GB2598394A - Two-part and terminal connectors with improved connector socket sealing and durability - Google Patents

Abstract

A two-part subsea electrical connector has male (figure 6b, 302) and female 304 parts. The male part (figure 6b, 302) comprises a plurality of probe pins (figure 6b, 312) adapted to be mated with corresponding circuit channels of the female part 304. The female part 304 comprises guide members to receive the pins, and through-body conductors 350, the through-body conductors being offset from the insertion axis of the guide members. The connector may comprise face 367 and rear 368 seals. The seals may define a chamber in which a dielectric fluid is held. Further aspects include a solderless connection between conductor elements, the connection comprises a conductor pin adapted to receive a conductor 325 at one end and having a profiled shape (figure 2) at the other end. A pin receiver 320 comprises a socket in which a pin retention means (figure 2) is disposed, where the pin has a bevelled surface which interacts with the retention means. A method of locking using the retention means is taught.

Description

TWO-PART AND TERMINAL CONNECTORS WITH IMPROVED CONNECTOR SOCKET SEALING AND DURABILITY

Field of the Invention

The present invention relates to two-part and terminal connectors specifically constructed for use in hazardous environments, particularly multiple conductor connectors but including single channel connectors.

The invention is more particularly directed to the provision of two-part, multi-conductor, connectors for use in extreme environments, most notably subsea environments, and includes terminal connectors, such as those adapted for coupling to fixed installations and remotely operated vehicles (ROV's). The invention is most particularly directed to the provision of two-part, multi-conductor, wet and dry mateable subsea electrical connectors for use in hyperbafic environments, which typically continuously operate at low voltages and low amperages.

The invention is further directed to multi-conductor connectors for data transmission and sensor feed receipt and includes applications where waveguides such as optical fibres are either the preferred conduits or are combined in hybrid connectors.

It will be understood that certain terms used in the description which follows are intended to describe specific situations and should not be interpreted as limiting of the scope of the invention or its use. The term "conductor" is, in its ordinary meaning, directed to single core or multi stranded wires covered by an insulating sleeve and one of usually a plurality of individual wires within a multi-conductor cable. Such cables can be constructed and rated for power applications, including for example, electrical feeds to remote equipment, and for data transmission, for example, signals or video camera feeds. Although the invention is primarily directed towards electrical connectors, single and multiple channel waveguide connectors, most commonly in the optical and near optical range, are often used in hyperbolic and extreme environments. Accordingly, in the description that follows, the term "conductor-includes any comparable conduit through which power or data may be transferred.

The term -hybrid connector-is often used interchangeably to denote the use of both wire and fibre channels within a connector but also to indicate use for both power and data connectivity (irrespective of whether data is carried by wire or fibre).

Although the invention is directed to low voltages and low power applications, no such limitation should be taken or inferred Disadvantages addressed herein apply equally to high power rated terminations.

A particular concern of the present invention is cable termination where the connectors are wet mateable and include multiple sealable chambers in which non-conductive fluid media is used to maintain electrical isolation between conductors which pass through or terminate in or adjacent the chambers This "dielectric fluid" and its movement between one chamber and another when the connectors are mated and demated is well appreciated in the art, however, the integrity of the chambers and the seals preventing loss of dielectric fluid or ingress of a conductive contaminant (primarily seawater) over the operational lifetime of the connector presents known problems, specifically the breakdown of electrical isolation of the conductors.

The term "hazardous environment" as used hereinafter is intended to refer to any environment where components or materials may be vulnerable to failure due to ambient conditions. Examples of such include: corrosion, due to seawater, drilling fluids, and the like; electrolytic decomposition or bombardment by atomic oxygen (common in orbital and deep space environments); and cycling between high and low pressure and cycling between high and low temperatures; and where subject to physical stresses. Reference to subsea environments hereafter is intended to include problems associated with other hyperbaric and hazardous environments In the exemplifying embodiments of the prior art and in the description below, it is common to illustrate in-line connectors as unmated male and female parts making up the connector. As is well appreciated, many applications relate to connections where one part (often the female part, as it has isolated terminals) is provided on a cable end and the corresponding (normally male) part is attached to or integrally formed with the body of a tool, piece of apparatus, remote vehicle or installation.

Where one part is fixed the connector is often referred to as a "terminal connector" or "bulkhead connector'. Accordingly, in the description provided hereinbelow, a reference to two-part connectors includes single parts of a connector and all comparable cable termination arrangements.

Background to the Invention

The offshore oil and gas, marine and oceanographic industries are well developed and have well-appreciated requirements with regards to the characteristics and operational environments within which people, machinery and equipment must operate. Subsea electrical systems have been developed to support and manage a variety of tasks at extreme pressures and within corrosive environments on the sea-floor at depths of up to several thousand metres and to provide electrical and communications feeds to allow remote operations. Electrical and data or hybrid connectors all find uses in multiple specialised fields whether that be for well completions, oil and gas separation, flowline connections, various maintenance tasks requiring diver or manipulator assistance and so forth, however, for ease of reference, subsea applications will be the primary focus in the description that follows. To provide the electrical power necessary to remotely operate the subsea systems, reliable electrical cables and connectors, operable at high voltages and amperages, are required. Other examples of subsea machinery having high electrical power requirements are underwater construction and mining equipment, subsea work vehicles and power transmission lines.

A particular concern of the invention is electrical pin-and-socket type connectors that are intended to be mated in a dry or wet environment and then deployed in a conductive, corrosive or high-pressure environment, most notably at depth in seawater. Connectors of this type generally have a first part comprising a female housing within which are disposed male probe pins and a corresponding connector part in a male housing configuration having a contact face within which female contact sockets (that are sealed from the exterior environment after mating) are located and whereby, when the connector parts are mated, an insulated and isolated electrical connection is made.

It is well-established to refer to two-part connectors as comprising male and female parts determined by the receipt by the female part of one or more plug probes associated with the male part, however, in many instances, a plurality of receiver or contact sockets are disposed in a housing configured as a plug for receipt within a corresponding receptable housing which encloses a corresponding plurality of plug probes into which the plug styled housing is received. As the styling or configuration of the outer housings is independent of the electrical/waveguide/hybrid connections and for the purpose of clarity hereafter the connector gender will be determined by the contact gender. Thus, the terms "plug", ''probe pin" and "male part" will be considered synonymous, the terms "socket" and "female part" will be interchangeable, and the term "receptacle-which is normally reserved for the outer housing or shell of the connector part will be replaced. Additionally, as the invention as hereinafter described related to the interior assembly of the connector parts, no protective housings are illustrated.

There are three main categories of terminal or two-part connector: the first being those that accomplish environmental sealing by having the male probe pin enter the channel or bore containing the female contact socket and simultaneously seal the bore and make the electrical connection with the contact socket and are generally referred to as "interference fit"; the second being those connectors that accomplish environmental sealing by having an elastomeric compression seal on the male connector that is energized when it is mated to the female connector and are generally referred to as "compression fit"; and the third where 0-ring or similar type seals are used to provide the environmental seal between the two mated connector halves (and between the outside and inside of the connectors); A modification to the connector types (particularly of the latter type) are those where at least one half of the two-part connector contains electrically insulating fluid (generally referred to as -dielectric media") located within defined and separate chambers. Of particular concern of the present invention are those connector parts in which one or more of the chambers are bounded by electrically non-conductive thin walled flexible membranes and where channel socket aperture openings that are normally sealed by spring-biased plungers in the unmated condition and are subsequently sealed by probe pins (and, depending on the embodiment, the spring biased plungers) in the mated configuration.

