GB2580376A

GB2580376A - Electrical Connector

Info

Publication number: GB2580376A
Application number: GB1900200.5A
Authority: GB
Inventors: De Laszlo Damon; Flower Scott; McGowan Fraser; Plested Mark
Original assignee: Harwin PLC
Current assignee: Harwin PLC
Priority date: 2019-01-07
Filing date: 2019-01-07
Publication date: 2020-07-22

Abstract

A genderless electrical connector 10 comprises a pin 12 from which opposing first 14 and second 16 legs extend in the axial direction, parallel to each other, and spaced apart in the radial direction. The legs comprise a distal end 18, a proximal end 20, and a main portion 22 extending between the ends. Each leg comprises an outermost contact surface, which in use is brought into contact to matingly engage with the legs of an identical genderless electrical connector 10. The contact surface of the legs has a rough, non-polished finish. The rough finish of the contact surface may comprise microscopic peaks and troughs, the height of a peak preferably being one nanometre. A genderless electrical connector comprising a pin and opposing first and second legs, in which the distal end comprises a rounded face which slopes radially inward, is also provided. The connector may comprise a collar 30 having a planar face 32. The pin may be a crimp barrel (34, Figure 3).

Description

GENDERLESS ELECTRICAL CONNECTOR

The present invention relates to a genderless or hermaphroditic contact element for electrical contact with an identical hermaphroditic contact element.

Hermaphroditic contact elements are well known. They comprise surfaces with male and female aspects, i.e. both protrusions and indentations, arranged such that two identical hermaphroditic contact elements can be brought together to matingly engage. A hermaphroditic connector, as the name suggests, is genderless and does not require a male or female equivalent to connect to. Genderless connectors are typically easier and quicker to connect together than male-to-female connectors because they are simpler to pair up, and are very useful when lengthy or heavy components or cables must be connected because a component with a genderless connector at either end will not have a "wrong end" that cannot be connected.

EP 1 965 470 discloses the genderless electrical connector shown in the appended Figure 1. This typical genderless electrical connector comprises a substantially tubular body 1 which is hollow at one end 2 and has two opposite and parallel legs 3 at the opposing end 4 extending in a "tuning fork" manner.

The hollow end 2 of the body 1 is arranged to receive the stripped portion of an insulated wire carrying a current such that the current can pass from the stripped wire to the legs 3 of the genderless contact element. The legs 3 of the genderless contact element are conically shaped such that they can be slid into contact to matingly-engage and form a friction-tight fit with the legs of an identical genderless contact element.

Numerous disadvantages exist, however, in the field of genderless electrical connectors.

A key concern when designing a genderless connector is the balance between ease of use, reliability, power-rating and size.

There is inevitably a trade-off between having a strong contact force which holds two genderless connectors together and there being a useable mating-force, i.e. the legs of a connector being suitably pliable such that two genderless 5 connectors can be pushed together easily.

Contact legs retained by the tuning fork design discussed above may have rough surfaces as a result of manufacturing said legs by shearing during die stamping. The contact forces of the two opposing legs are typically sheared edges of material produced during a stamping operation and therefore have a comparatively rough surface finish. Prior art in this field, such as US 5,980,337, concludes that the interface between rough contact surfaces creates a poor electrical contact and an increased possibility of damage during repeated mating cycles. It is taught in the prior art that the contact surface should be smooth.

There is also inevitably a trade-off between the size of legs, and thus the surface area, of the contact faces of two connected genderless connectors, and the amount of electrical power such a connector can reliably transmit. A small connector will have a lower power rating than compared to a larger connector.

Smaller connectors can improve their power ratings for their size by utilising a larger number of connector legs to thus increase the surface area of the contact faces, but this leads to an increase in mating-force (i.e. the force required to push two genderless connectors together into electrical contact).

It is known that the shape and profile of the legs of a connector determine the ease with which a pair of connectors can be fastened together. For example, a shallow slope gradient of the leading face of a connector leg will make it relatively easy to push two opposing connector legs over each other and into electrical contact. However, a shallow leading gradient may compromise the force from the resilient deformable connector legs which holds two mated connectors together. A low contact force results in a poor electrical connection which is not reliable and which cannot transmit a high power.

The present invention addresses these known problems by providing a genderless connector design which is highly reliably in severe environments, manufacturable on a miniature scale, and of a shape that provides low electrical contact resistance with a high power rating and with useable and reliable contact force and mating force.

According to the present invention, there is provided a genderless connector as defined in the appended independent apparatus claims. Further preferable 10 features of the connector of the present invention are defined in the appended dependent apparatus claims.

The rough, non-polished contact surface of the legs results in many microscopic contact points in the form of peaks and troughs. As such, the surface area of the contact surface is greater than compared to the surface area of an identically shaped leg with a smooth, polished surface finish. It has been found that a rough, non-polished finish to the contact surface of the legs wherein the peaks and troughs of said rough surface are on a microscopic scale improves the power-rating of the leg when compared to a similarly shaped leg with a smooth surface finish. This is in contradiction to that taught in US 5,980,337 discussed above and so can be considered a surprising effect.

