GB2541447A

GB2541447A - A connecting device and a method of manufacturing a connecting device

Info

Publication number: GB2541447A
Application number: GB1514846.3A
Authority: GB
Inventors: Marsden David; Maitland Bodley Scott David
Original assignee: Martec Ltd
Current assignee: Martec Ltd
Priority date: 2015-08-20
Filing date: 2015-08-20
Publication date: 2017-02-22
Anticipated expiration: 2035-08-20
Also published as: GB2541447B; GB201514846D0

Abstract

An Ethernet connecting device has metal contacts 28 passing through glass to which they are sealed, held in rounded holes in a metal body 29. The contacts are connected to Ethernet connectors 5 and 7, optionally via internal connectors 13 and 15. Body 29 is welded to tubes 23 and 37, to form a connecting device which can be inserted into outer tube 21 and locked there by member 47. The outer tube can be welded to a bulkhead which it passes through. The arrangement provides a hermetic seal, and allows easy replacement of the connecting device.

Description

A CONNECTING DEVICE AND A METHOD OF MANUFACTURING A CONNECTING DEVICE

FIELD

The present invention relates to the field of connecting devices and methods of manufacturing connecting devices. More specifically, it is related to connecting devices and methods of manufacturing connecting devices to withstand a pressure difference.

BACKGROUND

Ethernet using twisted pair cabling is commonly used to build Local Area Networks (LANs). Ethernet over twisted pair networks generally use cables which comprise twisted pairs and 8P8C connectors. 8P8C connectors comprise a male plug and a female socket. An 8P8C plug has a flattened shape with conducting contacts located on one of the faces of the plug. When mated with the socket, a biased locking member locks the plug into the socket. Inside the socket, conducting contacts are suspended diagonally downwards from a face of the socket. When the plug is mated with the socket, the contacts meet, causing an electrical connection between them. 8P8C connectors are commonly referred to as RJ45 connectors in the context of Ethernet applications.

There are many problems associated with building Ethernet LANs in environments having watertight or gas sealed bulkheads such as those found in submarines, aircraft, through pressurized cabin walls, or rescue chambers and diver decompression chambers in submersible vehicles or equipment and oil rigs. In particular, 8P8C connectors are not sealed in order to withstand differences in pressure on either side of the connector. This prevents the use of 8P8C sockets in submarine pressure bulkheads for example, where the pressure on one side of the bulkhead can be different to the pressure on the other side of the bulkhead. If such a pressure difference occurs between the sides of a bulkhead in which an 8P8C socket is installed, pressure leakage occurs through the socket. 8P8C connectors are not sealed to be fluid tight. Thus 8P8C connectors cannot be used in a bulkhead intended to separate fluids including gases, water vapour or smoke in the case of fire.

SUMMARY OF THE INVENTION

In one aspect of the present invention, there is provided an Ethernet connecting device comprising: a first metal member; a glass member, wherein the glass member forms a glass to metal seal with a first portion of the first metal member and wherein a second portion of the first metal member is exposed from one side of the glass member and a third portion of the first metal member is exposed from the opposite side of the glass member; a metal body comprising a hole with a rounded cross-section, wherein the glass member is located inside the hole and forms a glass to metal seal with an inner surface of the hole; a first Ethernet connector component positioned a first side of the glass member and electrically connected to the first metal member; a second Ethernet connector component positioned a second side of the glass member and electrically connected to the first metal member.

In an embodiment, the glass member surrounds the first metal member over a portion of the length of the first metal member. In an embodiment, the first metal member is cylindrical. The first metal member may comprise a matched expansion Iron Nickel alloy, such as Alloy 48, Alloy 50 or Alloy 52. The first metal member may be cylindrical. The first metal member may be 0.8mm in diameter.

In an embodiment, the hole is cylindrical. In one embodiment, the metal body is cylindrical. In an embodiment, the metal body comprises stainless steel. In an embodiment, the co-efficient of thermal expansion of the metal body is higher than that of the glass member.

In an embodiment, the Ethernet connecting device further comprises: a second metal member, a third metal member and a fourth metal member, wherein the first Ethernet connector component is electrically connected to each of the second metal member, third metal member and fourth metal member and the second Ethernet connector component is electrically connected to each of the second metal member, third metal member and fourth metal member.

In an embodiment, the Ethernet connecting device further comprises: a second glass member, wherein the second glass member forms a glass to metal seal with a first portion of the second metal member and wherein a second portion of the second metal member is exposed from one side of the second glass member and a third portion of the second metal member is exposed from the opposite side of the second glass member; a third glass member, wherein the third glass member forms a glass to metal seal with a first portion of the third metal member and wherein a second portion of the third metal member is exposed from one side of the third glass member and a third portion of the third metal member is exposed from the opposite side of the third glass member; a fourth glass member, wherein the fourth glass member forms a glass to metal seal with a first portion of the fourth metal member and wherein a second portion of the fourth metal member is exposed from one side of the fourth glass member and a third portion of the fourth metal member is exposed from the opposite side of the fourth glass member; and wherein the metal body comprises: a second hole with a rounded cross-section, wherein the second glass member is located inside the second hole and forms a glass to metal seal with an inner surface of the second hole; a third hole with a rounded cross-section, wherein the third glass member is located inside the third hole and forms a glass to metal seal with an inner surface of the third hole; a fourth hole with a rounded cross-section, wherein the fourth glass member is located inside the fourth hole and forms a glass to metal seal with an inner surface of the fourth hole.

In an embodiment, the glass member forms a glass to metal seal with a first portion of the second metal member and wherein a second portion of the second metal member is exposed from one side of the glass member and a third portion of the second metal member is exposed from the opposite side of the glass member, and wherein the glass member forms a glass to metal seal with a first portion of the third metal member and wherein a second portion of the third metal member is exposed from one side of the glass member and a third portion of the third metal member is exposed from the opposite side of the glass member, and wherein the glass member forms a glass to metal seal with a first portion of the fourth metal member and wherein a second portion of the fourth metal member is exposed from one side of the glass member and a third portion of the fourth metal member is exposed from the opposite side of the glass member.

In an embodiment, the connecting device has an elongated shape having a first end and a second end, the first end positioned the first side of the glass member and the second end positioned the second side of the glass member.

The connecting device may further comprise a first metal tube and a second metal tube. The first metal tube is attached to a first side of the metal body and the second metal tube is attached to the second side of the metal body. The second portion of the first metal member is located inside the first metal tube and the third portion of the first metal member is located inside the second metal tube. The first Ethernet connector component is located inside the first metal tube and the second Ethernet connector component is located inside the second metal tube.

In an embodiment, the connecting device further comprises: a first abutment; and a second abutment located along the length of the connecting device closer to the second end of the connecting device than the first abutment; wherein the first abutment and the second abutment face in opposite directions.

The first metal tube comprises the first abutment. The metal body comprises the second abutment.

The first abutment and the second abutment are configured to abut against oppositely facing surfaces.

In an embodiment, the first abutment faces in the direction from the glass to metal seal towards the first end of the connecting device and the second abutment faces along the direction from the glass to metal seal towards the second end of the connecting device.

In an embodiment, the second end of the connecting device is configured to be inserted inside an outer tube, and wherein the second abutment is configured to engage with an abutment on an inner surface of the outer tube, preventing further insertion of the connecting device into the outer tube.

The first abutment may be configured to engage with a locking member which attaches to the outer tube, such that movement of the connecting device out of the outer tube is prevented.

In an embodiment, the connecting device is a feedthrough. In a feedthrough, a cable is directly attached on both sides of the feedthrough, and the feedthrough is fixed to the surface of a box or bulkhead.

In another embodiment, the connecting device is a connector. A connector comprises a fixed part and a removable part that connects to the fixed part. The fixed part is fixed to a structure such as a box or bulkhead, i.e. it is permanently attached to the equipment. The removable part is connected to the cable.

In an embodiment, the first Ethernet connector component and the second Ethernet connector component are an RJ45 plug or an RJ45 socket.

In this specification, the term glass includes glass ceramic materials.

In this specification, the term metal includes metal alloys.

In another aspect of the present invention, there is provided an assembly comprising an outer tube and a connecting device comprising: a first metal member; a glass member, wherein the glass member forms a glass to metal seal with a first portion of the first metal member and wherein a second portion of the first metal member is exposed from one side of the glass member and a third portion of the first metal member is exposed from the opposite side of the glass member; a metal body comprising a hole with a rounded cross-section, wherein the glass member is located inside the hole and forms a glass to metal seal with an inner surface of the hole; a first Ethernet connector component positioned a first side of the glass member and electrically connected to the first metal member; a second Ethernet connector component positioned a second side of the glass member and electrically connected to the first metal member, and further comprising the outer tube.

