other type suitable seals.

The first electrical connector 42 is sealingly mounted within socket 36 at first section thereof 36a that is proximate to the chamber 33 of the housing 32. The first electrical connector 42 comprises a first sealing arrangement 50 having dual seals 51 disposed on grooves 43 formed at the periphery of the first electrical connector 42. The seals 51 seal the area between the first electrical connector 42 and the interior wall of the socket 36. The seals 51 may be any suitable seals including but not limited to 0-rings.

The first electrical connector 42 is permanently mounted within the socket 36. The first electrical connector 42, as shown in this embodiment, is an insert that is sized and profiled to sealingly, slide and fit within a first section 36a of the socket 36. However, it should be understood that the first electrical connector 42 may be made as an integral part of the housing 32 such as for example as an integral part of the end cap 35 without departing from the scope of the present invention.

The first electrical connector 42 comprises a first electrical arrangement 44 having a plurality of first electrical contacts 46 to electrically connect the first electrical connector 42 with the tail ends of the cables 34 of the one or more electrical components contained in chamber 33 of the housing 32. The tails ends of the cables 34 may be connected with the first electrical contacts using any suitable method such as soldering or crimping, The first electrical arrangement 44 may be arranged in a suitable configuration as shown in this embodiment to allow an electrical connection to be achieved with the tail ends of the cables 34 once the first electrical connector 42 is mounted within the socket 36. This may be achieved using any suitable configuration and method.

For example, as shown in this embodiment, the first electrical contacts 46 comprise elongated, metal pins having hollow ends for receiving the tail ends of cables 34 at a first side of the first electrical connector. The first electrical contacts 46 traverse the whole body of the first electrical connector 42 and form protruding pins on a second side of the first electrical connector 42 which are sized to fit and profiled within mating pins of the second electrical connector 52. The pins as shown in this embodiment are of a circular cross-section however, any type of cross-sectional shape may be used.

The first electrical connector 42 may be capable of supporting the same differential pressure as the housing 32. This may be any operating pressure of the application where the electrical connection system is used.

The first electrical connector 42 may be coated at least partially with a coating (not shown). The coating may provide additional sealing. The coating may hold the first electrical connector securely mounted within the socket. For example, a coating (not shown) may be used in the interface between the socket 36 and the first electrical connector 42 to permanently fix the first electrical connector in place within the socket 36. The coating may also be used to securely fix the first electrical contacts 46 to the first electrical connector 42. For example, the first electrical contacts 46 may be positioned within respective cavities formed within the first electrical connector 42 and a coating may then be used to fix the contacts 46 and seal the area between the contacts and cavities. When soldering is used to connect the tail ends of the cables 34 to the first electrical contacts 46, a coating may also be used to partially insulate the electrical contacts around their solder buckets.

The coating may be or comprise of any suitable material. For example, the coating may comprise of a polymeric material such as an epoxy resin.

The second electrical connector 52 is sealingly and removably mounted within second section 36b of the socket 36. The second electrical connector 52 comprises a second electrical arrangement 47 electrically coupling the second electrical connector 52 to the first electrical connector 42 via a plurality of electrical contacts 48. Electrical contacts 48 are elongated, metal pins that are hollow at a first end adapted to receive protruding matching metal pins 46 of the first electrical connector 42. The second electrical arrangement 47 may be arranged in a symmetrical configuration as shown in this embodiment to allow an electrical connection to be achieved once the second electrical connector 52 is mounted within the socket 36 regardless of the orientation of the second electrical connector 42.

The second electrical connector 52 may be a removable, replaceable connector in the form of an insert that is profiled and sized to sealingly be inserted and fitted within the second section 36b of the socket 36.

The second electrical connector 52 further comprises a second sealing arrangement 54 having two seals 55 for sealing the area between the second electrical connector 52 and the interior wall of the socket 36. The seals 55 of the second sealing arrangement 54 may be 0-rings, however, other suitable seals may be used.

The second electrical connector 52 may also be coated at least partially with a protective epoxy resin coating (not shown). However, care should be exercised in applying the coating to avoid hindering the movability of the second connector.

The electrical connector system 30 further comprises an electrical connector termination 56 comprising a body 58 having a third electrical connector 60 at a first end thereof and a fourth electrical connector 62 at a second end thereof. The fourth electrical connector 62 may be a cable connector.