In much of the prior art relating to subsea electrical and data connections, the subj ect of whether a connector is designed to be first mated outside of the hazardous environment (and generally referred to as "dry" or "dry mateable" connectors) or within (generally referred to a "wet or "wet mateable" connectors) is considered critical. For most practical purposes and in respect of the most relevant prior art, the preponderance of the prior art is related to connectors that can be repeatedly connected and disconnected within their respective hazardous environments as it is highly impractical to remove the connector or system to which it is attached into a non-hazardous environment for the purpose of mating the two connector halves together.

Most wet mateable connectors must be capable of operating in extreme environments and deal with significant hydrostatic and often fluctuating pressures and the corrosive nature of seawater or, where applicable, drilling fluids. Connectors which have dielectric fluid within one or each part of the connector, and capable of equalising the pressure differentials between the external (outside the connector) and the internal environment (within the connector) when mated or unmated, eliminate many of the problems associated with hyperbaric pressures.

Interference tit connectors can be mated dry or wet and typically comprise male and female el astomer portions that when mated together provide a squeezed interference fit between the male and female parts, thereby generating an environmental seal between the outside and inside of the connector contact parts. Interference fit connectors are typically used for short term applications especially where they can be readily replaced.

Known performance and reliability issues that exist with interference fit connectors include the inability to support compression forces that are generated during service by cyclic and high differential hyperbaric pressures, in the unmated, 'open face' condition. The general construction of this type of connector can also include unsupported electrical contacts, uncontrolled conductor management and uncontrolled potting at the rear of the bulkhead connector. These uncontrolled elements can lead to poor product quality arid in-service performance and reliability issues.

Compression seal connectors should ideally be mated in a dry environment and typically comprise a male connector with pin receivers that are located within a moulded elastomeric body. The elastomeric body is bonded to the male connector body (typically metal) in such a way that a face compression seal is created. When the male and female connectors are fully mated together, the face compression seal is energized against the front face of the female connector, thereby generating an environmental seal between the outside and inside of the mated connector pair. Compression seal connectors are typically not suitable for long term use or applications where high reliability is required.

Known performance and reliability issues that exist with compression seal connectors include the lack of robustness of the elastomeric compression seal, the inability to support compression and resultant shear forces that are generated during service by cyclic and high differential hyperbaric pressures, in the 'reverse pressure' condition. The general construction of this type of connector can also include unsupported electrical contacts, uncontrolled conductor management and uncontrolled potting at the rear of the bulkhead connector. These uncontrolled elements can lead to poor product quality and in-service performance and reliability issues as addressed in the present Applicant's earlier United Kingdom Patent Application No 1902561.8 (Patent Publication No GB 2 581 958) One of the primary perceived advantages of utilizing connectors where the female part incorporates dielectric fluid-filled socket channels is that they are rendered spark-proof in that they can be mated and demated when the female part of the connector is energized (although in practice, this is not recommended). If the male connector is inadvertently disconnected from the female connector when the female connector part is energized or if power is accidentally applied in the unmated condition, they remain "dead-faced-to the outside environment, preventing short-circuits In wet-mateable connectors, socket channels formed within the female part of the connector are not protected from the surrounding environment by sealing and must be protected during the mating and demating processes and throughout its effective operational life, whether mated or unmated. The common manner in which this is achieved is to locate the conductive channel connectors within the body of the female part and form a chamber within which a dielectric fluid is retained to protect the conductive sockets from corrosion and to provide effective electrical insulation from other socket connectors and from the conductive tips of the probe pins of the male part prior to mating. To prevent leakage of the dielectric fluid and prevent ingress of seawater into the chamber, seals are provided. To allow the connecting probe pins of the male connector part to engage the corresponding circuit channels, external seals are formed to retain integrity of the chamber while allowing passage of the connecting probe pins. To prevent the dielectric fluid displaced by the probe pins being forced outwardly through the external seals, a secondary chamber in fluid connection with the first accepts the displaced volume. Alternatively, flexible elements are provided to accommodate the change in volume within a channel chamber when the probe pin is inserted or withdrawn.

A large body of existing art is overviewed in the preamble of United States Patent No. 5,194,012 to Cairns, in which an electrical connector has a female part with cylindrical socket assemblies or modules extending into the interior support body. The socket assemblies and a region of the interior of the female part are immersed in dielectric fluid, the pressure of which is equalized to that of the surrounding environment. Spring-biased plungers are located within apertures of resilient seals at the open (sealing face) end of the socket assemblies to seal the interior of the socket assemblies against the outside environment. When mated probe pins of the male connector part push the plungers into the socket assemblies. The plungers have a fluted retaining end to allow dielectric fluid to flow within the socket assemblies when the plungers move between the mated and demated condition.

The art brought forward in United States Patent No. 5,194,012 (Cairns) includes United States Patent No. 4,795,359 to Alcock (Tronic Electronic Services Ltd), US Patent No. 4,142,770 to Butler (Exxon Production Research Co.), US Patent No. 3,729,699 to Briggs (Southwest research Institute) and United States Patent No. 4,039,242 to Wilson (US Navy). United States Patent No. 5,645,442 to Cairns (Ocean Design, Inc., hereinafter "ODI") addressed in more detail below makes further reference to United States Patent Nos. 4,948,377 and 5,203,805 both to Cairns and attempted to negate the earlier referenced US Patent Nos. 4,142,770 (Exxon) and 3,729,699 (Southwest).

In United States Patent No. 4,142,770 (Exxon), a two-part underwater wet-mateable connector is disclosed, which is capable of repeated mating and unmating underwater at great depths. The connector employs cylindrical probe pins in the male part and a dummy piston and cylinder mechanism in the receiving channels of the female part to protect the conductive socket contacts prior to mating. Dielectric insulating blocks, preferably machined from polycarbonate, and a dielectric insulating fluid provide the electrical insulation for the conductive components of both the male and female connector parts. Passageways within the dielectric block of the female part permit flow of dielectric fluid through the conductive channel cylinder during mating and allow convective circulation of the dielectric fluid through the cylinder to dissipate heat from the vicinity of the electrical conductors and solid insulating blocks.

Mounted within each cylinder is a non-conductive piston which is maintained in an extended position by a spring when the male probe pin is not inserted in the cylinder. When the connector is not mated, the piston is fully extended and seals the entrance of the cylinder. This sealing action prevents the entry of seawater and escape of dielectric fluid and thus protects the electrical integrity of the female conductive socket. When the male and female parts are mated, the piston is rearwardly displaced within the cylinder, thereby exposing the socket contact to the conductive component of the male probe pin.

United States Patent No. 3,729,699 (Southwest) describes an electrical connector designed for engagement and disengagement under water at very great depths with high voltage and amperage capacity. The connector incorporates a dummy piston reciprocally mounted in a circuit channel of the female part arranged to prevent the entrance of seawater into the channel when a probe pin of the male part is not inserted therein. A dielectric fluid compensator is disposed in the circuit channel and has biasing means therein to provide a positive pressure on the fluid at all times.

United States Patent No. 4,795,359 (Tronic) introduces an underwater electrical connector comprises male and female parts which are mated to form an electrical connection. The female part includes a plurality of chambers containing dielectric fluid, one chamber being located within the other. A non-conductive shuttle piston extends through a contact socket in one such chamber and extends through aligned seal openings of each chamber. The shuttle piston is arranged to be urged back by a probe pin of the male part of the connector during insertion thereof such that the probe pin is received and directly engaged by the contact socket to effect the electrical connection.