The connecting device is located inside the outer tube.

The first abutment faces in the direction from the glass to metal seal towards the first end of the connecting device and the second abutment faces along the direction from the glass to metal seal towards the second end of the connecting device

The second abutment engages with an abutment on an inner surface of the outer tube such that movement of the connecting device out of the outer tube is prevented.

In an embodiment, the assembly further comprises a locking member attached to the outer tube and comprising an abutment which engages with the first abutment, such that movement of the connecting device out of the outer tube is prevented. In an embodiment, the locking member is removably attached to the outer tube. The locking member may be configured to screw onto the outer tube.

In an embodiment, the assembly further comprises a locking plate comprising one or more rotational locking features which engage with one or more rotational locking features on the connecting device, and which is attached to the locking member such that rotation of the locking member and the connecting device relative to each other is prevented.

In an embodiment, the locking plate is removably attached to the locking member. The locking plate may be attached to the locking member by one or more screws.

In another aspect of the present invention, there is provided a bulkhead, comprising an assembly comprising an outer tube and a connecting device comprising: a first metal member; a glass member, wherein the glass member forms a glass to metal seal with a first portion of the first metal member and wherein a second portion of the first metal member is exposed from one side of the glass member and a third portion of the first metal member is exposed from the opposite side of the glass member; a metal body comprising a hole with a rounded cross-section, wherein the glass member is located inside the hole and forms a glass to metal seal with an inner surface of the hole; a first Ethernet connector component positioned a first side of the glass member and electrically connected to the first metal member; a second Ethernet connector component positioned a second side of the glass member and electrically connected to the first metal member, and further comprising the outer tube.

The connecting device is located inside the outer tube. The outer tube is located in a hole in the bulkhead.

In another aspect of the present invention, there is provided a method of manufacturing an Ethernet connecting device, comprising: forming a glass member having at least one hole; arranging a first metal member inside the hole in the glass member such that a first portion of the first metal member is inside the hole, a second portion of the first metal member is exposed from one side of the glass member and a third portion of the first metal member is exposed from the opposite side of the glass member; arranging the glass member in a hole in a metal body, the hole having a rounded cross-section; heating the metal body in order to form a glass to metal seal between the glass member and an inner surface of the hole; positioning a first 8P8C connector component on one side of the glass member and a second 8P8C connector component on the opposite side of the glass member; electrically connecting the first 8P8C connector component to the first metal member and the second 8P8C connector component to the first metal member.

In an embodiment, the method further comprises electron beam welding a first metal tube and a second metal tube to the metal body.

In an embodiment, the method further comprises applying potting compound around the second portion of the first metal member and the third portion of the first metal member.

In another aspect of the present invention there is provided a method of assembling a connecting device assembly in a bulkhead, the connecting device assembly comprising an Ethernet connector connecting device comprising: a first metal member; a glass member, wherein the glass member forms a glass to metal seal with a first portion of the first metal member and wherein a second portion of the first metal member is exposed from one side of the glass member and a third portion of the first metal member is exposed from the opposite side of the glass member; a metal body comprising a hole with a rounded cross-section, wherein the glass member is located inside the hole and forms a glass to metal seal with an inner surface of the hole; a first Ethernet connector component positioned a first side of the glass member and electrically connected to the first metal member; and a second Ethernet connector component positioned a second side of the glass member and electrically connected to the first metal member; a first abutment; and a second abutment located along the length of the connecting device closer to the second end of the connecting device than the first abutment; the connecting device assembly further comprising an outer tube and a locking member, the method comprising: welding the outer tube into the bulkhead; inserting the connecting device into the outer tube until the second abutment engages with an abutment on an inner surface of the outer tube preventing further insertion of the connecting device into the outer tube; attaching the locking member to the outer tube such that an abutment on the locking member engages with the first abutment, such that movement of the connecting device out of the outer tube is prevented.

The method of assembling the connecting device assembly may further comprise: positioning a locking plate such that one or more rotational lock features on the locking plate engage with one or more rotational locking features on the connecting device; attaching the locking plate to the locking member such that rotation of the locking member and the connecting device relative to each other is prevented.

BRIEF DESCRIPTION OF THE FIGURES

Figure 1 shows a schematic illustration of a cross-sectional view along the length of an assembly connecting device in accordance with an embodiment of the present invention, comprising a connecting device, an outer tube and a locking member;

Figure 2 shows a schematic illustration of an enlarged view of a first end of the assembly of Figure 1;

Figure 3 shows a schematic illustration of an enlarged view of a second end of the assembly of Figure 1;

Figure 4a shows a schematic illustration of the assembly of Figure 1 seen in an end on view from the first end;

Figure 4b shows a schematic illustration of the assembly of Figure 1 seen in an end on view from the second end;

Figure 5 shows a schematic illustration of the assembly of Figure 1 seen in a perspective view;

Figure 6a shows a schematic illustration of an end on view of a mating plug that is designed to mate with either end of the connecting device shown in Figure 1;

Figure 6b shows a schematic illustration of a side on view of the mating plug of Figure 6a;

Figure 7 shows a schematic illustration of a lengthwise cross-section through the middle of a perspective image of the connecting device in accordance with an embodiment of the present invention;

Figure 8a is a photograph of a connecting device in accordance with an embodiment of the present invention;

Figure 8b is a photograph of the connecting device shown in Figure 8a, in which the end piece and connector are connected to the rest of the connecting device;

Figure 9 shows a flow chart of a method of manufacturing a connecting device in accordance with an embodiment of the present invention;

Figure 10 shows a flow chart of a method of a method of assembling a connecting device assembly in a bulkhead in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

The illustrations of figures 1, 2, 3, 4a, 4b, 5, 6a and 6b are schematic illustrations which are representative of the connecting device, and are not intended as scale drawings of the device.

Figure 1 shows a schematic illustration of a cross-sectional view along the length of a connecting device assembly in accordance with an embodiment of the present invention, comprising a connecting device, an outer tube 21 and a locking member 47. The connecting device assembly provides an Ethernet connection through a bulkhead, such as a pressure bulkhead in a submarine for example, or a bulkhead intended to separate fluids including gases, water vapour or smoke in the case of fire. A submarine pressure bulkhead is a wall within the submarine designed to withstand a pressure difference. The pressure bulkhead is designed such that the pressure on one side of the bulkhead can be different to the pressure on the other side of the bulkhead.

The connecting device may also be designed to withstand a pressure difference. The connecting device can additionally or alternatively be designed to separate fluids including gases, or smoke in the case of fire on either side of the bulkhead.

When the connecting device assembly is assembled and installed, the outer tube 21 of the assembly is welded into a hole in the bulkhead. An end portion of the connecting device extends out from each side of the bulkhead. An RJ45 socket is attached to each end of the connecting device. A sealed electrical connection is provided through the connecting device, such that there is an electrical connection through a hermetic glass to metal seal between the RJ45 socket at one end of the connecting device and the RJ45 socket at the other end of the connecting device.

An Ethernet cable connected to a first device, such as a computer, can be connected to the RJ45 socket at one end of the connecting device. A second Ethernet cable connected to a second device, such as an Ethernet hub, can be connected to the RJ45 socket at the other end of the connecting device, such that there is a sealed Ethernet connection between the first device and the second device. The connecting device therefore enables building of LANs between devices which are located in different compartments of the vessel.

In an embodiment, the connecting device is able to withstand a pressure difference. In an embodiment, the connecting device is able to withstand a pressure difference of up to 20000 psi. In an embodiment, the connecting device is able to withstand a pressure difference of up to 40000 psi. The connecting device thus may provide an Ethernet connection between a device located in one compartment and a device located in another compartment which has a different pressure, without leakage of pressure through the connecting device.

In an embodiment, the connecting device is fluid or gas tight. Where fluid or gas is contained in one of the compartments, the connecting device is thus able to prevent leakage of fluid or gas between the compartments. For example, the connecting device may provide an Ethernet connection between a device located in one compartment containing smoke caused by a fire and a device located in another compartment, without leakage of smoke through the connecting device.