The third electrical connector 60 has a fastener 70 comprising a one or more retaining screws (not shown) for securing the electrical connector termination 56 to the end cap 35 of the housing 32 once the electrical termination connector 56 is mounted on the housing 32 as shown in Figure 4. The retaining screws may be turned to tighten the fastener 70 to the housing. Fastener 70, as shown, is in the form of a washer, however, any other suitable type of many well-known fastening devices may also be used.

The third electrical connector comprises a third electrical arrangement 64 having a plurality of electrical contacts 66 for effecting an electrical connection with the second electrical connector at one end thereof and with the fourth electrical connector 62 at a second end thereof.

The third electrical connector 60 is sized and profiled so that it can be readily mounted within a third section 36c of the socket 36 to effect electrical connection between the second electrical connector 52 and the electrical connector termination 56.

The third electrical connector comprises a key 72 adapted to co-operate with a respective keyway 73 formed within the internal wall of section 36c of the socket 36.

The key/keyway combination allows the third electrical connector 60 to be guided and positioned within the socket 36 in a suitable orientation that ensures that electrical contact is established between the second and third electrical connectors 52, 60 via their respective electrical contacts 48 and 66.

The third electrical connector 60 has a third sealing arrangement 76 comprising dual seals 74 (shown in Figure 4) disposed inside grooves 78 formed on an exterior side wall of the third electrical connector 60. Seals 74 seal the area between the third electrical connector 60 and the internal wall of socket 36.

Figure 4 shows the electrical connector system 30 of Figure 3 in an assembled installed configuration with the electrical connector termination 56 being mounted within the socket 36 of housing 32 and secured on the housing 32 with fastener 70.

Referring now to Figures 5A and 58, a method of inserting the second electrical connector 52 inside the socket 36 is shown. In Figure 5A an electrical connector system 30 is shown with a first electrical connector 42 permanently mounted within section 36a of the socket 36 of the housing 32.

Permanent positioning of the first electrical connector 42 may be accomplished via a number of different ways. According to one method, the first electrical connector 42, is first installed inside the first section 36a of the socket 36, and them it is coated with a suitable coating such an epoxy. The resin is then allowed to set or harden. The hardened resin may then provide sufficient attachment of the first electrical connector to the connector socket Hardening of the resin may be achieved by any suitable means such as heating.

In applying the epoxy resin care should be taken to avoid covering the contact area of the first electrical contacts 46 used to make the connection with the second electrical connector 52.

According yet to another embodiment, the body of the first electrical connector 42 is first formed from a suitable material such as, for example, an epoxy resin in the form of a billet. For example, the body may have a generally cylindrical or rectangular shape. The body may be pre-cured and pre-shrunk. Then the body is machined to a desired size. The billet may be formed with a plurality of cavities extending the whole length of the body of the first electrical connector 42 for positioning the electrical contacts 46 therein. Alternatively, the cavities may be machined after forming the billet.

Then electrical contacts 46 are fitted within the cavities. To ensure proper alignment of the electrical contacts 46 within the cavities the body of the first electrical connector 42 may be mounted to a jig replicating the second electrical connector 52 and its electrical arrangement. This ensures that the electrical connectors 46 are positioned properly in the correct configuration to ensure proper electrical contact with the electrical arrangement of the second electrical connector 52.

Epoxy resin may then be applied to securely fix the electrical contacts 46 to the body and seal the area between the electrical contacts 46 and the cavities of the first electrical connector 42.

Then cables 34 are soldered to the electrical contacts 46. It should be understood, however, that other techniques may also be used. The first electrical connector 42 may then be guided within the socket 36 in a desirable orientation. For example, the first electrical connector 42 may be placed within a guiding member (not shown) also referred to as a bulkhead or socket jig (not shown) that is sized and shaped to replicate the external shape of the second and third electrical connectors, including importantly of a key identical to key 72. This way using the key of the guiding member the first electrical connector 42 may be guided within the socket 36 in a suitable orientation that will ensure proper alignment between the electrical connectors.

The space between cables 34 and the socket may be filled with an adhesive coating such as an epoxy resin for sealing the connection and affixing permanently the first electrical connector 42 to the socket 36 of end cap 35.