In United States Patent No. 5,645,442 (ODI), there is disclosed a submersible connector for use in an underwater environment in which the connector has a female and a male connector halves which are mated together. The female connector has a shell, an inside chamber, a circuit contact, and outer chamber, and a stopper (plunger). Both chambers contain dielectric fluid. When the stopper (plunger) is disposed in the inside and outside chambers, and those chambers are open to one another, permitting free flow of dielectric fluid therebetween. As the probe pin is inserted into the female connector, it first enters the outside chamber. The outside chamber has an end seal and is closed off from the outside environment by the stopper (plunger) in contact with the end seal, when the connector is unmated, and by the probe pin in contact with an end seal when mated.

When the probe pin is inserted further into the outside chamber, it forces dielectric fluid into the inside chamber which has a flexible bladder that expands with increases in volume in the inside chamber. The probe pin then enters the inside chamber and makes electrical contact with the circuit contact thereby making an electrical connection. -When fully inserted into the female connector, the probe pin seals off the outside environment from the inside chamber forming a fluid tight seal between the two chambers.

As will be readily appreciated from the patent literature, there are many different approaches taken to solving some of the known technical disadvantages. Each area presents specific concerns, however, many aspects are common and will be addressed hereinafter.

It is an object of the present invention to seek to obviate the primary disadvantages associated with prior art constructions of multi-conductor connectors It is a further object of the present invention to provide a mateable and dem ateable connector suitable for use in hazardous environments It is a yet further object of the present invention to provide a means for increasing the conductor density within the internal assembly of the connectors.

The invention yet further seeks to provide a means for reducing the bore of at least one connector of a two-part connector or the multi-conductor cable connected thereto.

The invention additionally provides a means for ensuring volume and pressure compensation of dielectric fluid media is maintained within the immediate vicinity of the receiving socket and is not transferred to a further volume or chamber of fluid. Where further chambers are provided within a connector part, additional volume and pressure compensation is also provide without transfer of media between chambers.

It is yet a further object of the invention to increase significantly the reliability of connectors having features in accordance with the preferred constructions.

It is an additional object of the invention to provide a family of modular products that incorporate features refined from those known in the prior art which, in combination with the improved features of the present invention, describe connectors and connector assemblies which in use provide repeatably matable and de-matable connectors having a component life which exceeds the anticipated operational life of the cable, tool, component, apparatus, vehicle or installation to which it is attached.

The variants of the product of the invention and the uses to which they are applied are not intended to be taken as limiting, merely illustrative of the typical scenarios within which the product, method and system of the invention is adapted for use.

It is also an object of the present invention to provide a solderless conductor interface between a single or multi-conductor cable and at least one part of a two-part connector.

In a further aspect of the invention, it is an object hereof to provide a crimp connector for a conductor having an integral retention means to prevent inadvertent withdrawal.

A retention means for a crimp connector having releasably locking and permanently connecting configurations.

A conductor pin adapted to be soldered or crimped to one exposed conductor and, profiled to engage with a conductor receiving socket retained within the cable connection end of a connector body, the pin having an angled surface adapted to engage with the retention means of the socket, in which the angle of the pin interface determines the force required to withdraw the pin or whether the pin is permanently installed therein It is a yet further object of the invention to provide improved sealing at the rear of a connector part.

Summary of the Invention

Accordingly, in a first aspect the present invention provides a terminal or two-part connector having improved sealing and durability characteristics and comprising male and female parts having a common centrally disposed longitudinal mating axis, the male part including a plurality of probe pins corresponding to a desired number of circuit channels and the female part including axially aligned guide members for each one of the circuit channels, the guide members being adapted to receive the probe pins when the parts are mated, in which the female part has a support body encapsulating through-body conductors disposed parallel to the longitudinal mating axis and offset from the axially aligned guide members.

The displacement of the through-body conductors from the circuit channel axis means that the conductive sockets connected to and electrically communicating with the through-body conductors remain parallel with the longitudinal mating axis and the axially aligned guide members without being coincident with either.

Advantageously, the axially aligned guide members comprise a face seal and rear seal between which is disposed a connecting socket adapted to communicate with a conductive element of a probe pin.

Conveniently, the front and rear seals together define a channel chamber from which dielectric fluid is displaced during mating of the connector parts.

In each of the preferred embodiments of the invention, seals are provided on either side of the conductive socket and together they guide each circuit channel probe pin to correct alignment within the channel chamber.

Preferably, a wiper arrangement is disposed between said front and rear seals to remove excess dielectric fluid or external fluid or debris from a probe pin during mating or dem ating of the connector parts.

Optionally, a unitary flexible face seal element is removably secured to the support -13 -body and incorporates at least said front and rear seals.

In a preferred construction, the axially aligned guide members includes a biasing spring and plunger on which the spring acts, the plunger being moveable between an extended position, in which the plunger cooperates with the front and rear seals to maintain dielectric fluid within defined channel chambers, and a retracted position when dielectric fluid is displaced during mating of the connector parts.

The advantage of providing an offset to the through-body conductors with respect to the circuit channel axis becomes more pronounced with the inclusion of a spring-biased plunger located within and acting along each circuit channel axis.

The spring and plunger are accommodated in a channel chamber defined on one side by a first or inner bellows seal which is adapted to entrain the volumetric total of the dielectric fluid of each of the plunger channel chambers.

Advantageously, the inner bellows seal is overlaid by an outer bellows seal defining therebetween an expansion chamber to accommodate displacement of dielectric fluid during mating or demating of the connector parts.

Ideally, the outer bellows seal includes an enhanced face seal to present an improved compression surface for the mated component parts.

In a preferred construction, the female part has a connecting socket located within a first chamber of each circuit channel, the channel chamber containing dielectric fluid and being bounded on at least one surface by an electrically insulative thin wall membrane and axially aligned openings normally sealed (when unmated) by a spring-biased plunger and in which a second annular chamber axially aligned with each of said first chambers, bounded on at least one surface by an electrically insulative thin wall membrane, axially aligned guide members normally sealed by said spring-biased plunger which extends in a sealable manner through said guide members.

Advantageously, a third annular chamber is disposed in a position that is axially aligned with and surrounding said first and second chambers, being bounded on at least one surface by an electrically insulative thin wall membrane and said axially aligned guide members which are normally sealed by said plunger which extends in a sealable manner through said first, second and third chambers Preferably, said first, second and third chambers of the female part contain dielectric fluid and each provided with respective openings, the openings being axially aligned and normally sealed by the plunger which extends therethrough when unmated, the first chamber being axially aligned with the circuit channel of the respective plunger, the second and third chambers being substantially annular and axially aligned with the longitudinal mating axis, said third chamber annularly overlying the second chamber In the preferred construction, the second chamber contains a biasing spring and plunger on which the spring acts, the spring and plunger being electrically isolated from the conductive connecting socket of its respective circuit channel and conductive and/or corrosive fluid within which the connector is operably immersed.

Ideally, said first and second chambers of the female part contain dielectric fluid and each provided with respective openings, the openings being axially aligned and normally sealed by the plunger which extends therethrough when unmated, the first chamber being axially aligned with the circuit channel of the respective plunger and bounded by the second annular chamber, whereby as the plunger is electrically non-conductive, should the dielectric fluid of first and/or second chamber become contaminated or be replaced by a conducting media, such as seawater, the affected circuit channel will not fail.