The connecting device comprises a first ledge and a second ledge 32. The first ledge 56 is an example of a first abutment. The second ledge is an example of a second abutment. The first ledge 56 is configured to abut against an abutment, for example the inner face 58, on the locking member 47. The second ledge 32 is configured to abut against an abutment, for example the ledge 34, on the inner surface of the outer tube 21. When the connecting device is installed, it is inserted into the outer tube 21, with the second end 2 being inserted first. The second ledge 32 abuts against the ledge 34 on the inner surface of the outer tube 21, preventing the connecting device from being inserted into the outer tube 21 past this point. The locking member 47 is then screwed onto the end of the outer tube 21 at the first end 4 of the connecting device, until the inner face 58 of the locking member 47 abuts against the first ledge 56. The connecting device is thus preventing from moving relative to the outer tube 21.

The connecting device is configured to be installed in a range of different bulkheads. For example, the connecting device can be installed within different bulkheads having a range of thicknesses. Thus it is not material to know the thickness of the bulkhead, but one skilled in the art would be able to select a length L of the outer tube 21 for a given bulkhead thickness.

Furthermore, a standard connecting device can be installed in different outer tubes 21, having a range of different lengths. This is because the locking member 47 has a continuous range of different locking positions. For example, the locking member 47 shown in Figure 1 screws onto the outer tube 21 until the inner face 58 of the locking member 47 abuts against the first ledge 56, at which point it is in the locking position. The amount by which the locking member 47 is screwed down onto the outer tube 21 when in the locking position varies depending on the relative dimensions of the connecting device and the outer tube 21. However, as the locking member 47 can screw down onto the outer tube 21 by a continuous range of amounts, i.e. any distance at which the screw threads on the locking member 47 and the outer tube 21 engage, a range of relative lengths of the outer tube 21 and parts of the connecting device can be accommodated. There may be constraints on the relative lengths of the parts of the connecting device and the outer tube 21. For example, the outer tube 21 may be required to be short enough to allow access to the metal tube 23 to attach the end piece 25 after the connecting device is inserted in the outer tube 21.

Furthermore, as the locking member 47 is removable, the connecting device can be installed from one side of the bulkhead. The connecting device can also be removed from the bulkhead and replaced, by unscrewing the locking member 47 and removing the connecting device from the outer tube 21. An alternative connecting device can then be inserted in the outer tube 21. The installation of the connecting device is thus simple and easily reversible, and can be done in the field.

The Ethernet connector component, in this case the RJ45 socket, attached to each end of the connecting device means that the connecting device assembly can be installed and assembled in the bulkhead without wiring. A connecting device of the design shown in Figure 1 has been pressure tested and demonstrated to withstand a pressure differential of greater than 50 bar without leakage. It has also been tested to 10Base-T Ethernet transmission standards.

The RJ45 sockets at each end of the connecting device are two-sided RJ45 sockets, each having an RJ45 socket facing out of the connecting device and an RJ45 socket internal to the connecting device. Two-sided RJ45 socket 1 is located at a first end 4 of the connecting device and two-sided RJ45 socket 3 is located at a second end 2 of the connecting device. Devices such as computers can be connected to the outward facing RJ45 sockets via a standard Ethernet cable having an RJ45 plug.

Inside the connecting device, the hermetic glass to metal seal is located in a metal body 29. The metal body 29 has a first face and a second face opposing the first face. The metal body 29 comprises the second ledge 32. The metal body may have a circular cross-section, and circular faces. One or more metal members 28 run through one or more holes having a rounded cross-section in the metal body 29. A rounded cross-section is a cross section that does not comprise any corners, for example a circular cross-section. The metal members 28 may be elongate metal members 28, for example pins. The metal members 28 are each surrounded by a glass member, such that they are insulated from the metal body 29. Alternatively, two or more metal members 28 may be surrounded by a single glass member. The glass member may be a glass sleeve, for example. The glass sleeve is fused to both the metal member 28 or metal members 28 and the inside surface of the hole, such that there is a hermetic glass to metal seal between the glass sleeve and the metal member 28 or metal members 28, and between the glass sleeve and the inside surface of the hole.

The metal members 28 extend out from either side of the metal body 29. On one side of the metal body 29, wires connect the ends of the metal members 28 to an RJ45 plug 13, which is mated with the internal socket of the two-sided RJ45 socket 1 at the first end of the connecting device. There is therefore an electrical connection between the outward facing RJ45 socket of two-sided RJ45 socket 1 and the metal members 28 in the glass to metal seal. RJ45 plug 13 is an example of a first Ethernet connector component. Alternatively, the wires can connect directly to a RJ45 socket for example, in which case the RJ45 socket is the first Ethernet connector component.

Similarly, on the other side of the metal body 29, wires connect the ends of the metal members 28 to a second RJ45 plug 15, which is mated with the internal RJ45 socket of two-sided RJ45 3 at the second end of the connecting device, such that there is an electrical connection between the second outward facing RJ45 socket of two-sided RJ45 socket 3 and the metal members 28 in the glass to metal seal. RJ45 plug 15 is a second Ethernet connector component. Alternatively, the wires can connect directly to a RJ45 socket for example, in which case the RJ45 socket is the second Ethernet connector component.

The first Ethernet connector component and second Ethernet connector component may be any 8P8C plug or socket suitable for Ethernet signals, for example RJ45 plugs or sockets, or any 4P4C plug or socket suitable for Ethernet signals, for example M12 plugs or sockets, for example.

The metal body 29, wires, RJ45 plugs and internal RJ45 sockets are encased inside the outer parts of the connecting device. The metal body 29 shown in Figure 1 is a circular metal disk located near the middle of the connecting device. In one embodiment, metal body 29 is made of stainless steel. In one embodiment, four holes penetrate through the metal body 29, from one face of the metal body 29 to the other. In one embodiment, eight holes penetrate through the metal body 29, from one face of the metal body 29 to the other. In an embodiment, the holes are cylindrical and have a circular cross-section. Cylindrical glass sealing holes are used in order to inhibit cracking of the glass, which would then not be leak tight. The holes are spaced apart from each other. A metal member 28 runs through each of the holes, extending out from both faces of metal body 29. Alternatively, two or more metal members 28 may run through a single hole. The metal members 28 may be metal pins for example. The metal members 28 may be cylindrical. In one embodiment, the metal members 28 are made of alloy 52, which is an iron nickel alloy. Alternatively, the metal members 28 may be any matched expansion iron nickel alloy, for example Alloy 48 or Alloy 50. In an alternative embodiment, the metal members 28 are copper conductors housed in alloy 52 tubes, which are suitable for high speed Ethernet. In an alternative embodiment, the metal members 28 are kovar in a titanium housing.

In one embodiment, the metal members 28 are 0.8mm in diameter. In one embodiment, the length of the metal members 28 is in the range of 20mm to 60mm. A middle portion of each metal member 28 is surrounded by a glass sleeve. In one embodiment, the glass sleeve is a cylindrical glass tube that fits around the metal member 28. In one embodiment, the glass sleeve is borosilicate glass. In one embodiment, the glass sleeve is 2mm in outer diameter. The glass sleeve surrounds the entire portion of the metal member 28 that runs through the hole in the metal body 29, such that the metal member 28 is electrically insulated from the metal body 29. One end portion of the metal member 28 is exposed from one side of the glass sleeve and the other end portion of the metal member 28 is exposed from the opposite side of the glass sleeve. The glass sleeve is fused to both the metal members 28 and the metal body 29, forming a hermetic glass to metal seal. The formation of the glass to metal seal will be described in more detail later.

In an alternative embodiment, two or more metal members 28 are located in a single hole in the metal body 29. The glass sleeve corresponding to the hole in the metal body 29 surrounds a middle portion of the two or more metal members 28. Each metal member 28 runs through a different location in the glass sleeve such that the metal members 28 are spaced apart from each other, with the glass material between the metal members 28. The glass forms a glass to metal seal with each of the two or more metal members 28. For example, there may be a single hole in the metal body 29, comprising a glass sleeve with four metal members 28 running through.