Preferably the height of a peak is approximately 1x10^-9 metres.

Further preferably, the peaks and troughs that comprise the rough surface may be formed by machining marks made during manufacture of the electrical connector. There is no need to remove machining marks and polish the contact surface of the connector legs as may have been previously thought. Thus the manufacture of the present invention is quicker and cheaper than known connectors. The number of contact points on the surface of the connector is increased. These points of contact then, in use, mate with the surfaces of another, identical, genderless connector. The high number of contact points enables a high power rating for the connector and boosts data transfer speeds.

The distal end of the first and second legs of the electrical connector may 5 comprise a rounded face which slopes radially inward. This sloped and rounded lead-in face enables a smooth and easy sliding of one connector according to the present invention over another.

Advantageously, the proximal end of the first and second legs comprises a 10 complementarily rounded and sloped face such that, in use, the distal end of an identical genderless electrical connector can be brought into electrical contact therewith and matingly engage thereto.

Furthermore, the slope extends from the radially outermost surface of the first 15 and second legs such that the leading edge of the first and second legs is a rounded wedge portion. The rounded wedge portion reduces initial mating force as the lead-in is multi directional (i.e. both axial and radial).

The main portion of the first and second legs may comprise a radially inward sloping face. To ensure that all contact points on the surfaces have sufficient contact force at all times, the interference fit experienced when two connectors according to the present invention are connected together is such that after any deflection of the legs caused by the interference fit when mating, the contact surfaces are substantially parallel, ensuring even contact force over the entire mating surfaces.

The slope of the main portion of the first and second legs preferably extends from the radially outermost surface of the first and second legs such that a wedge-shaped profile is provided and the radially outermost face of the first and second 30 legs may be rounded.

Advantageously, the opposing first leg comprises a first inner face parallel to a second inner face on the opposing second leg, wherein the first and second inner faces are planar. Such a configuration enables the legs to remain substantially parallel and thus maintain an even pressure contact there between when engaged. In this respect, an end portion located at the proximal end of the first and second legs which comprises an end face perpendicular to the plane of the first and second inner faces may also serve to provide good even contact between matingly engaged connectors.

The genderless electrical connector of the present invention may further comprise a collar between the pin and the proximal end of the first and second legs. The collar preferably having a radius portion greater than the radius of the pin to form a shoulder for, in use, abutting against insulator housing and thus retaining the insulator housing thereto.

A planar face on a portion of the outermost radius of the collar enables the orientation of the connector to be determined quickly and by feel alone, thus aiding connection.

Preferably, the pin is hollow, thus enabling easy connection to a wire, or easy soldering to a PCB or the like.

The pin may also comprise a crimp barrel for simple crimping electrical contact to a current carrying wire.

In order that the invention may be more readily understood, reference will now be made, by way of example, to the accompanying drawings, in which: Figure 1 is a perspective view of a prior art connector; Figure 2 is a perspective view of the connector according to an embodiment of the present invention; Figure 3 is a perspective view of the connector according to an embodiment of the present invention; Figure 4 is a perspective view of the connector of Figure 2, said connector positioned relative to a second connector as shown in Figure 2, wherein the connectors are about to be matingly engaged or have recently been disengaged; Figure 5 is a perspective view of the connector of Figure 2, said connector matingly engaged with a second connector as shown in Figure 2; and Figure 6 is a perspective view of the ringed portion of Figure 5.

Referring firstly to Figure 2, there is shown a genderless electrical connector 10 according to an embodiment of the present invention. The connector comprises a cylindrical pin 12. Extending from the pin 12 in the axial direction are first and second legs 14 and 16 respectively. The legs 14, 16, are electrically conductive and spaced apart in the radial direction such that a gap runs between -the gap running axially.

The first and second legs 14, 16 comprise a contact surface which, in use, is brought into contact with the legs of an identical genderless connector. This connection is shown best in Figure 5.

When brought into contact with a second genderless connector, the legs of each connector form a friction tight, interference fit, such that the two connectors are then held in place together and an electrical connection is made.

The first and second legs 14, 16 have a distal end 18 which is furthest from the pin 12 and a proximal end 20 which is nearest the pin 12. A main portion 22 extends between the distal end 18 and proximal end 20.

The distal end 18 has a rounded face which slopes radially inward to form a gentle, wedge-shaped profile. Such a profile enables the leg to smoothly and easily engage with the legs of a second identical connector and slide over said legs and into the friction tight mating position.

The proximal end 20 of the first and second legs 14, 16 have complementary rounded and sloped faces such that the rounded face of the distal end 18 of an identical genderless electrical connector can be brought into electrical contact to abut the rounded proximal end 20 and matingly engage. The proximal end 20 is recessed, or convex, so as to receive the rounded, or concave distal end, much like a male and female engagement portion.

The plane of the concave distal end 18 is perpendicular to the plane of the convex proximal end 20. This arrangement of offsetting mating pieces by 90 degrees enables the connector to fix rotationally fast in the axial direction with the second, identical, connector.