Preferably, the male part has a support body encapsulating through-body conductors disposed parallel to the longitudinal mating axis and extending into the probe pins to form a conductive element thereon which operably connects to a connecting socket of the corresponding circuit channel of the female part during mating of the connector parts.

Ideally, the conductive element forms a collar on the shaft of the probe pin electrically isolating the tip thereof In a preferred arrangement, through-body conductors of the male and female parts have at their respective terminal ends a pin receiver embedded within the support body thereof and operably connected to a conductor of a conductor bundle or multi-conductor cable via a conductor pin attached to the exposed end of said conductor.

Advantageously, each of the male and female parts have at their respective terminal ends multiple conductors of a conductor bundle or multi-conductor cable operably connected thereto, each conductor passing through an inner and outer boot seal, the inner boot seal having a male member for securing within a corresponding receiver within the terminal end of the support body thereof and said outer boot seal being fastened to the inner boot seal by a retaining pin adapted to fix to the male member of said first boot seal.

In yet a further preferred construction, each of the male and female parts have at the terminal ends of the respective support bodies multiple conductors of a conductor bundle or multi-conductor cable operably connected thereto via pin receivers embedded within each support body, each conductor being provided with a conductor pin soldered or crimped thereto, each conductor pin includes profiled head and neck portions defining angled or bevelled transitional surfaces therebetween, the angle of said surfaces determining the amount of force required to release a pin from locking engagement with a corresponding pin receiver, each pin receiver having a retention means which include locking portions adapted to engage the neck of the conductor pin received therein.

Advantageously, the retention means releasable locks the pin within the receiver according to the prescribed angles of the bevels and includes means to permanently lock the conductor pin within the receiver.

In one arrangement, the receiving end of the conductor pin is tubular with crimp pinch points for inward deflection.

Alternatively, the receiving end of the conductor pin includes a slot within a tubular wall to allow solder to flow easily into the interior of the pin In a further aspect of the invention there is provided a solderless interconnection between conductor elements comprising: a conductor pin having a substantially tubular socket adapted to receive the unsheathed end of a conductor (wire) at one end and a profiled shaft at the other end, and a pin receiver adapted for coupling to a (through-body) connector and having a receiving socket portion within which is disposed a pin retention means applying a constant retaining force on an inserted conductor pin, in which the profile shaft includes a bevel surface against which the retaining means operatively acts to determine the retention force to be overcome to withdraw the pin.

Conveniently, the profiled shaft includes a distal head portion connected thereto by a neck between which the bevel surface is disposed.

It will be seen that the angle of the bevel surface with respect to the longitudinal axis of the profiled shaft determines the retention force to be overcome.

In a yet further aspect of the invention, there is provided a method of locking conductors within a connector part, the method including: unbundling conductors from a multi conductor cable; exposing the conductor tips by stripping the sheathing therefrom, fixing the exposed conductor tips within receiving ends of profiled conductor pins; and slidingly engaging the conductor pins into pin receivers having pin retaining means secured to or fixed within a terminal contact of a through-body conductor of a connector part.

Ideally, the method further comprising crimping the receiving ends of the profiled conductor pins to the exposed conductor tips to provide a solderless connection between conductors of a multi-conductor cable and a connector part.

It will be appreciated by the skilled addressee that in an additional aspect the invention presents a family of modular cable terminations and connectors that incorporate features refined from those known in the prior art which, in combination with the improved features of the present invention, describe connectors which in use provide repeatably detachable connectors having a component life which exceeds the anticipated operational life of the cable, tool, component, apparatus, vehicle or installation to which it is attached

Brief Description of the Drawings

The present invention will now be described more particularly with reference to the accompanying drawings which show, by way of example only, a cable termination in the form of a two-part connector having dielectric fluid-filled chambers therein, together with details of preferred embodiments of internal connector part assemblies and components making up an improved termination or connector part, and illustrating a means for and method of securing and retaining individual conductors from a multi-strand feed or a multi-conductor cable within the body of at least one terminating part. In the drawings: Figures la and lb are a schematic side elevation and a sectional side elevation of a conducting body incorporating a spring-biased plunger mechanism and dielectric fluid expansion chamber of the exemplifying prior art; Figure lc is a partial sectional side elevation of a cable termination of the exemplifying prior art and comprising a female, receiving part of a two-part, wet mateable, dielectric fluid-filled connector having volume and pressure compensation in accordance with the more general established prior art, Figures 2a to 2d are partial sectional side elevations of pin connectors and corresponding pin receivers for through-body conductors of the type described as a preferred aspect of the present invention; Figures 3a and 3b are sectional side elevations of a male portion of a two-part connector in which probe pins are shown in end conductor and collar conductor configurations and illustrating the preferred use of the pin connectors of Figures 2a and 2b; Figures 4a and 4b are sectional side elevations of a first embodiment of a two-part connector in unmated and mated configurations, respectively; Figures 5a and 56 are sectional side elevations of a second embodiment of a two-part connector in unmated and mated configurations, respectively; Figure Ga is a simplified sectional side elevation of the female or receiving portion of a third embodiment of a two-part connector of the present invention with essential components removed for clarity; Figure 6b is a detailed sectional side elevation of male and female parts of the third embodiment of a two-part connector in an unmated configuration illustrating the spring-biased plunger of a single circuit channel and including a first bellows seal adapted to define a common expansion chamber for dielectric media for each of the circuit channels of the connector part; Figure 6c is a more detailed sectional side elevation of male and female connector parts of the third embodiment of two-part connector of Figure 6b in a-mated configuration and including a second bellows seal overlying the first and including an enhanced face seal; Figure 7 is a sectional perspective view of a female part of a two-part connector of the third embodiment illustrating two circuit channels of the multi-channel connector; and Figures 8a and 8b are detailed part sectional side elevations taken from Figure 7 illustrating three separate media filled chambers and sealing elements of multi-channel connector.

Detailed Description of the Drawings

As noted in the preamble to the description above, the acknowledged closest prior art is that exemplified by US Patent No. 5,645,442 (referred to herein as the ODI disclosure) which incorporates by reference much of the relevant earlier art and the disadvantages associated therewith. There are, however, numerous disadvantages associated with the exemplifying art and the limitations inherent specifically to the ODI disclosure.

Referring to the drawings and initially to Figures la to lc which represents the closest prior art referred to above and is well-known in the technical field, the ODI disclosure describes a two-part wet-matable submersible connector of which the female receiving portion is illustrated in Figure lc.

The connector part comprises an outer shell housing 1 having threaded portion 3,5 on which additional external housing and sealing components are threaded for further sealing and attachment functions. The shell housing 1 sealingly encapsulates the main internal support body 7 of the connector part and includes a mating face end cap 8 retained in the housing 1 and defining a series of apertures 9 corresponding to and aligned with circuit channel "modules" having common features for each circuit channel. The modules comprise a cylindrical through-body conductor 10, described in more detail with reference to Figures la and lb, about which there is provided a bellows seal 12 defining a channel chamber 14 for accommodating dielectric fluid displacement, the bellows seal 12 further defining an outer chamber 16 with the housing 1. A vent 17 is provided in the housing 1 to permit fluid from the external environment to enter and to act upon the external circumferential face of bellows seal 12, transferring and equalizing the pressure from the external environment to the internal dielectric fluid media filled chambers within the connector.