Soldered joints connect wire conductors to the ends of each of the metal members 28, such that there is an electrical contact between the wire and the metal member 28. The other ends of the wires connect to one of the conductive contacts in RJ45 plug 13 or RJ45 plug 15. The wires connecting the metal members 28 to the RJ45 plug are formed into a single cable. One end of each of the wires in cable 17 connects to one of the metal members 28 extending out of the middle section 29. The other end of each of the wires in cable 17 connects to one of the conductive contacts in RJ45 plug 13. One end of each of the wires in cable 19 connects to one of the metal members 28 extending out of the middle section 29. The other end of each of the wires in cable 19 connects to one of the conductive contacts in RJ45 plug 15. RJ45 plug 13 is mated with the internal socket of the two-sided RJ45 socket 1 and RJ45 plug 15 is mated with the internal socket of the two-sided RJ45 socket 3. An RJ45 plug has eight flat conducting contacts arranged linearly across one face of the plug. An RJ45 socket has eight conducting contacts suspended diagonally downwards from an inside face of the socket. On Ethernet connectors, only 4 off terminals in the RJ45 are used. The other 4 off terminals are used for Power Over Ethernet (PoE) applications, or High Speed Variants. When an RJ45 plug is mated with one of the RJ45 sockets, the contacts meet, causing an electrical connection. An RJ45 connector comprises an RJ45 plug and an RJ45 socket, and is an 8P8C un-keyed modular connector.

The connecting device comprises two cylindrical metal tubes. Metal tube 23 is attached to one face of metal body 29 at one end by an electron beam welded connection. Two-sided RJ45 socket 3 is attached to the other end of metal tube 23. The RJ45 plug 15 and attached wires are located inside metal tube 23. Metal tube 37 is attached to the opposite face of metal body 29 at one end by an electron beam welded connection. Two-sided RJ45 socket 1 is attached to the other end of metal tube 37. The RJ45 plug 13 and attached wires are located inside of metal tube 37. The outer tube 21 surrounds a portion of metal tube 23, a portion of metal tube 37 and metal body 29. When installed, an end portion of metal tube 23 at the second end of the connecting device extends out of outer tube 21 and an end portion of metal tube 37 at the first end of the connecting device extends out of the other end of outer tube 21.

Metal tube 23 is attached to the face of the metal body 29 to which cable 19 is connected. Metal tube 23 is a cylindrical tube. Metal tube 23 may be, for example, titanium or hastalloy, depending on the bulkhead material. Cable 19 is located inside metal tube 23. The face of metal body 29 facing towards the second end 2 of the connecting device comprises a raised circular ring 30. The outer diameter of the raised circular ring 30 is smaller than the diameter of the outer edge of metal body 29. The portion of the face of metal body 29 which is outside of the raised circular ring 30 forms the second ledge 32. When installed, the second ledge 32 abuts against the ledge 34 on the inner surface of the outer tube 21. The raised circular ring 30 has substantially the same inner and outer diameter as the walls of metal tube 23. There is a step on the top surface of the raised circular ring 30, i.e. the surface substantially parallel to the face of the metal body 29, which runs around the top surface of the ring 30. The top surface of the ring 30 therefore comprises a part with a first height above the face of the metal body 29, forming an inner part of the ring, and a part with a second height above the face of the metal body 29 that is less than the first height, forming an outer part of the ring. A step runs around the ring-shaped end face of metal tube 23 which is connected to metal body 29. The end surface therefore comprises a first part, forming an inner ring, and a second part that extends further than the first part, forming an outer ring. The step on the end face of metal tube 23 locates with the step on the raised ring 30, such that the inner ring on the metal body 29 locates inside the outer ring on the end surface of the metal tube 23.

Metal tube 37 may be, for example, titanium or hastalloy, depending on the bulkhead material. Metal tube 37 has an outer diameter that is substantially equal to the diameter of the outermost edge of metal body 29. Thus the part of the connecting device between the second ledge 32 and the first end 4 of the connecting device, which comprises the metal tube 37, has a larger outer diameter than the part of the connecting device between the second ledge 32 and the second end 2 of the connecting device, which comprises the metal tube 23. In one embodiment, the outer diameter of the metal tube 37 is 37.80 mm. Metal tube 37 fits onto the face of the metal body 29 which faces towards the first end 4 of the connecting device. Cable 17 is located inside metal tube 37. A step runs around the end surface of metal tube 37. The end surface therefore comprises a first part, forming an inner ring, and a second part that extends further than the first part, forming an outer ring. There is a step 33 in the outer edge of metal body 29, such that the face of the metal body 29 has a raised circular middle portion. The step in metal tube 37 locates with this step 33 such that the outer ring on the metal tube 37 locates outside the raised circular middle portion of metal body 29.

Metal tube 37 comprises the first ledge 56. The first ledge 56 comprises a step change in the outer diameter of the metal tube 37, such that the part of metal tube 37 closest to the first end 4 of the connecting device has a smaller outer diameter. The direction normal to the surface of the first ledge 56 is in the direction from the metal body 29 towards the first end 4 of the connecting device. The direction normal to the surface of the second ledge 32 is in the direction from the metal body 29 towards the second end 2 of the connecting device. The surface of the first ledge 56 therefore faces in the opposite direction to the surface of the second ledge 32. In an alternative embodiment, the first abutment comprises the end face of the metal tube 37.

The first abutment and second abutment may alternatively comprise one or more protruding members, which protrude from the outer surface of the connecting device. These protruding members may be configured to engage with an end of one or more grooves in the inner surface of the outer tube 21. Alternatively, the first and second abutment may comprise one or more grooves in the surface of the connecting device. The grooves may be configured to engage with one or more protruding members on the inner surface of the outer tube 21.

Potting compound encapsulates the soldered joints where the wires attach to the metal members 28 extending out of the metal body 29, on both sides. Potting compound blocks fill the ends of the metal tubes 23 and 37 past the height of the metal members 28, such that they cover the soldered joints. The wires extend out of the potting compound blocks. Block 31 of potting compound encapsulates the joints inside metal tube 23. A second block of potting compound, block 39, encapsulates the joints inside metal tube 37.

The assembly further comprises outer tube 21, which surrounds a portion of metal tube 23, metal tube 37 and metal body 29 of the connecting device. In an embodiment, outer tube 21 is stainless steel. When installing the device, the outer tube 21 is welded to the submarine bulkhead, providing a housing for the connecting device, which is sealed by O- rings to the outer surface of metal tube 37. The arrangement of the outer tube 21 in this embodiment enables the device to be installed into a pre-existing cable gland on the bulkhead. In some embodiments therefore, a different outer housing is used, to enable the device to be installed in a different location. In some embodiments, there is no outer housing and the connecting device is welded directly to the bulkhead.

The length of outer tube 21 is indicated by the arrow labelled L in Figure 1. The outer tube 21 is cylindrical. In one embodiment, the outer diameter of outer tube 21 is 48.50 mm. When the connecting device is installed in a submarine bulkhead, outer tube 21 encloses the portion of the connecting device located inside the hole in the bulkhead. A first part of outer tube 21 has a smaller wall thickness and larger inner diameter than the second part of outer tube 21. The inner diameter of the second part of the outer tube 21 is configured such that the metal tube 37 fits inside such that the outer surface of the metal tube 37 contacts the inner surface of the second part of the outer tube 21 and the metal tube 37 can slide inside the outer tube 21. The inner diameter of the first part of the outer tube 21 is configured such that the metal tube 23 fits inside such that the outer surface of the metal tube 23 contacts the inner surface of the first part of the outer tube 21 and the metal tube 23 can slide inside the outer tube 21. The second part of outer tube 21 is the end proximal to RJ45 socket 3. There is a step, or ledge 34, in the inner surface of the outer tube 21 between the first part and the second part. The direction normal to the surface of the ledge 34 is in the direction from the second part of the outer tube 21 to the first part of the outer tube 21, parallel to the lengthwise axis of the outer tube 21. When the connecting device is installed in the outer tube 21, the step, or ledge 34, abuts the portion of the face of the metal body 29 outside raised ring 34 and facing the second end 2 of the connecting device. The face of the metal body 29 contacts the step or ledge surface of the outer tube 21. The outer edge of the metal body 29 contacts the inner surface of the first part of outer tube 21.

When installed, a first part of metal tube 23 is located inside the second part of the outer tube 21, with the lengthwise axis of outer tube 21 being substantially parallel to the lengthwise axis of metal tube 23. The outer surface of metal tube 23 contacts the inner surface of outer tube 21. A second part of metal tube 23 has a wall thickness which is less than that of the first part and an outer diameter that is less than that of the first part. The second part of metal tube 23 extends out of outer tube 21. There may be a step in the outer surface of the metal tube 23 between the first and second part. The location of the step coincides with the end of outer tube 21. In one embodiment, the outer diameter of the first part of metal tube 23 is 25.30 mm.