The second electrical connector 52 may then be inserted inside section 36b of the socket 36 using a T-bar tool 80 as shown in Figure 5A. The second electrical connector 52 may have a slot 82 for receiving a matching protruding prong of the T-bar tool 80 for positioning the second electrical connector on the tool 80 as shown in Figure 5A.

The second electrical connector 52 may then be guided within the socket 36 and mounted within the socket section 36b with the protruding ends of the electrical contacts 46 of the first electrical connector 42 received within the matching hollow ends of the electrical contacts 48 of the second electrical connector 52 as shown in Figure 5B.

The second electrical connector 52 as shown in this embodiment is not affixed permanently within the socket 36 allowing it to be readily replaced as may be needed. Referring now to Figures 6A to 7B another embodiment of the electrical connector system 130 will be described. The electrical connector system 130 of Figures 6A to 78 has many features in common with the embodiment shown in Figures 3 to 5B and for ease of reference same or similar features are denoted using the same numerals as in Figures 3 to 5B augmented by 100.

Referring now to Figure 6A a side, perspective view of an electrical connector system 130 mounted on a housing 132 is shown. The electrical connector system 130 has a connector socket 200 and an electrical connector termination 156. A fastener 161 couples the electrical connector termination 156 with the connector socket 200. The connector socket 200 has a cylindrical body 210 terminating at an enlarged diameter flange 215 and an end member 220 having a groove 222 for receiving a seal (not shown) for sealing the area between the housing and the end member 220.

The electrical connector termination 156 has a body 158 having a first generally cylindrical portion 158a, a substantially conical or tapered second portion 158b, and a cable connector end portion 158c.

Referring now to Figure 6B, the electrical connector system 130 further comprises first, second, and third electrical connectors 142, 152, 160 mounted within respective sections 136a, 136b and 136c of a socket 136 defined within the cylindrical body 210 of the connector socket 200. Seals (not shown) are disposed on grooves 225 formed on the flange 215 to seal the area between the housing 132 and the flange 215.

First electrical connector 142 is electrically connected via cables 134 to one or more electrical components housed within the housing 132. First, second and third dual seals, 151, 155 and 174 seal the areas between the respective electrical connectors and the interior wall of the socket 136 of connector socket 200.

Each electrical connector comprises respective electrical arrangements 144, 154, and 164, each electrical arrangement having a plurality of respective electrical contacts 146, 148 and 166 for obtaining electrical connectivity between one or more electrical components housed within the housing 132 and one or more electrical components external to the housing.

The third electrical connector 160 may comprise a key (not shown) as in the embodiment of Figure 3, adapted to co-operate with a respective keyway (not shown). The keyway may be formed within the internal wall of section 136c of the socket 136 as in the embodiment of Figure 3. The key/keyway combination may allow the third electrical connector 160 to be guided and positioned within the socket 136 in a suitable orientation that ensures electrical contact is established between first, second and third electrical connectors 142, 152, 160 via their respective electrical contacts 146, 148 and 166.

Referring now to Figures 7A and 7B a method of assembling the electrical connector system 130 will be described. In Figure 7A a partial, side cross-sectional view of connector socket 200 is shown with a first electrical connector 142 permanently mounted within a first section 136a of the socket 136 of the connector socket 200. Permanent positioning may be accomplished via a number of different ways. According to one method, the first electrical connector 142 is first installed inside the first section 136a of the socket 136, and then it is coated with a suitable coating such as an epoxy resin. The epoxy resin is then allowed to set or harden. The hardened resin may then provide sufficient attachment of the first electrical connector 142 to the connector socket 200. In applying the epoxy resin care should be taken to avoid covering the contact areas of the electrical contacts 146.

According yet to another embodiment, the first electrical connector 142 is formed using a suitable material such as an epoxy resin to form the body of the first electrical connector 142 in the form of a billet having a desired shape. The billet may for example have a generally cylindrical or rectangular shape. The billet may be pre-cured and pre-shrunk. Then the body is machined to a desired size and precise shape. A plurality of cavities may then be machined extending through the whole length of the body of the first electrical connector. The cavities may be adapted for receiving the electrical contacts 146 therein. A suitable material such as an epoxy resin may be applied to securely fix the electrical contacts 146 to the body and seal the area between the electrical contacts 146 and the cavities. According to an embodiment, proper positioning and fitting of the electrical contacts 146 within the cavities of the first electrical connector 142 may be ensured by mounting the electrical connector 142 to a jig which is a replica of the second electrical connector 152 including cavities replicating the hollow ends of the electrical contacts 148.