Each circuit channel module defines a socket assembly which is adapted to receive a probe pin of a correspondingly configured male portion (not shown) of the two-part connector. Each socket includes a probe pin receiver assembly comprising said cylindrical through-body conductor 10 together with mounting seals 21, 22, 0-ring seal 23 and said bellows seal 12 As illustrated in Figures 1 a and lb, the through-body conductor 10 includes a hollow cylindrical section 25 within which a biasing spring 26 retains a non-conductive plunger 28 in an extended position, through an annular socket element 29, into a receiver portion of a soft elastomeric sleeve 30 which covers a major portion of the conductive body of the assembly. The sleeve 30 comprises a flexible section 32 which defines an inner dielectric fluid expansion chamber 35 and said receiver portion which guides the probe pin of a mating or demating male part of the connector past a series of wiper seals 36 between which further dielectric fluids chambers 37 are disposed. When a probe pin enters a pin receiver channel, the conductive tip thereof engages the concave end of the stopper (plunger), the spring 26 compresses and any debris and/or fluid external to the connector plus any excess dielectric fluid carried by the probe pin is wiped therefrom and accommodated within the wiper chambers 37. As the stopper (plunger) 28 is carried into the hollow cylindrical section 25, dielectric media therein is displaced through holes (not shown) in the cylinder wall and accommodated within the expandable chamber 35 defined by the flexible section 32 of the sleeve. This expansion is in turn accommodated in the channel chamber 14 by the bellows seal 12.

The plunger 28 carries the conductive tip of the probe pin into the annular pin receiver 29 where spring components ensure a clean electrical contact is made. Consequently, electrical power can pass through the conductive body to its terminal end 40 which includes a bored-out solder pot 42 into which the exposed unsheathed end of a conductor wire is received Although not essential to the working of the present invention, a significant limitation of the ODI device is the structure of the through-body conductor and its various iterations (including fluted plunger and vented chamber variants) and the required sealing and movement of dielectric fluid between chambers, however, it is the conductor structure and the necessity for it to penetrate the entire body that will be first addressed, as a matter of convenience, as all of the preferred embodiments of the present invention illustrate an alternative beneficial arrangement.

In the exemplifying prior art, as illustrated in Figures la to lc, it is the number of through-body conductors and the distance required between each cylindrical conductor assembly that determines the capacity and rating of the connector, respectively.

As noted, the terminal end 40 of the through-body conductor is where cable unbundling and/or individual conductor connections are made to the respective terminal ends. In Figure lb, the through-body conductor has a cable conductor receiving solder pot 42 within which an individual conductor is fixed. As it is well appreciated, soldering each conductor is a skilled, time-consuming process involving dexterity and close observation of the connection made. Soldered joints and wire terminations are also known to be a reliability weakness of all electrical connectors. In high reliability systems, they also require expensive and time-consuming non-destructive testing to verify each joint.

Crimping of the receiver over an exposed conductor end is considered a more accurately repeatable process but access to the receiver within the body housing of a connector or terminal part is not often easy or possible with multi-circuit connectors.

Referring now to Figures 2a to 2d, although more advantageous than essential to the working of the present invention and equally applicable to improve any of the prior art arrangements, the provision of a simple standardised pin receiver 50 at the terminating end of a through-body connector 52 embedded within the support body of a connector part allows for the simple retention of a profiled conductor pin 60. Ideally, the pin receiver 50 has an open end 55 within which there is provided a spring clip 57 for positively engaging the conductor pin 60 to ensure electrical connectivity therebetween.

The conductor pin 60 has a coupling end 62 for receiving the unsheathed end of a conductor, usually unbundled from a multiconductor cable, which may be crimped thereon or soldered thereto. At the opposite end, the conductor pin is profiled to define a shaft portion 64 connected to a head 65 via a neck portion 66. The spring clip 57 has regions 58 which engage the shaft portion and ends 59 which align with the neck portion 66 intermediate the head 65 and shaft 64.

As shown in Figure 2a, there is no distinguishable diameter differential between the neck 66 and head 65 portions meaning that there is no mechanical pin retention and the pin 60 is easily retractable from the pin receiver 50. In each of Figures 2b to 2d, the head diameter is a substantially consistent with that of the shaft 64 and there is a bevel provided between the neck 66 and head 65 portions to define a retention withdrawal force characteristic depended on the angle of the bevel between said neck 66 and head 65 portions.

As shown in Figure 2b, the angle of the bevel is set at 20 degrees with respect to the longitudinal axis of the pin 60 and the pin is retractable with minimal manual force from the pin receiver 50. In Figure 2c, the bevel angle is set at 45 degrees to provide a controlled retraction force which must be overcome before the pin may be withdrawn from the pin receiver. In Figure 2d, the bevel angle is defined at 90 degrees or perpendicular to the longitudinal axis of the pin and this equates to a permanent installation over which the pin cannot be extracted without deforming or permanently damaging the spring clip 57.

The conductor pins 60 and pin receivers 50 together define a solderless interconnection between unbundled conductors from a multi-conductor cable and any one or more of a terminal or bulkhead connector, a male part or a female part of a two-part connector.

By crimping the conductor pins onto the exposed ends of conductors, a completely solder-free connection between the individual conductors within a multi-conductor cable or installation to a terminal or connector part may be achieved.

This arrangement provides significant advantages over the prior art construction exemplified by the ODI disclosure in Figures la to lc by removing the necessity to join wire conductors to through body conductor 40 via solder pot 42 using traditional soldering techniques. It will be understood that the preferred crimped conductor pin and pin receiver combination can be adapted and utilised in numerous prior art connector arrangements to improve connector reliability and reduce costs.

Figures 3a and 3b illustrate the most basic application of the probe pin 60 and pin receiver 50 combination where conductors 70 unbundled from a multi-conductor cable have been terminated by removing insulating sheathing 72 and fixing them by crimping (or optionally soldering) conductor pins over their unsheathed ends as described with reference to any one of Figures 2a to 2d Fixed within the insulating body portion 82 of a male part 80 of a two-part connector, a pin receiver 50 for each one of the circuit channels provided within the male connector electrically communicates along a though-body conductor 85 to the conducting tip 87 of a standard probe pin 88, as shown in Figure 3a The probe pin 88 of each circuit of the male connector part 80 has a rounded conductive tip 87 which conveys data or power via the through-body conductor 85 to the pin receiver. The remaining shank of each plug probe 88 is insulated to ensure electrical isolation post assembly.

In Figure 3b, the male connector part 80 includes a probe pin 88 having an inert tip 91 and an electrically conductive collar portion 92 which is in electrical connection with the through body conductor 85 to the pin receiver 50. As before, the remaining shank of probe pin is insulated.

Where the unbundled or individual conductors 70 enter the connector body there is first provided an inner boot seal 94 which engages the main support body 82 via a centrally disposed plug 95 within which there is a receiver 96. An outer boot 97 having conductor sleeves 98 includes a retaining pin 99 which locks the outer boot 97 to the inner boot receiver 96. Advantageously, dielectric fluid is provided between the inner and outer boot seals.

In each of the embodiments of the two-part connector illustrated hereinafter there is a choice of which probe pin configuration is used. As the traditional conductive tip configuration is well appreciated, the collared variant is preferentially used, however, both variants are illustrated in the embodiments which follow but no such limitation should be inferred or taken as to the choice of pin probe configuration.