The slope of the distal end 18 extends from the radially outermost surface of the first and second legs 14, 16 such that the leading edge of the first and second legs 14, 16 is a rounded wedge portion. The main portion 22 comprises a radially inward sloping face as can been seen from the figures. The slope extends from the outermost surface of the first and second legs to describe a wedge-shaped profile. The thinnest part of this wedge being proximate the radially outermost section of each first and second leg 14, 16.

In order that a substantially cylindrical shape is defined when two of the connectors according to the invention are fastened together, the outermost face of the first and second legs 14,16 is rounded.

The first and second legs 14, 16 have opposing first and second inner faces 24, 26. These inner faces 24, 26 are planar and lie parallel to each other. They provide a substantially flat surface which, when connected to an identical electrical connector, pass over the sloped face of the main portion 22 of the first and second legs 14, 16 respectively.

An end portion 28 is located proximate the proximal end of the first and second 5 legs 14, 16 and comprises a face perpendicular to the plane of the first and second inner faces. The width of the end portion 28 is dictated by the axial spacing of the first leg 14 from the second leg 16.

As can be seen most clearly in Figures 5 and 6, the connector 10 has a collar 30 between the pin 12 and the proximal end 20 of the first and second legs 14, 16. The collar 30 has a radius portion greater than the radius of the pin 12 such that a shoulder is formed to, in use, abut against insulator housing and retain the insulator housing thereto.

The collar 30 includes a planer face 32. This is a flat face on the periphery of the collar 30 which enables a user to determine the orientation of the connector by feel. The flat face also enables the contact to be kept within reasonable orientation alignment when in an insulator with a corresponding feature.

The pin 12 may be hollow. As can be seen in Figure 3, the pin may be a crimp barrel 34 for crimping electrical contact to a current carrying wire.

In a further embodiment the contact surfaces of the connector 10 may have a rough, non-polished finish. The rough finish of the contact surface comprises microscopic peaks and troughs which improve the electrical connection therebetween by increasing surface area. The height of a peak is approximately 1x10^-9 metres and the surface finish may be deliberately created during manufacture through machining marks.

Claims

CLAIMS1. A genderless electrical connector comprising; a pin from which opposing first and second legs extend parallel to each other and in the axial direction, the first and second legs spaced apart in the radial direction and comprising a distal end, a proximal end, and a main portion which extends between the distal and proximal ends, and wherein each leg comprises an outermost contact surface, which, in use, is brought into contact to matingly engage with the legs of an identical genderless electrical connector, the contact surface of the legs having a rough, non-polished finish.
2. A genderless electrical connector according to claim 1, wherein the rough finish of the contact surface comprises microscopic peaks and troughs.
3. A genderless electrical connector according to claim 2, wherein the height of a peak is approximately 1x10^-9 metres.
4. A genderless electrical connector according to any of the preceding claims, wherein the contact surface comprises machining marks formed during manufacture.
5. A genderless electrical connector comprising; a pin from which opposing first and second legs extend parallel to each other and in the axial direction, the first and second legs spaced apart in the radial direction, and wherein each leg comprises an outermost contact surface, which, in use, is brought into contact to matingly engage with the legs of an identical genderless electrical connector, the first and second legs comprising a distal end, a proximal end, and a main portion which extends between the distal and proximal ends, wherein the distal end comprises a rounded face which slopes radially inward.
6. A genderless electrical connector according to any of the preceding claims, wherein the proximal end of the first and second legs comprises a complementarily rounded and sloped face such that, in use, the distal end of an identical genderless electrical connector can be brought into electrical contact therewith and matingly engage thereto.A genderless electrical connector according to any of the preceding claims, wherein the slope extends from the radially outermost surface of the first and second legs such that the leading edge of the first and second legs is a rounded wedge portion.A genderless electrical connector according to any of the preceding claims, wherein the main portion of the first and second legs comprises a radially inward sloping face.A genderless electrical connector according to claim 8, wherein the slope of the main portion of the first and second legs extends from the radially outermost surface of the first and second legs such that a wedge-shaped profile is provided.A genderless electrical connector according to any of the preceding claims, wherein the radially outermost face of the first and second legs is rounded.A genderless electrical connector according to any of the preceding claims, wherein the opposing first leg comprises a first inner face parallel to a second inner face on the opposing second leg, wherein the first and second inner faces are planar.
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16.A genderless electrical connector according to any of the preceding claims, further comprising an end portion located at the proximal end of the first and second legs, wherein the end portion comprises an end face perpendicular to the plane of the first and second inner faces.A genderless electrical connector according to any of the preceding claims, further comprising a collar between the pin and the proximal end of the first and second legs, the collar having a radius portion greater than the radius of the pin to form a shoulder for, in use, abutting against insulator housing and thus retaining the insulator housing thereto.A genderless electrical connector according to any of the preceding claims, further comprising a collar having a planar face on a portion of the outermost radius.A genderless electrical connector according to any of the preceding claims, wherein the pin is hollow.A genderless electrical connector according to any of the preceding claims, wherein the pin is a crimp barrel for crimping electrical contact to a current carrying wire.