At the second end 2 of the connecting device, RJ45 socket 3 sits inside socket housing 24 and is connected to the end of metal tube 23 by an end piece 25 and a connector 27. The end piece 25 and socket housing 24 are connected to the end of metal tube 23 by the connector 27. This connection is made after the connecting device has been inserted in outer tube 21. This connection is described in more detail later. End piece 25 is a metal tube connected to the end of metal tube 23, the lengthwise direction of end piece 25 being substantially parallel to the lengthwise direction of metal tube 23. Two-sided RJ45 socket 3 is located in a first part of end piece 25 which has an increased inner and outer diameter compared with the second part of the end piece 25. There is a step in the outer surface of end piece 25 between the first and second part. The inner surface of the second part of end piece 25 is substantially parallel to the lengthwise direction. The inner surface of end piece 25 between the first part and the second part forms a cone shape, with the smaller diameter end of the cone being at the second part. The inner surface of the end piece 25 at the larger diameter end of the cone forms a shelf section, in which the inner surface is perpendicular to the lengthwise direction. The inner diameter of end piece 25 is increased at this location. The end piece 25 therefore forms a cup shape, in which the socket housing 24 and the two-sided RJ45 socket 3 is located.

The two ends of the connecting device shown in Figure 1 have different configurations in order to facilitate the installation of the connecting device into the submarine bulkhead from one side. In other embodiments, the ends of the connecting device may both have the same configuration.

At the first end of the connecting device, two-sided RJ45 socket 1 sits inside socket housing 49 which is connected to the end of metal tube 37. This connection will also be described in more detail below.

Locking member 47 is attached to outer tube 21 at the first end 4 of the connecting device by a screw connection. The assembly also comprises a locking plate 48. Locking member 47 has a lower cylindrical part, with the screw thread on the inner surface of the cylindrical part. Outer tube 21 has a ring shaped groove 45 in the outer surface, and a screw thread in the outer surface of outer tube 21 between groove 45 and the end of the outer tube 21. The ring shaped groove 45 is a locking mechanism to prevent the locking member 47 from unscrewing. The longer the length of the locking member 47, the greater the range of outer tube lengths to which the connecting device will fit. However, the length of the locking member 47 should not be too long, as it must fit between the bulkhead and the first end 4 of the connecting device.

Locking member 47 prevents the connecting device from moving out of the outer tube 21 from the first end 4. The locking member 47 is attached to outer tube 21 by a screw connection. The inner face of the locking member 47 contacts against the first ledge 56 in the surface of metal tube 37. The step or ledge 34 in the inner surface of outer tube 21 prevents the connecting device from moving out of the outer tube 21 from the second end 2. The step or ledge 34 contacts against the surface of metal body 29 outside the raised ring 34, meaning that the connecting device is effectively locked into place with respect to the outer tube 21.

In an embodiment, metal tube 37 has two incremental steps in the outer surface at the end proximal to the first end of the connecting device, where the outer diameter decreases, forming two ledges in the outer surface of metal tube 37: the first ledge 56 and a third ledge 55. The underside, or inner face of the top part of locking member 47 contacts the ledge furthest from the end of metal tube 37, i.e. the first ledge 56. The underside, or inner face, of the top part of the locking member 47 does not contact the end face of the outer tube 21.

Figure 2 shows a schematic illustration of an enlarged view of the first end of the assembly of Figure 1, comprising two-sided RJ45 socket 1. Where the same features are shown, like reference numerals have been used as for Figure 1. The screw connection between locking member 47 and outer tube 21 is labelled 53. Locking plate 57 is attached to the top face, i.e. that facing away from metal body 29, of the top part, i.e. the part furthest from metal body 29, of the locking member 47 by M3 screws, for example by six M3 screws. Other connection means are possible. Locking plate 57 has approximately the same inner diameter and a smaller outer diameter as the top part of locking member 47. M3 screws 59 and 61 are shown in the figure. A number of indented portions, such as indented portion 51 shown in the figure, are cut down into the surface of the third ledge 55 in metal tube 37, i.e. the ledge closest to the first end of metal tube 37. These indented portions 51 are U-shaped, and also cut into the outer surface of metal tube 37 such that the thickness of the metal tube 37 is decreased in the indented portion. The indented portions 51 are examples of rotational lock features on the metal tube 37 of the connecting device. Corresponding indents are cut into the inner surface of locking plate 57. These indents are examples of rotational lock features on the locking plate 57. The locking plate is positioned such that the indented portions 51 on the metal tube 37 engage with the sections between the indented portions on the locking plate 57. The screws fix the locking plate 57 into this position, preventing the locking member 47 from rotating and thus unscrewing once installed.

An O-ring on the outer surface of metal tube 37 is configured to form a seal against the outer tube 21. In an embodiment there are two O-rings located in two grooves in the outer surface of metal tube 37, in order to provide a redundant seal. As shown in Figure 2, there are two grooves which have a rectangular cross section in the outer surface of metal tube 37, which form rings around the tube. A first ring is located approximately midway along the tube. A second ring is located between the first ring and the first end of the metal tube 37, i.e. the end proximal to two-sided RJ45 socket 1. A first O-ring 41 is located in the first ring and a second O-ring 43 is located in the second ring. The outer surface of metal tube 37 contacts the inner surface of the second part of outer tube 21. The first O-ring 41 and second O-ring 43 form a seal against the inner surface of outer tube 21.

Socket housing 49 houses the two-sided RJ45 socket 1 and sits inside the end of metal tube 37. Socket housing 49 is a metal cylinder. The outer surface of socket housing 49 contacts the inner surface of metal tube 37. A raised ring 63 running around the outer surface of socket housing 49 locates against the end face of metal tube 37, preventing socket housing 49 from moving further inside metal tube 37. There is a second raised ring 65 on the inner surface of socket housing 49, at approximately the same location. The surface of this raised ring 65 contacts the two-sided RJ45 socket 1. An O-ring 67 sits on the outer face of the raised ring, i.e. the face that faces out of the connecting device away from the metal body 29.

Figure 3 shows a schematic illustration of an enlarged view of the second end of the assembly of Figure 1 with two-sided RJ45 socket 3. Where the same features are shown, like reference numerals have been used as for Figure 1. Socket housing 24 houses the two-sided RJ45 socket 3 and sits inside the end piece 25. Socket housing 24 is the same as socket housing 49. The raised ring 69 on the outer surface of socket housing 24 locates against the end face of end piece 25. A step 71 is cut into the outer surface of end piece 25 at a location close to the end furthest from the metal body 29.

Connector 27 connects end piece 25 to metal tube 23. This connection is made after the connecting device has been inserted into the outer tube 21. Connector 27 is a metal tube that is located around the outside of metal tube 23. Connector 27 is connected to metal tube 23 by the screw connection. A screw thread 74 is cut into the outer surface of part of metal tube 23. A corresponding screw thread is cut into the inner surface of connector 27.

There is a raised ring 75 with a square profile around the outer surface of end piece 25. The underside, inner face of ring 75 contacts against the end face of metal tube 23. This prevents end piece 25 moving further into metal tube 23.

There is a grooved ring around the inside surface of connector 27. A washer 77 is located such that it sits inside the grooved ring and around the end piece 25. The washer 77 has an inner diameter that fits around the end piece 25. The washer 77 contacts against the upper, outer face of the ring 75. This prevents the end piece 25 from moving out of the connector 27.

There is a slot 79 in the end of metal tube 23, extended lengthwise down a portion of the metal tube 23. The slot does not extend to the location of the screw thread 74. A raised tab 81 on the outer surface of end piece 25 locates into the slot 79, such that the end piece 25 cannot rotate once screwed into position.

Figure 4a shows a schematic illustration of the assembly of Figure 1 seen in an end on view, from the first end 4. Where the same features are shown, like reference numerals have been used as for Figure 1. The line AA shows the line through which the cross-section view of Figure 1 is taken.

There is a rectangular indent in one face of the RJ45 socket (the lower face in the view shown in the figure). The lock-in tab on an RJ45 plug will locate in the rectangular indent when the plug is inserted into the socket. An indented socket 7 is surrounded by an outer portion 11, which has a circular shape seen in the end on view. Outer portion 11 is located inside socket housing 49, which seen in the end on view is a ring shape. There is a gap between socket housing 49 and outer portion 11. The socket housing 49 has five grooves in the inner surface. Groove 85 is larger than the other grooves and located opposite to the rectangular indent in the socket. The four smaller grooves are arranged on the opposite side to groove 85.