As will be seen at by comparison of Figures 3a and 3b, the length of the probe pin 88 from support body 82 to conductive tip 87 and from support body 82 to conductive collar 92 is identical.

Additionally, in the embodiments which follow, the selection of a short or long probe length is determined by the depth of the face seals employed on each of the parts of a terminal or two-part connector. Again, no limitation should be inferred, however, the appropriate pin configuration and length will be selected according to the application used and the configuration and dimensions of the corresponding socket receiver and face seals used thereon.

Figures 4a and 4b illustrate a first embodiment 100 of two-part connector of the invention, comprising a male plug part 102 (represented by the interior assembly thereof rather than a complete structure including exterior shell or housing) with probe pins and a corresponding female part 104 with socket channels, in unmated and mated configurations, respectively.

The male part 102 of the connector 100 is substantially identical to that illustrated in Figure 3b in that it comprises a main support body 110 of a rigid thermoplastics material having a plurality of probe pins 112 extending from a sealing face 114 thereof In Figure 4a, a single probe pin is shown for clarity and presents an insulated tip 115 and conductive collar 116 configuration, the collar connecting to a through-body conductor 118 to a terminal pin receiver 120, ideally of the type described with reference to Figures 2a to 2d. Unbundled conductors 125 are, at their exposed (unsheathed) ends, secured to conductor pins 1 30 for engagement with the pin receivers 120 As described with reference to Figures 3a and 3b, an inner boot seal 132 is retained to the main support body 110 by a plug element 134 of the inner boot seal and an outer boot seal 136, having conductor sleeves 137, is fixed to the inner boot seal by a retaining pin 139 which engages the plug element 134. An identical arrangement is illustrated for the unbundled conductors of the female part.

The female part 104 comprises a main support body 140 of a rigid thermoplastics insulator material of a type well established in the art. As noted above, at the unbundled conductor end of the support body 140, there is secured inner 132 and outer 136 boot seals retained thereto by said plug 134 and pin 139 fixing. At the sealing face end of the body, there is provided an extending annular flange 145 within which a series of axially aligned guide members for each one of the circuit channels are arranged for receipt of the corresponding probe pins 112. Disposed within annular flange 145 and axially aligned with each guide member is a conductive socket 148 connected to a through-body conductor 150 which, at its terminal end, has a conductor pin receiver 120 within which is operably coupled a conductor pin 130.

A resilient, soft elastomeric material unitary face seal 160 is disposed at the sealing face end of the body and is held thereto by a face plug element 162 and a collar part 165 which overlies the front and rear faces of the annular flange 145 and includes apertures 167 168 which align with the socket apertures thereof The apertures 167 overlying the front face of the annular flange 145 of the main support body 140 are profiled to present face seals which receive and align the tip of the corresponding probe pin 112 and guide it into the socket chamber via guiding face apertures 167. The apertures 168 to the rear face of the annular flange 145 accept the non-conducting tip 115 of the probe pin when the conductive collar 116 thereof aligns with the conductive socket 148, as shown in the mated configuration of Figure 4b.

Conductors, unbundled from multi-conductor cables (not shown), are ideally connected via conductor pins as described with reference to Figures 2a to 2d over which protective boot seals are provided. It will be appreciated by the skilled addressee that in this and the following embodiments, sealing of the illustrated connector parts is provided by a combination of 0-rings, annular seals and external housing components, which include threaded fixings, for ensuring compressive interengagement of the two connector parts.

It will be seen in the female interior part assembly 104 that due to the offset provided by the collar sockets 148 and the through-body conductors 150 to the pin receivers 120, the number of circuits that can be accommodated within in a connector part can be increased and that the bore of the cable accommodating the multiple conductors of a multi conductor cable can be significantly decreased and that the capacity of the connector part may be adjusted accordingly. Similarly, the through-body conductors of the male part may be provided with an offset so that the corresponding pin receivers are brought into closer axial alignment with the central longitudinal axis thereof Thus, the boot seals used on both parts may be identical and accommodate the identical cable bore.

In the first embodiment of connector 100 illustrated in Figures 4a and 4b, it will be seen that the face seal 160 of the female part 104 presents face seal apertures 167 of reduced depth and, consequently, the length of the male probe pin 112 can be shortened without compromising the sealing between the male and female parts. At the base of each probe pin 112 there is included a tapered conical region for enhancing the sealing engagement under compression between the sealing face of the interior assembly of the male part 102 and the face seal 160 of the corresponding female part 104.

The sealing face of the unitary face seal 160 of the female part 104 comprises a plurality of apertures 167 aligned with and corresponding to each conductive socket 148 which is connected to the through-body conductors 150. Each aperture 167 comprises a distinct and separate sealed path for the corresponding male probe pin 112 and is initially loaded with a sealing or dielectric grease which prevents any ingress of seawater, drilling fluid or similar ambient material when unmated. During mating, the dielectric grease is pushed through the socket aperture and expelled into a void 170 rearwardly of the rear face apertures 168. As the sealing face of the male part is pushed toward that of the female part, any remaining dielectric grease is pushed laterally by the action of the tapered conical base of the probe pin 112 and a compression seal is established.

This arrangement provides for a single mating procedure as after demating of the connector parts what is remaining of the dielectric grease does not refill the front seal aperture 167 or socket aperture and ambient material may encroach.

In a minor variation of this embodiment, the sealing face may comprise a series of interengaged face apertures 167 whereby excess extraneous dielectric grease may be pushed into adjacent apertures which comprise essentially a common chamber for the total volume of the dielectric grease. Any grease not expelled rearwardly into the void chamber 170 remains at the face.

Figures SA and 5B illustrate as a second embodiment of an enhanced two-part connector 200 comprising a male plug part 202 and a female socket or receiving part 204 in unmated and mated configurations, respectively.

The male part 202 of the connector 200 is substantially identical to that illustrated in Figures 4a and 4b in that it comprises a main support body 210 of a rigid thermoplastics material having a plurality of probe pins 212 extending from a sealing face 214 thereof As before, each probe pin 212 presents an insulated tip 215 and conductive collar 216 configuration, the collar connecting to a through-body conductor 218 to a terminal pin receiver 220, via conductor pins 230 to conductor wires 225. As noted above, the conductor wires 225 penetrate an inner boot seal 232 which is retained to the main support body 210 by a plug element 234 and an outer boot seal 236, having conductor sleeves 237, is fixed to the inner boot seal by a retaining pin 239.

As with the first embodiment, the female part 204 comprises a main support body 240 and, at the unbundled conductor end of the support body 240, there is secured inner 232 and outer 236 boot seals retained thereto by said plug 234 and pin 239 fixing. At the sealing face end of the body, there is provided a radially extending annular flange 245 within which a series of axially aligned guide members for each one of the circuit channels are arranged for receipt of the corresponding probe pins 212. Disposed within the annular flange 245 and axially aligned with each guide member is a conductive socket 248 connected to a through-body conductor 250 which, at its terminal end, has a conductor pin receiver 220 within which is operably coupled a conductor pin 230, which connects to conductor wires 225.

A unitary face seal 260 is again disposed at the sealing face end of the body and is held thereto by a face plug element 262 and a collar part 265 which overlies the front and rear faces of the annular flange 245. As before, the face seal includes front 267 and rear 268 apertures which align with the socket apertures thereof In this instance, the front seal apertures 267 are deeper and incorporate a wiper arrangement 272 presenting annular blades between which chambers 274 for dielectric grease are disposed.

