WO2018152207A1 - Connecteur électrique submersible pouvant être accouplé par voie humide - Google Patents
Connecteur électrique submersible pouvant être accouplé par voie humide Download PDFInfo
- Publication number
- WO2018152207A1 WO2018152207A1 PCT/US2018/018187 US2018018187W WO2018152207A1 WO 2018152207 A1 WO2018152207 A1 WO 2018152207A1 US 2018018187 W US2018018187 W US 2018018187W WO 2018152207 A1 WO2018152207 A1 WO 2018152207A1
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- WO
- WIPO (PCT)
- Prior art keywords
- pin
- connector
- insert holder
- sheath
- electrical connector
- Prior art date
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
- H01R24/28—Coupling parts carrying pins, blades or analogous contacts and secured only to wire or cable
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
- H01R13/521—Sealing between contact members and housing, e.g. sealing insert
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
- H01R13/5216—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases characterised by the sealing material, e.g. gels or resins
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
- H01R24/20—Coupling parts carrying sockets, clips or analogous contacts and secured only to wire or cable
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
- H01R13/523—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases for use under water
Definitions
- the present disclosure relates to an electrical connector that can be mated and unmated in a harsh environment, such as when wet, to connect two cables or to connect a cable to electrical equipment, and to an electrical pin for this type of connector.
- Electrical connectors typically consist of a plug and receptacle that are attached to cables and/or equipment.
- a first type of common design for electrical connectors consists of a plug and receptacle that each include a housing, an insert to hold various numbers of electrical pins, male conductor pins, and female conductor sockets. The pins and sockets are installed into the inserts and those subassemblies are then installed into the plug and receptacle housings. To make an electrical connection, the plug is inserted into the receptacle so that the male pins make an electrical connection with the female sockets. Typically a threaded coupling sleeve or other retaining method is used to secure the plug to the receptacle.
- a polarized electrical pin pattern, polarizing pin, or keyway can be used to prevent the connector from being incorrectly mated.
- This general design is used on many different types of connectors due to its simplicity and because connectors with different numbers of conductors can be created with different inserts while using the same pins and housings.
- a second common design is used for wet-mateable submersible electrical connectors that consists of a plug and receptacle that include electrical pins that are connected to wires and overmolded with rubber or similar material.
- the male electrical pins are partially sheathed with overmolded rubber material with a diameter slightly larger than the electrical pin.
- the overmolded material around the female sockets is made such that the female sockets are recessed so that when the male half of the connector is mated to the female half of the connector, the sheath around the male pin seals within the female portion of the connector, forming an individual watertight seal for each pin.
- Each pin is then electrically isolated, even if the connector is mated when wet or submersed.
- the above-mentioned first known type of connector is often made to be submersible by including O-ring seals in the connector housing to prevent water from entering the connector when submerged.
- O-ring seals in the connector housing to prevent water from entering the connector when submerged.
- a small amount of air is enclosed in the connector when it is mated and the pins are not individually sealed from one another. Therefore, the connector cannot be mated and unmated when wet, a feature that is highly desirable on electrical equipment that is installed near water or submersed.
- the above-mentioned known overmolded connector design is typically manufactured by assembling the pins to the wires of a cable, inserting the pins into a mold, and overmolding the rubber material to the assembly.
- Various problems are encountered with that connector design.
- a separate mold design is required for the plug and the receptacle.
- molds are needed for each connector with a different number of pins and for each connector with different shape and size. Molding tooling is generally expensive, requires expensive machinery to utilize (or to manufacture), and requires tedious setup.
- the known overmolded type of connector is difficult to install to equipment or cables in situ.
- the overmolded connectors are fully assembled when manufactured and are typically sold with a short length of cable, or pigtail, attached to the connector.
- the user To install the connector to a cable or piece of equipment, the user must splice the cable with the pigtail and then add an additional overmolded section to seal the splice. Kits consisting of a mold and pre-measured overmolding compound are sold to address this need but they are expensive and result in bulky connections.
- a unique electrical connector is provided in which one or more connector pin assemblies are individually inserted into a discrete pin insert holder to each form a watertight seal.