The indents around the inner surface of the locking plate 57 and the indented portions 51 in the metal tube 37 can be seen in this view. The top face, i.e. facing away from the metal body 29, of the locking plate 57 is shown. The six M3 screws that fix the locking plate to the locking member 47 are arranged at regular locations around the locking plate 57. Around the outside of locking plate 57, the outer edge of locking member 47 can be seen. There are six grooves in the outer surface of locking member 47. These grooves extend down the length of the locking member 47. The grooves are located approximately midway between the locations of the M3 screws used to screw the locking plate 57 into the locking member 47. The width of groove 83 is indicated with arrows. The grooves enable the locking member 47 to be held and turned in order that it can be screwed tightly onto the outer tube 21. The grooves enable a user or a tool to grip the locking member 47.

Figure 4b shows a schematic illustration of the assembly of Figure 1 seen in an end on view from the second end 2. Where the same features are shown, like reference numerals have been used as for Figure 1. The RJ45 socket has a rectangular indent in one face. The lock-in tab on an RJ45 plug locates in the rectangular indent when the plug is inserted into the socket. An indented socket 5 is surrounded by outer portion 9, which has a circular shape seen in the end on view. Outer portion 9 is located inside socket housing 24, which seen in the end on view is a ring shape. There is a gap between socket housing 24 and outer portion 9. The socket housing 24 has five grooves in the inner surface, in the same arrangement as for socket housing 49. End piece 25 is seen as a ring in the end on view and a portion of outer tube 21 can be seen around the outside.

Around the outside of the outer tube 21, the edge of locking member 47 can be seen. The six grooves in the outer surface of locking member 47 are also seen in this view.

Figure 5 shows a schematic illustration of the assembly of Figure 1 seen in a perspective view. Where the same features are shown, like reference numerals have been used as for Figure 1. Two-sided RJ45 socket 1 is shown on the far left side of the view, located inside socket housing 49. Socket housing 49 has three tabs spaced at equal distances around the outer surface. Tab 97 and tab 99 are shown in the figure. Socket housing 49 extends out of metal tube 37. Metal tube 37 extends from locking member 47. Locking member 47 is screwed onto outer tube 21. Locking plate 57 is fixed to the top face of locking member 47 with six M3 screws.

Metal tube 23 extends out of the opposite end of outer tube 21, and connector 27 is screwed onto metal tube 23. In this view, it can be seen that connector 27 has grooves in the outer surface, which extend along the length of the connector 27. The grooves enable the connector 27 to be held and turned in order that it can be screwed tightly onto the outer tube metal tube 23. The grooves enable a user or a tool to grip the connector 27. End piece 25 extends out of connector 27, and socket housing 24 extends out of end piece 25. Socket housing 24 has three tabs in the outer surface, spaced at equal distances around the outer surface. Two of these tabs are shown in the figure, tab 93 and tab 95.

Figure 6a shows a schematic illustration of an end on view of a mating plug that is designed to mate with either end of the connecting device shown in Figure 1. An RJ45 plug 101 is located in the centre of the mating plug. The RJ45 plug has a lock in tab 103 designed to fit in the rectangular indent in the indented portion of a RJ45 socket. The plug 101 can be inserted in indented socket 7 or indented socket 5 for example. Eight contacts 105 are arranged linearly on one face of the plug which is the upper face in the view shown. Each of these contacts 105 contact to one of the contacts in the RJ45 socket when plug and socket are mated. The plug is housed in plug housing 107. Plug housing 107 is a metal cylinder. The diameter of plug housing 107 is such that it can locate inside socket housing 49 or socket housing 24. Plug housing 107 has five tabs arranged around the outside surface. These tabs are arranged such that they can locate in the grooves in the inner surface of socket housing 49 or socket housing 24 when plug and socket are mated. Tab 109, which is located on the opposite side of the plug to lock in tab 103 is larger in size that the other four tabs, which are located on the same side of the plug to lock in tab 103. The plug housing 107 is housed in plug body 111.

Figure 6b shows a schematic illustration of a side on view of the mating plug of Figure 6a. Lock in tab 103 protrudes from RJ45 plug 101. Plug body 111 has a cylindrical shape, with the plug housing 109 located inside plug body 111. A cable 113 runs through the middle of the mating plug. The end portion of plug body 111 proximal to RJ45 plug 101 has a step in the outer surface, such that a first portion 113, which is located at the edge of the plug body 111 has a decreased outer diameter compared to a second portion 115. A third portion 117 of plug body 111 which abuts the second portion 115 has a decreased outer diameter compared to the first portion 113 and the second portion 115. A fourth potion 119 abuts the third portion 117 and has a decreased outer diameter and a decreased length compared to the third portion 119. A fifth portion 121 abuts the fourth portion 119 and has an increased outer diameter compared to the fourth potion 119 and a similar length as the fourth portion 119. The fifth portion 121 has a decreased outer diameter compared to the first portion 113 and the second portion 115 and the third portion 117. A sixth portion 123 abuts the fourth portion 121. The sixth portion 123 has approximately the same outer diameter as the third portion 111 and has a larger length than any of the other portions. The cable 113 extends out of the sixth portion 123.

Figure 7 shows a schematic illustration of a lengthwise cross-section through the middle of a perspective image of the connecting device in accordance with an embodiment of the present invention. The locking member 47 is also shown. Where the same feature is shown, like reference numerals have been used as for Figure 1. The outer tube 21 is not shown, and the locking member 47 is shown separated from the connecting device.

The six grooves in the outer surface of locking member 47 run lengthwise along the entire length of the locking member 47. The grooves have a rectangular profile. The screw thread in the inner surface of the locking member 47 allows it to be screwed onto the outer tube 21. The locking plate 57 is fixed onto the top face of locking member 47 with six M3 screws.

Two-sided RJ45 socket 1 is housed in socket housing 49 at the first end of the connecting device. The raised ring 65 on the inner surface of socket housing 49 contacts the two-sided RJ45 socket 1. On both sides of the raised ring 65 there is a gap between two-sided RJ45 socket 1 and socket housing 49. O-ring seal 67 is located on the face of raised ring 65 that faces out of the connecting device. Socket housing 49 is located inside an end of metal tube 37. The outer surface of the portion of socket housing 49 located inside metal tube 37 contacts the inner surface of metal tube 37. A raised ring 63 running around outer surface of socket housing 49 locates against the end face of metal tube 37.

The U-shaped indented portions 51 around the third ledge 55 are shown in the figure. The first, lower, ledge 56, which is located between the indented ledge 55 and the second O-ring 41 runs around the metal tube 37. The top portion of locking member 47 locates against this ledge when the locking member 47 is screwed down onto the outer tube 21. RJ45 plug 13 is mated with the inward facing socket of two-sided RJ45 socket 1. Cable 17 sits inside metal tube 37, and is connected to RJ45 plug 13.

The other end of cable 17 is soldered to the four metal members 28 that extend out of metal body 29. Metal body 29 is attached to the end of metal tube 37. A block of potting compound inside metal tube 37, sitting against metal body 29, surrounds the metal members 28 and soldered joints. The potting compound block 39 fills the end of metal tube 37. The metal members 28 run through holes in middle section 29. The metal members 28 are surrounded by glass, that is fused to the metal members 28 and the inside surfaces of the holes, insulating the metal members 28 from the middle section 29 and forming a hermetic glass to metal seal. The other ends of the metal members 28 extend out of the other side of middle section 29. The other ends of the metal members 28 are attached to cable 19 by soldered joints. Metal tube 23 is attached to metal body 29, and a potting compound block in the end of metal tube 23 surrounds the metal members 28 and soldered joints.

Cable 19 is connected to RJ45 plug 15, which is mated with the inward facing socket of two-sided RJ45 plug 3. Two-sided RJ45 plug 3 is located in socket housing 24. Socket housing 24 is the same as socket housing 49.

Grooves in the outer surface of connector 27 run lengthwise along the entire length of connector 27. The grooves have a rectangular cross-section. The grooves allow the connector 27 to be gripped and screwed tightly onto metal tube 37. The second portion of end piece 25 sits inside metal tube 23. There is a grooved ring in the outer surface of the second portion of end piece 25. The grooved ring is near the end of the end piece 25 that is located inside metal tube 23. An O-ring 113 sits inside the grooved ring. The outer surface of end piece 25 contacts the inner surface of metal tube 23.