The focus of the enhancement comprises a face seal 260 of more complexity on the female part 204 which comprises longer front aperture channels 267 within which the wiper arrangement 272 is provided proximate the discrete face seal openings to remove excess dielectric grease from the probe pin 212 as it is mated to the corresponding socket channel The voids between the wipers 272 also act as a chamber for dielectric grease thereby reducing the amount of grease pushed into the void 270 rearwardly of the channel and providing a reservoir to recharge the face seal openings after demating of the two parts 202, 204.

To ensure a comprehensive compression seal between the male part and a female part having the enhanced face seal with wiper arrangement, it is necessary for the probe pins 212 to be correspondingly longer. The base of the probe pins is profiled as before to ensure a good compression seal.

By comparing the face seal shown in Figure 4a with that of Figure 5a it will be appreciated that the construction is essentially modular and that the-replacement of the face seal in Figure 4a with that shown in Figure 5a will provide the same construction.

Figures 6a to 6c illustrate a third embodiment of a two-part connector 300, comprising male 302 and female 304 parts, and are shown with successively more interior assembly components for clarity.

In Figure 6a, an exposed representation of the formative internal assembly components of the female part is illustrated in which a longer support body 310 accommodates a U-shaped plunger chamber 380. In this preferred construction, the face seal 360 configuration is substantially identical to that of Figures 5a to 5b and accommodates a wiper arrangement 372 within each of the circuit channels each of which have an axis defined by the front 367 and rear 368 apertures of the unitary face seal 360, the socket aperture 348 and the longitudinal axis of the plunger chamber 380.

As before, the conductive socket 348 is connected electrically to the through-body conductor 350 which, as it is radially inwardly displaced from the plunger channel chamber 380 axis, obviates any requirement for the plunger channel chamber components to carry electrical current or data signals or to comprise any conductive elements.

Each through-body conductor 350 is provided at its terminal end with a pin receiver 320 which a conductor wire 325, having a conductor pin 330 thereon, is coupled and the connection sealed by inner and outer boot seals 332, 336.

Figure 6b shows the male part 302 and female part 304 in an unmated configuration. The male connector assembly part 302 is substantially identical to that illustrated in Figure 3a in that the conductor tip configuration is shown and that is shorter probe pin length can be utilized. As noted below, the conductive collar configuration can equally be utilized with the identical female part 304.

The plunger chamber 380 houses a plunger 382 having a concave tip 383, for receiving the rounded tip of a probe pin 312 of either conductive tip or collar conductor configuration, and at its opposite end a plunger retaining collar 384 for retaining the plunger within the channel chamber and against which a biasing spring 386 acts to retain the plunger in a sealed extended position when the connector parts are unmated An inner bellow seal 388 sits over the plunger chamber 380 of each circuit channel to provide a single chamber for dielectric media which fills each of the U-shaped plunger channels. At one end, the seal is secured in an annular ring 389 formed in the collar part 365 of the unitary face seal 360. As the plunger 382 is pushed back against the spring 386, dielectric media is free to move within the chamber. Any volumetric changes are accommodated by the inner bellows seal without expelling dielectric fluid from one chamber to another.

As shown in Figure 6c, an outer bellows seal 390 is sealingly disposed over the inner bellows seal 388 to form a further annular expansion chamber 392. The outer bellows seal may include an enhanced face seal 394 to overlie the exposed tips 383 of the plungers shown in Figure 6b and provide compressive forces for retaining the inner bellows seal 388 in position when the exterior housing or shell is fitted.

The outer bellows seal again defines a single expansion chamber for dielectric media, however, this is isolated from the dielectric material retained within the inner bellows seal and plunger chambers but allows for movement thereof when accommodating the displaced volume as the plungers are moved inwardly towards the channel chambers when the plunger springs are compressed, as illustrated in Figure 6c.

The enhanced face seal 394 includes apertures 395 and channels corresponding to the apertures 367, 368 of the inner face seal 360 and again may either be presented as discrete apertures or connected to one another to allow dielectric grease, seawater or surrounding ambient media to be expelled from the mating face region when the probe pins are introduced to the outer apertures 395.

In Figure 7, the female part 304 of a terminal or two-part connector exemplifying the invention is shown. The connector part illustrates three successive chambers 374, 380, 392 and shows two separate circuits channels which allow for different dielectric fluid flow between the chambers. Details of the two channels are shown in Figures 8a and 8b and show the female connector part assembly 304 having connecting sockets 348 located within respective "a" and "6" channels and including a first chamber 374 dielectric fluid and being bounded by electrically insulative thin wall membranes with wiper arrangements 372a and 372b. Axially aligned guide member front and rear seals 367, 368 define corresponding apertures normally sealed by the spring-biased plunger 382. A second annular chamber 380 is axially aligned with the first chamber 374 and overlies the U-shaped channel of the plunger 382 bounded by electrically insulative thin wall membranes including the inner bellows seal 388 and axially aligned openings normally sealed by the spring-biased plunger 382 which extends in a sealable manner through first chamber front and rear opening 367, 368. In the preferred embodiment, a third chamber 392 axially aligned with and surrounding the first and second chambers 374a, 374b, 380, bounded by electrically insulative thin wall membranes and outer bellows seal 390 and axially aligned openings normally sealed by the spring-biased plunger 382 which extends in a sealable manner through said first, second and third chamber seal openings 367, 368 of the respective "a" and "b" channels. As will be S seen from Figure 8a, the annular expansion chamber 392 is common with plunger 382 with wiper arrangement 372a and is isolated therefrom in the construction shown with the "b" channel wiper arrangement 372b.

The enhanced face seal 394 of the outer bellows seal 390 presents discrete channel access apertures 395 which can be presented in higher density than heretofore. As the OD1 style cylindrical conductor bodies exemplified in Figures la to lc are eliminated, enhanced sealing of the dielectric media chambers is facilitated. By radially offsetting the through-body conductors 350, the bore of the termination cable can be reduced. Additionally, the incidence of conductor failure after mating is minimized.

Connector reliability and durability is enhanced by protecting the socket contacts 148, 248, 348 by providing successive seals encapsulating dielectric media chambers which are less likely to be exposed to contamination or suffer loss of media.

The improved construction, sealing and durability of the connectors hereinabove described lend themselves to increase capacity and hybrid use. In addition to the angular arrangement of the sockets circuit channels, as will be seen particularly in Figure 7, further channels may be disposed at or adjacent the central longitudinal axis of the connector part and may form any one or more of the following: an additional electric or data circuits; a fiber optic connector interface; and a valve assembly for coupling a fluid feed hose.

It will be noted that in each of the preferred embodiments of the invention described, exterior protective housings or shell have been omitted. The interior support bodies and closely associated components of any given connector parts have been illustrated only to aid in clarity and to avoid any undue inference that the shape and configuration of the exterior profiles of the support bodies, chambers, channel seals or support body 0-ring seals is determined by or restricted to any given exterior S housing or protective shell shape. Similarly, it will be understood that the connector parts illustrated do not form complete component parts for connector implementation and represent the interior assemblies only.

It will of course be understood that the invention is not limited to the specific details described herein, which are given by way of example only, and that various modifications and alterations are possible within the scope of the appended claims.