Then tail ends or cables 134 are soldered to the electrical contacts 146. It should be understood, however, that other techniques may also be used for connecting the cables 134 to the electrical contacts 146.

In this embodiment, cables 134 are loose cables not connected to any electrical component. The first electrical connector 142 may then be guided within the socket 136 in a desirable orientation. For example, the first electrical connector may be placed within a guiding member also referred to as a bulkhead or socket jig (not shown) that is sized and shaped to replicate the external shape of the second and third electrical connectors. The guiding member may also employ a key (not shown) that cooperates with a keyway (not shown) formed within the socket 136 for ensuring proper alignment of first electrical connector within the socket 136. The key/keway may be made like the key 72 and keyway 73 shown in the embodiment of Figures 5A and 6A. This way using the key of the guide member the first electrical connector 142 may be guided within the socket 136 in an orientation that ensures proper alignment.

A suitable material such as an epoxy resin may then be added to fill the gap between the cables 134 and the socket 136 for sealing and affixing permanently the first electrical connector 142 to the connector socket 200.

The second electrical connector 152 may then be inserted inside a second area of 136b of socket 136 of the connector socket 200 using a T-bar tool 180 as shown in Figure 7A. The second electrical connector 152 may have a slot 182 for receiving a matching protruding prong of the T-bar tool 180 for positioning the second electrical connector 152 on the tool 180.

The second electrical connector 152 may then be guided within the socket 136 of the connector socket and mounted within the socket section 136b with the protruding ends of the electrical contacts 148 of the second electrical connector 152 received within matching hollow ends of the electrical contacts 146 of the first electrical connector 142 as shown in Figure 68. The second electrical connector may be preferably not permanently affixed within the socket 136 of the connector socket to allow ready replacement as may be needed.

The connector socket 200 having the first electrical connector mounted therein may then be used to make an electrical connection as may be needed.

It should be appreciated that although the invention is described in relation to certain embodiments, that many variations maybe envisaged by the skilled person without departing of the scope of the invention.

Claims

CLAIMS1. An electrical connector system comprising: a connector socket defining a socket; a first electrical connector sealingly mounted within or on the socket, the first electrical connector being electrically connectable to a first electrical component; a second electrical connector sealingly mounted within or on the socket, the second electrical connector being electrically connectable to the first electrical connector; and an electrical connector termination sealingly mounted within or on the socket, the electrical connector termination being electrically connectable to the second electrical connector and to a second electrical component.
2. The electrical connector system according to claim 1, wherein the first and/or cr) 15 second electrical component includes at least one of an active electronic component, a passive electronic component and an electromechanical component. C\I
3. The electrical connector system according to claim 2, wherein an active (r) electronic component includes at least one of a diode, an integrated circuit, an C\I 20 optoelectronic device, a display technology, a transistor and a power source.
4. The electrical connector system according to claim 2 or 3, wherein a passive electronic component includes at least one of a capacitor, a magnetic electrical device, a resistor, a RC circuit, a LC circuit, a transducer, a sensor, a detector, an antenna, an oscillator and a liquid display device.
5. The electrical connector system according to claim 2, 3 or 4, wherein an electromechanical component includes at least one of a piezoelectric device, a power cable, a connector, a terminal, a switch, a circuit breaker, a heat sink and a printed circuit board.
6. The electrical connector system according to any preceding claim, wherein the connector socket is sealingly mountable to a housing containing the first electrical component.
7. The electrical connector system according to any preceding claim, wherein the connector socket is an integral part of a housing containing the first electronic component.
8. The electrical connector system according to any preceding claim, wherein the connector socket is defined within a wall of a housing containing the first electrical component.
9. The electrical connector system according to any preceding claim, wherein the connector socket forms part of an end cap of a housing.
10. The electrical connector system according to any preceding claim, wherein the connector socket comprises an insert adapted to be sealingly mounted to a mating receptacle of a housing.