Raised ring 75 contacts against the end face of metal tube 23 preventing end piece 25 moving further into metal tube 23. Washer 77 sits in the grooved ring in the inner surface of connector 27 and fits around end piece 25. The connector is attached to the metal tube 23 such that one face of the ring 75 contacts the end face of the metal tube 23 and the washer 77 contacts against the opposite face of the ring 75. This prevents the end piece 25 from moving out of the connector 27.

Figure 8a is a photograph of a connecting device in accordance with an embodiment of the present invention. The end piece 25 and connector 27 are also shown, disconnected from the rest of the connecting device. The locking member 47 is also shown, separated from the connecting device. Two mating plugs 115 and 117 are also shown in the figure.

When assembled, the connecting device as shown in Figure 8a is inserted into the outer tube 21. The locking member 47 is then attached to the outer tube 21. The end piece 25 is attached to the second end of the connecting device by the connector 27.

The second portion of end piece 25 is located inside connector 27. End piece 25 and connector 27 are stood on one end on a surface in the photo of Figure 8a, with the connector 27 at the bottom of the arrangement. Because the connector 27 is not screwed into the metal tube 23, the end piece 25 is free to move downwards through the connector 27. The first portion of end piece 25 is therefore positioned closer to the connector 27 in this arrangement than when the connector 27 is screwed onto the metal tube 23.

Cable 19 extends out of metal tube 23. RJ45 plug 15 is connected to the end of cable. When assembling, this cable will be guided inside end piece 25, and the RJ45 plug 15 plugged into the inward facing socket of two-sided RJ45 socket 3.

When the connecting device is fully positioned and assembled, the indented portions 51 on the metal tube 37 sit inside the locking member and are not visible from a side view. Because locking member 47 is not screwed onto the outer tube 21 in this view, the indented portions on the ledge 55 are visible. These indented portions lock with indented portions on the inside of locking plate 57 when the locking plate 57 is screwed into place, preventing locking member 47 from rotating and unscrewing.

Mating plugs 115 and 117 are shown without a cable 113 or an RJ45 plug 101.

Figure 8b is a photograph of the connecting device shown in Figure 8a, in which the end piece 25 and connector 27 are connected to the rest of the connecting device. The end of metal tube 23 is located in the gap between the connector 27 and the end piece 25, such that end piece 25 sits inside metal tube 23, and metal tube 23 sits inside connector 27. Connector 27 is attached to metal tube 23 by a screw connection, such that the raised ring 75 around the outer surface of end piece 25 contacts against the end of metal tube 23, preventing the connector from screwing down further. The washer 77 locates against the opposite surface of raised ring 75, preventing the end piece from falling out of the connector. The three pieces are therefore attached together such that there is no relative movement of the pieces.

Figure 9 shows a flow chart of a method of manufacturing a connecting device in accordance with an embodiment of the present invention.

The first step is S1: “form metal body with one or more rounded holes”. In one embodiment, four cylindrical holes with a circular cross-section are formed in metal body 29. The one or more rounded holes penetrate through the metal body 29 from on face to the other. The metal body 29 with one or more rounded holes may be formed by machining, for example drilling or milling. Alternatively, it can be formed by additive manufacturing, for example stereolithography.

The next step is S3 “Form glass into one or more preforms having one or more holes”. A glass powder is pressed into a preform. One or more glass preforms are made. The or each glass preform is rounded in shape and has one or more holes, each configured to accommodate a corresponding metal member 28. If two or more holes are formed in the preform, the holes are substantially parallel and spaced apart. The or each glass preform is configured to be positioned inside the corresponding rounded hole in the metal body 29.

The next step is S5 “Assemble metal body, glass and elongate metal member”. The or each metal member 28 is located in the hole or holes in the glass preform such that a middle portion of the metal member 28 is located inside the corresponding hole in the glass preform. An exposed portion of the metal member 28 is left either side of the glass preform. The glass preform is located in the hole in the metal body 29, such that the portion of each metal member 28 surrounded by the glass preform sits inside the hole in the metal body 29. The exposed portions of the metal member 28 extend out of the hole either side of the metal body 29. If there are two or more rounded holes in the metal body 29, each glass preform is located in the corresponding rounded hole in the metal body 29, each glass preform having a metal member 28 in the hole in the glass preform. The metal body 29 is then assembled onto a carbon fixture.

In step S7 “heat metal body in order to form glass to metal seals”, the metal body is heated, such that the glass material softens. In an embodiment, the metal body is heated in a furnace to above the softening point of the glass material. For example, it may be heated to a temperature in the range 850 to 1050 degrees Celsius. In an embodiment, it is heated to 940 degrees Celsius. The glass material fuses to an inside surface of the one or more holes formed in metal body 29 and to the outside surface of the one or more metal members 28. The bonding between the glass material and the metal materials occurs at the high temperature and is an oxide diffusion process. A chemical bond is formed between the glass and the metal, forming a seal. The arrangement is then allowed to cool down. As it cools, the metal body 29 shrinks and forms a compression seal with the glass. The co-efficient of thermal expansion of the metal body 29 is higher than that of the glass. This means that as it cools, the metal body contracts around the glass, putting the glass into compression and further strengthening the seal. In an embodiment, the metal body is stainless steel having a coefficient of thermal expansion of substantially equal to 13x1 O'6 K'1. In an embodiment, the glass sleeve is borosilicate glass having a coefficient of thermal expansion of substantially equal to 9x1 O'6 K'1. In an embodiment, the metal member is Kovar having a coefficient of thermal expansion of 3 to 4 x10'6 K'1.The glass therefore forms a glass to seal with the metal member 28 and with an inside surface of the hole.

The next step is step S9 “solder wire to each end of each metal member”. Once the metal body 29 with the glass to metal seals is manufactured, wire conductors are soldered to the exposed portions of each metal member 28. The conductors may be formed into a single cable.

In step S11 “electron beam weld metal tubes to either side of metal body”, metal tube 23 and metal tube 37 are electron beam welded to the metal body 29. The top surface of the raised ring 30 on the face of metal body 29 is electron beam welded to the end face of metal tube 23. The opposite face of metal body 29 is electron beam welded to the end surface of metal tube 37.

The wires or cables are run through the insides of the metal tubes. In step S13 “applying potting compound around metal members”, potting compound is applied around the metal members 28 such that the potting compound fills the ends of the tubes past the height of the metal members 28. The wires or cable extend out of the potting compound. The potting compound is set until hardened. The potting compound is applied in order to cover and protect the soldered joints.

In step S15 “connect ends of wires to RJ45 plug”, the other ends of the wires or cable are connected to an RJ45 plug.

The connecting device manufactured using the method described in relation to Figure 9 is shown in Figure 8a.

The method of assembling the assembly including the connecting device, the outer tube 21 and the locking member 47 will now be described.

During the assembly process, the connecting device is installed in the bulkhead from one side. Figure 10 shows a flow chart of a method of a method of assembling a connecting device assembly in a bulkhead in accordance with an embodiment of the present invention. The connecting device may be manufactured as described in relation to Figure 9.

In step S21, the outer tube 21 is welded into a hole in the bulkhead. The hole may be an existing cable gland for example.

In step S23, the connecting device is inserted into the outer tube 21. The second end 2 of the connecting device is inserted first into the outer tube 21. The connecting device is pushed into the outer tube 21 until the second abutment on the connecting device abuts an abutment on an inner surface of the outer tube 21. For example, for the connecting device shown in Figure 1, the connecting device is pushed into the outer tube 21 until the second ledge 32 engages, or abuts, the ledge 34 on the inner surface of the outer tube 21, preventing the connecting device from being inserted into the outer tube 21 past this point.

In step S25, the locking member is screwed onto the outer tube 21 at the first end 4 of the connecting device, until it abuts against the first abutment. For example, the locking member 47 is screwed onto the connecting device shown in Figure 1 until the underside, inner face of the locking member 47 abuts the first ledge 56.

In step S27, the locking plate 57 is located on the locking member such that the rotational locking features on the locking plate engage with the rotational locking features on the connecting device. For example, for the connecting device shown in Figure 1, the locking plate 57 is placed on the outer face of the locking member 47, and rotated until the indented portions 51 on the metal tube 37 engage with the sections between the indented portions on the locking plate 57.

In step S29, the locking plate 57 is attached to the locking member. For example, for the connecting device shown in Figure 1, the locking plate 57 is attached to the locking member 47 by 6 M3 screws, which are screwed through the locking plate 57 into the locking member 47. This prevents the locking member 47 from rotating relative to the metal tube 37, and thus prevents it from unscrewing once in position.