Claims (25)

1. CLAIMS: I. A terminal or two-part connector comprising male and female parts having a common centrally disposed longitudinal mating axis, the male part including a plurality of probe pins corresponding to a desired number of circuit channels and the female part including axially aligned guide members for each one of the circuit channels, the guide members being adapted to receive the probe pins when the parts are mated, in which the female part has a support body encapsulating through-body conductors disposed parallel to the longitudinal mating axis and offset from the axially aligned guide members.
2. 2. A terminal or two-part connector as claimed in Claim 1, in which the axially aligned guide members comprise a face seal and rear seal between which is disposed a connecting socket adapted to communicate with a conductive element of a probe pin.
3. 3. A terminal or two-part connector as claimed in Claim 2, in which the front and rear seals together define a channel chamber from which dielectric fluid is displaced during mating of the connector parts.
4. 4. A terminal or two-part connector as claimed in Claim 2 or Claim 3, in which a wiper arrangement is disposed between said front and rear seals to remove excess dielectric fluid from a probe pin during mating or demating of the connector parts.
5. A terminal or two-part connector as claimed in any one of Claims 2 to 4, in which a unitary flexible face seal element removably secured to the support body incorporates at least said front and rear seals.
6. 6 A terminal or two-part connector as claimed in any one of the preceding claims, in which the axially aligned guide members includes a biasing spring and plunger on which the spring acts, the plunger being moveable between an extended position, in which the plunger cooperates with the front and rear seals to maintain dielectric fluid within defined channel chambers, and a retracted position when dielectric fluid is displaced during mating of the connector parts.
7. 7. A terminal or two-part connector as claimed in Claim 6, in which the spring and plunger are accommodated in a channel chamber defined on one side by a first or inner bellows seal which is adapted to entrain the volumetric total of the dielectric fluid of each of the plunger channel chambers.
8. 8. A terminal or two-part connector as claimed in Claim 7, in which the inner bellows seal is overlaid by an outer bellows seal defining therebetween an expansion chamber to accommodate displacement of dielectric fluid during mating or demating of the connector parts.
9. 9. A terminal or two-part connector as claimed in Claim 8, in which the outer bellows seal includes an enhanced face seal to present an improved compression surface for the mated component parts.
10. 10. A terminal or two-part connector as claimed in Claim 1, in which the female part has a connecting socket located within a first chamber of each circuit channel, the channel chamber containing dielectric fluid and being bounded on at least one surface by an electrically insulative thin wall membrane and axially aligned openings normally sealed (when unmated) by a spring-biased plunger and in which a second annular chamber axially aligned with each of said first chambers, bounded on at least one surface by an electrically insulative thin wall membrane, axially aligned guide members normally sealed by said spring-biased plunger which extends in a sealable manner through said guide members
11. 11. A terminal or two-part connector as claimed in Claim 10, in which a third annular chamber axially aligned and surrounding said first and second chambers, is bounded on at least one surface by an electrically insulative thin wall membrane and said axially aligned guide members normally sealed by said plunger which extends in a sealable manner through said first, second and third chambers.
12. 12 A terminal or two-part connector as claimed in Claim 11, in which said first, second and third chambers of the female part contain dielectric fluid and each provided with respective openings, the openings being axially aligned and normally sealed by the plunger which extends therethrough when unmated, the first chamber being axially aligned with the circuit channel of the respective plunger, the second and third chambers being substantially annular and axially aligned with the S longitudinal mating axis, said third chamber annularly overlying the second chamber.
13. 13 A terminal or two-part connector as claimed in any one of Claims 10 to 12, in which the second chamber containing a biasing spring and plunger on which the spring acts, the spring and plunger being electrically isolated from the conductive connecting socket of its respective circuit channel and conductive and/or corrosive fluid within which the connector is operably immersed.
14. A terminal or two-part connector as claimed in any one of Claims 10 to 13, in which said first and second chambers of the female part contain dielectric fluid and each provided with respective openings, the openings being axially aligned and normally sealed by the plunger which extends therethrough when unmated, the first chamber being axially aligned with the circuit channel of the respective plunger and bounded by the second annular chamber, whereby as the plunger is electrically nonconductive, should the dielectric fluid of first and/or second chamber become contaminated or be replaced by a conducting media, such as seawater, the affected circuit channel will not fail.
15. 15. A terminal or two-part connector as claimed in any one of the preceding claims, in which the male part has a support body encapsulating through-body conductors disposed parallel to the longitudinal mating axis and extending into the probe pins to form a conductive element thereon which operable connects to a connecting socket of the corresponding circuit channel of the female part during mating of the connector parts
16. 16. A terminal or two-part connector as claimed Claim 15, in which the conductive element forms a collar on the shaft of the probe pin electrically isolating the tip thereof
17. 17. A terminal or two-part connector as claimed in any one of the preceding claims, in which through-body conductors of the male and female parts have at their respective terminal ends a pin receiver embedded within the support body thereof and operably connected to a conductor of a conductor bundle or multi-conductor S cable via a conductor pin attached to the exposed end of said conductor.
18. 18. A terminal or two-part connector as claimed in any one of the preceding claims, in which each of the male and female parts have at their respective terminal ends multiple conductors of a conductor bundle or multi-conductor cable operably connected thereto, each conductor passing through an inner and outer boot seal, the inner boot seal having a plug member for securing within a corresponding receiver within the terminal end of the support body thereof and said outer boot seal being fastened to the inner boot seal by a retaining pin adapted to fix to the plug member of said first boot seal.
19. 19. A terminal or two-part connector as claimed in any one of the preceding claims, in which each of the male and female parts have at the terminal ends of the respective support bodies multiple conductors of a conductor bundle or multi-conductor cable operably connected thereto via pin receivers embedded within each support body, each conductor being provided with a conductor pin soldered or crimped thereto, each conductor pin includes profiled head and neck portions defining angled or bevelled transitional surfaces therebetween, the angle of said surfaces determining the amount of force required to release a pin from locking engagement with a corresponding pin receiver, each pin receiver having a retention means which include locking portions adapted to engage the neck of the conductor pin received therein
20. 20. A terminal or two-part connector as claimed in Claim 19, in which the retention means releasable locks the pin within the receiver according to the prescribed angles of the bevelled surfaces and includes means to permanently lock the conductor pin within the receiver.
21. 21. A solderless interconnection between conductor elements comprises: a conductor pin having a substantially tubular socket adapted to receive the unsheathed end of a conductor (wire) at one end and a profiled shaft at the other end, and a pin receiver adapted for coupling to a (through-body) connector and having a receiving socket portion within which is disposed a pin retention means applying a constant retaining force on an inserted conductor pin, in which the profile shaft includes a bevel surface against which the retaining means operatively acts to determine the retention force to be overcome to withdraw the pin.
22. 22. A solderless interconnection between conductor elements as claimed in Claim 21, in which the profiled shaft includes a distal head portion connected thereto by a neck between which the bevel surface is disposed.
23. 23. A solderless interconnection between conductor elements as claimed in Claim 22, in which the angle of the bevel surface with respect to the longitudinal axis of the profiled shaft determines the retention force to be overcome.
24. 24. A method of locking conductors within a connector part, the method including: unbundling conductors from a multi conductor cable, exposing the conductor tips by stripping the sheathing therefrom; fixing the exposed conductor tips within receiving ends of profiled conductor pins; and slidingly engaging the conductor pins into pin receivers having pin retaining means secured to or fixed within a terminal contact of a through-body conductor of a connector part.
25. 25. A method of locking conductors within a connector part as claimed in Claim 24, the method further comprising crimping the receiving ends of the profiled conductor pins to the exposed conductor tips to provide a solderless connection between conductors of a multi-conductor cable and a connector part.