- the one or more connector pin assemblies each include an electrically conductive shaft and a sheath surrounding at least a portion of the shaft, in which each pin assembly is individually separate and distinct from the pin insert holder, and each pin assembly is configured to be individually insertable into a cavity of the pin insert holder, whereupon each pin assembly is configured to interface with an interior wall defining the cavity to form a watertight seal between the pin assembly and the holder.
- each connector pin assembly may be a discrete standalone unit that is independent of the other connector pin assemblies, in which each discrete pin assembly is configured for individual sealing insertion into a respective cavity of the distinct insert pin holder.
- Such an electrical connector may enable a user to assemble the one or more connector pin assemblies with the pin insert holder in situ, such as in the field, without special skill and/or without the electrical connector being pre-fabricated to have the connector pins integrated into the pin insert holder, which may eliminate or reduce cable splicing in the field, or the need for overmolding the connector pins integrally with the holder.
- an aspect of this disclosure relates to an electrical connection system and parts thereof with low manufacturing cost, high pressure resistance, and highly flexible configuration.
- enabling the one or more connector pin assemblies to be individually insertable and/or removable from the housing may allow the connector pin assemblies to be produced in mass quantities separate from the pin insert holders, which improves manufacturing flexibility, modularity, and/or manufacturing costs.
- An aspect of this disclosure relates to at least one electrical connector pin assembly having a rigid or hard sheath, in which the sheath is made of a non-electrically conductive material and is configured to be slidably inserted into a cavity of a discrete pin insert holder to thereby sealingly engage with a resilient or elastic interior wall of the holder to form a watertight seal.
- Another aspect of this disclosure relates to at least one electrical connector pin assembly having a resilient or elastic sheath configured to be inserted into a cavity of a discrete pin insert holder to form a watertight seal between the sheath and the holder.
- Another aspect of this disclosure relates to at least one discrete connector pin assembly having a sheath at least partially surrounding an electrically conductive shaft, the pin assembly further including one or more seals surrounding the shaft, in which the seals are configured to sealingly engage an interior wall of a discrete pin insert holder when the pin assembly is slidably inserted into a cavity of the holder, thereby forming a watertight seal.
- Another aspect of this disclosure relates to one or more individually discrete electrical connector pin assemblies, each having an electrically conductive shaft and a sheath surrounding at least a portion of the shaft, in which the sheath has a sealing interface configured to slidably insert into a cavity of a discrete pin insert holder to thereby sealingly engage with an interior wall of the holder to form a watertight seal.
- FIG. 18 Another aspect relates to a connector including of a plug and receptacle that may include the connector pin with an elastic or resilient sheath sealing material.
- Another aspect relates to a connector system that while submerged in water or in another harsh environment can be assembled to make effective connections.
- Another aspect relates to a connector system that is waterproof and can be assembled to make connections while submerged in water.
- Another aspect relates to a connector that operates in a submersed environment such as the ocean and at high pressures such as at substantial depth, possibly even the full depth of the ocean.
- Another aspect relates to a connector that can be mated and unmated when submersed or in a harsh environment.
- Another aspect relates to a connector that is substantially lower cost than existing submersible connectors and wet-mateable submersible connectors.
- Another aspect relates to a connector and connector pin structure or design described here that is a unique approach that addresses one or more of the above needs.