(r)
11. The electrical connector system according to any preceding claim, wherein the socket is substantially cylindrical. C\I

CD
12. The electrical connector system according to any preceding claim, wherein the connector socket has a first section of a first diameter adapted to sealingly receive the C\I first electrical connector, a second section of a second diameter adapted to sealingly receive the second electrical connector and a third section of a third diameter adapted to receive the third electrical connector.
13. The electrical connector system according to claim 12, wherein the third section of the socket has a larger diameter than the second section which in turn has a larger diameter than the first section of the socket.
14. The electrical connector system according to any of claims 1 to 12, wherein the connector socket has a substantially constant diameter along the length of the connector socket.
15. The electrical connector system according to any preceding claim, wherein the first end portion of the connector socket comprises a flanged connector for attaching the connector socket to a housing.
16. The electrical connector system according to any preceding claim, wherein the first electrical connector is permanently mounted within or on the socket of the connector socket.
17. The electrical connector system according to any preceding claim, wherein the first electrical connector is removably mounted within or on the socket of the connector socket.
18. The electrical connector system according to any preceding claim, wherein the first electrical connector comprises a first seal arrangement for sealing the area between the first electrical connector and the connector socket.
19. The electrical connector system according to any preceding claim, wherein the first electrical connector comprises a first electrical contact arrangement comprising (r) one or more electrical contacts.

C\I
20. The electrical connector system according to claim 19, wherein the electrical CD contacts comprise conductor pins.

C\I
21. The electrical connector system according to any preceding claim, wherein the second electrical connector is permanently mounted within or on the socket of the connector socket.
22. The electrical connector system according to any preceding claim, wherein the second electrical connector is removably mounted within or on the socket of the connector socket.
23. The electrical connector system according to any preceding claim, wherein the second electrical connector comprises a second seal arrangement for sealing the area between the second electrical connector and the connector socket.
24. The electrical connector system according to any preceding claim, wherein the second electrical connector comprises a second electrical contact arrangement comprising one or more electrical contacts.
25. The electrical connector system according to any preceding claim, wherein the first electrical connector is permanently mounted within or on the socket of the connector socket, while the second electrical connector is removably mounted within or on the socket of the connector socket.
26. The electrical connector system according to any preceding claim, wherein the electrical connector termination comprises a body having a third electrical connector for electrically connecting to the second electrical connector at one end thereof and a fourth electrical connector for connecting to a second electrical component at a second end thereof.
27. The electrical connector system according to any preceding claim, wherein the first, second and third connectors have the same size. 15 (r)
28. The electrical connector system according to any of claims 1 to 26, wherein the first, second and third connectors have different sizes. C\ICD
29. The electrical connector system according to any preceding claim wherein the C\I 20 housing is a water-fight housing.
30. The electrical connector system according to any preceding claim, wherein the electrical connector system is modular.
31. The electrical connector system according to any preceding claim, for use in land or air applications requiring protection from water damage.
32. The electrical connector system according to any preceding claim, for use in marine applications. 30
33. The electrical connector system according to any preceding claim, for use in subsea applications.
34. The electrical connector system according to any preceding claim, for use in subsea oil and gas applications.
35. A method for making an electrical connection, comprising: providing an electrical connector system according to claims 1 to 34; and coupling the electrical connector system to a first electrical component via a first electrical connector.
36. A method for redressing a damaged electrical connector system according to claims 1 to 34, the method comprising decoupling a damaged component and replacing said damaged component with a new or redressed component.
37. The method according to claim 36, comprising removing the electrical connector termination from the connector socket, removing the second electrical connector from the connector socket; and inserting a new or redressed second electrical connector into the connector socket.(r)
38. The method according to claim 37, wherein the second electrical connector is removed using a tool. C\ICD
39. An electrical connector system, comprising: a connector socket defining a socket adapted to receive first, second and third C\I electrical connectors; a first electrical connector sealingly mounted within or on the socket, the first electrical connector being electrically connectable to a first electrical component; wherein said third electrical connector forms part of an electrical connector termination and said second and third electrical connectors are sealingly mountable within or on the socket to thereby establish electrical connection between said first, second and third electrical connectors.
40. A method for making an electrical connector system, comprising: providing a connector socket having a socket defined therein, the socket being adapted for receiving a first, second and third electrical connector, the third electrical connector being part of an electrical connector termination; providing a first electrical connector, the first electrical connector being electrically connectable to a first electrical component; and sealingly mounting the first electrical connector within or on the socket.