Further assembly steps can be performed. For example, for the feedhtrough shown in Figure 1, the socket housing 49 housing the two-sided RJ45 socket 1 is located inside the end of metal tube 37 before the locking member 47 is screwed on. The RJ45 plug 13 is connected to the inner socket of two-sided RJ45 socket 1. The socket housing 49 is then inserted into metal tube 37 until a raised ring 63 running around the outer surface of socket housing 49 locates against the end face of metal tube 37, preventing socket housing 49 from moving further inside metal tube 37.

For the connecting device shown in Figure 1, the end piece 25 is attached to the connecting device at a stage after the connecting device has been inserted in the outer tube 21. The RJ45 plug 15 is connected to the inner RJ45 socket of two-sided RJ45 socket 3. The end piece 25 is inserted into the end of metal tube 23 until the raised ring 75 around the outer surface of end piece 25 contacts against the end face of metal tube 23 preventing end piece 25 moving further into metal tube 23. The connector 27, which sits around the outside of end piece 25, locates around the outside of metal tube 23 as the end piece 25 is inserted. The raised tab 81 on the outer surface of end piece 25 locates into the slot 79 in metal tube 23 as the end piece 25 is inserted.

Connector 27 is then screwed onto metal tube 23 by the screw connection until the washer 77 located inside the grooved ring in the inner surface of the connector 27 contacts against the outer face of the ring 75 on the end piece 25. This prevents the end piece 25 from moving out of the connector 27, and thus prevents it from moving out of the metal tube 23.

Claims

CLAIMS:

1. An Ethernet connecting device comprising: a first metal member; a glass member, wherein the glass member forms a glass to metal seal with a first portion of the first metal member and wherein a second portion of the first metal member is exposed from one side of the glass member and a third portion of the first metal member is exposed from the opposite side of the glass member; a metal body comprising a hole with a rounded cross-section, wherein the glass member is located inside the hole and forms a glass to metal seal with an inner surface of the hole; a first Ethernet connector component positioned a first side of the glass member and electrically connected to the first metal member; a second Ethernet connector component positioned a second side of the glass member and electrically connected to the first metal member.

2. The Ethernet connecting device according to claim 1, wherein the glass member surrounds the first metal member over a portion of the length of the first metal member.

3. The Ethernet connecting device according to claim 1, wherein the first metal member comprises an Iron Nickel alloy.

4. The Ethernet connecting device according to claim 1, further comprising: a second metal member, a third metal member and a fourth metal member, wherein the first Ethernet connector component is electrically connected to each of the second metal member, third metal member and fourth metal member and the second Ethernet connector component is electrically connected to each of the second metal member, third metal member and fourth metal member.

5. The Ethernet connecting device according to claim 4, further comprising a second glass member, wherein the second glass member forms a glass to metal seal with a first portion of the second metal member and wherein a second portion of the second metal member is exposed from one side of the second glass member and a third portion of the second metal member is exposed from the opposite side of the second glass member; a third glass member, wherein the third glass member forms a glass to metal seal with a first portion of the third metal member and wherein a second portion of the third metal member is exposed from one side of the third glass member and a third portion of the third metal member is exposed from the opposite side of the third glass member; a fourth glass member, wherein the fourth glass member forms a glass to metal seal with a first portion of the fourth metal member and wherein a second portion of the fourth metal member is exposed from one side of the fourth glass member and a third portion of the fourth metal member is exposed from the opposite side of the fourth glass member; and wherein the metal body comprises: a second hole with a rounded cross-section, wherein the second glass member is located inside the second hole and forms a glass to metal seal with an inner surface of the second hole; a third hole with a rounded cross-section, wherein the third glass member is located inside the third hole and forms a glass to metal seal with an inner surface of the third hole; a fourth hole with a rounded cross-section, wherein the fourth glass member is located inside the fourth hole and forms a glass to metal seal with an inner surface of the fourth hole.

6. The Ethernet connecting device according to claim 4, wherein the glass member forms a glass to metal seal with a first portion of the second metal member and wherein a second portion of the second metal member is exposed from one side of the glass member and a third portion of the second metal member is exposed from the opposite side of the glass member, and wherein the glass member forms a glass to metal seal with a first portion of the third metal member and wherein a second portion of the third metal member is exposed from one side of the glass member and a third portion of the third metal member is exposed from the opposite side of the glass member, and wherein the glass member forms a glass to metal seal with a first portion of the fourth metal member and wherein a second portion of the fourth metal member is exposed from one side of the glass member and a third portion of the fourth metal member is exposed from the opposite side of the glass member.

7. The Ethernet connecting device according to claim 1, wherein the connecting device has an elongated shape having a first end and a second end, the first end positioned the first side of the glass member and the second end positioned the second side of the glass member.

8. The Ethernet connecting device according to claim 7, further comprising: a first abutment; and a second abutment located along the length of the connecting device closer to the second end of the connecting device than the first abutment; wherein the first abutment and the second abutment face in opposite directions.

9. The Ethernet connecting device according to claim 8, wherein the first abutment faces in the direction from the glass to metal seal towards the first end of the connecting device and the second abutment faces along the direction from the glass to metal seal towards the second end of the connecting device

10. The Ethernet connecting device according to claim 9, wherein the second end of the connecting device is configured to be inserted inside an outer tube, and wherein the second abutment is configured to engage with an abutment on an inner surface of the outer tube, preventing further insertion of the connecting device into the outer tube.

11. The Ethernet connecting device according to claim 10, wherein the first abutment is configured to engage with a locking member which attaches to the outer tube, such that movement of the connecting device out of the outer tube is prevented.

12. An assembly comprising the connecting device of claim 10, and further comprising the outer tube.

13. The assembly of claim 12, further comprising: a locking member configured to attach to the outer tube and comprising an abutment configured to engage with the first abutment, such that movement of the connecting device out of the outer tube is prevented.

14. The assembly of claim 13, wherein the locking member is configured to screw onto the outer tube.

15. The assembly of claim 14, further comprising: a locking plate comprising one or more rotational locking features configured to engage with one or more rotational locking features on the connecting device, and configured to attach to the locking member such that rotation of the locking member and the connecting device relative to each other is prevented.

16. The assembly of claim 15, wherein the locking plate is attached to the locking member by one or more screws.

17. A bulkhead, comprising the assembly according to any of claims 12 to 16.

18. A method of manufacturing an Ethernet connecting device, comprising: forming a glass member having at least one hole; arranging a first metal member inside the hole in the glass member such that a first portion of the first metal member is inside the hole, a second portion of the first metal member is exposed from one side of the glass member and a third portion of the first metal member is exposed from the opposite side of the glass member; arranging the glass member in a hole in a metal body, the hole having a rounded cross-section; heating the metal body in order to form a glass to metal seal between the glass member and an inner surface of the hole; positioning a first 8P8C connector component on one side of the glass member and a second 8P8C connector component on the opposite side of the glass member; electrically connecting the first 8P8C connector component to the first metal member and the second 8P8C connector component to the first metal member.

19. A method of assembling a connecting device assembly in a bulkhead, the connecting device assembly comprising an Ethernet connector connecting device comprising: a first metal member; a glass member, wherein the glass member forms a glass to metal seal with a first portion of the first metal member and wherein a second portion of the first metal member is exposed from one side of the glass member and a third portion of the first metal member is exposed from the opposite side of the glass member; a metal body comprising a hole with a rounded cross-section, wherein the glass member is located inside the hole and forms a glass to metal seal with an inner surface of the hole; a first Ethernet connector component positioned a first side of the glass member and electrically connected to the first metal member; and a second Ethernet connector component positioned a second side of the glass member and electrically connected to the first metal member; a first abutment; and a second abutment located along the length of the connecting device closer to the second end of the connecting device than the first abutment; the connecting device assembly further comprising an outer tube and a locking member, the method comprising: welding the outer tube into the bulkhead; inserting the connecting device into the outer tube until the second abutment engages with an abutment on an inner surface of the outer tube preventing further insertion of the connecting device into the outer tube; attaching the locking member to the outer tube such that an abutment on the locking member engages with the first abutment, such that movement of the connecting device out of the outer tube is prevented.

20. The method of assembling a connecting device assembly according to claim 19, further comprising: positioning a locking plate such that one or more rotational lock features on the locking plate engage with one or more rotational locking features on the connecting device; attaching the locking plate to the locking member such that rotation of the locking member and the connecting device relative to each other is prevented.