- Another aspect relates to a connector including one or more of the following and/or a combination of all of the following:
- an individually sealed electrical conductor pin with first and second ends, at least one end adapted for connection to an electrical wire, and a sheath extending along part of the length of the pin, configured such that a seal is formed when the pin is inserted into a discrete pin insert holder or properly designed cavity;
- the sheath may be made of non-conductive material
- the sheath may be made of a rigid or hard material, and may be configured to engage a resilient or elastic interior wall of a pin insert holder to form a watertight seal;
- the rigid sheath may be made of acetal, polyether ether ketone (PEEK),
- PTFE polytetrafluoroethylene
- PC polycarbonate
- ABS acrylonitrile butadiene styrene
- HDPE high-density polyethylene
- LDPE low-density polyethylene
- PVC polyvinyl chloride
- PPS polyphenylene sulfide
- the pin insert holder and/or the interior wall of the pin insert holder may be made of rubber or other similar resilient or elastic material, such as nitrile-butadiene rubber (NBR), ethylene propylene diene monomer rubber (EPDM), fluoroelastomer rubber (e.g., FKM), Buna- N, chloroprene, thermoplastic elastomer (TPE), polyurethane, and urethane;
- the sheath may be made of a rubber or similar resilient or elastic material, such as NBR, EPDM, FKM, Buna-N, chloroprene, TPE, polyurethane, and urethane, and may be configured to engage a rigid interior wall of the pin insert holder to form a watertight seal;
- the rigid interior wall and/or the pin insert holder may be made of acetal, PEEK, PTFE, PC, ABS, HDPE, LDPE, PVC, PPS, ceramic, or other suitable material;
- the connector pin may further include one or more seals, such as a rubber O-ring seal, in which at least one of the seals is configured to sealingly engage with an interior wall of the pin insert holder to form a watertight seal;
- seals such as a rubber O-ring seal, in which at least one of the seals is configured to sealingly engage with an interior wall of the pin insert holder to form a watertight seal;
- the connector pin may be an individually discrete connector pin assembly, which may be independent of the other connector pin assemblies, in which each discrete pin assembly may be configured for individual sealing insertion into a respective cavity of a separate insert pin holder;
- a pin insert subassembly that includes a pin insert that holds one or more individually sealed electrical conductor pins in such a way that the interaction between the sheath of non- conductive material on each pin and the insert material form a high-pressure watertight seal;
- a socket insert subassembly that includes a socket insert that holds one or more electrical conductor sockets
- an inline plug assembly including plug housing, a threaded coupling, a pin or socket insert subassembly, an electrical cable, and a sealing compound used to fill the open space in the plug housing and prevent water intrusion to the plug assembly from the side that the cable enters;
- an inline receptacle assembly including receptacle housing, a pin or socket insert subassembly, an electrical cable, and a sealing compound used to fill the open space in the receptacle housing and prevent water intrusion to the receptacle assembly from the side that the cable enters;
- a bulkhead receptacle assembly including bulkhead housing, a pin or socket insert subassembly, an electrical cable or wires, an O-ring seal, and a sealing compound used to fill the open space inside the bulkhead housing and secure the pin or socket insert subassembly;
- an integrated receptacle assembly including a unit of electrical equipment with the features of the bulkhead receptacle assembly substantially designed into the equipment.
- An aspect of the disclosure relates to an electrical connector, such as a signal conducting device, including an elongate shaft, the shaft having first and second terminal ends, a sheath surrounding the shaft along a length of the shaft, the sheath including a portion having an external diameter that is greater than the external diameter of another portion of the sheath, and wherein the greater diameter portion of the sheath is resilient and is configured to be deformed in response to engagement with another structure with respect to which the signal conducting device is at least partly inserted to cooperate with such another structure to form a seal.
- a signal conducting device including an elongate shaft, the shaft having first and second terminal ends, a sheath surrounding the shaft along a length of the shaft, the sheath including a portion having an external diameter that is greater than the external diameter of another portion of the sheath, and wherein the greater diameter portion of the sheath is resilient and is configured to be deformed in response to engagement with another structure with respect to which the signal conducting device is at least partly inserted to cooperate with such another structure to form
- An aspect of the disclosure relates to an electrical connector, such as a signal conducting device, having at least one electrical connector pin including an elongate shaft, the shaft having first and second terminal ends, a sheath surrounding the shaft along at least a portion of a length of the shaft, the sheath including a portion with at least one O-ring gland within which an O-ring is disposed, and in which the at least one O-ring is configured to be inserted and deformed in response to engagement with another structure, such as a pin insert holder, with respect to which the at least one connector pin is at least partially inserted to cooperate with such another structure to form a seal.
- another structure such as a pin insert holder
- An aspect of the disclosure relates to an electrical connector, such as a signal conducting device, having at least one connector pin that includes an elongate shaft, the shaft having first and second terminal ends, a sheath surrounding the shaft along at least a portion of a length of the shaft, wherein the sheath is made of hard or rigid material and is configured to engage at least partially with another structure made of soft or elastic material that will deform to cooperate with the connector pin to form a seal.
- Another aspect relates to a pin insert assembly, including the signal conducting device just above, and a body having at least one through cavity therein, the signal conducting device at least partly extending into the through cavity, at least part of the cavity having an interior wall configured to engage at least one external diameter portion of the sheath to form a seal.
- a socket insert assembly including an insert body having a cylindrical opening in the body, a signal conducting socket mounted in the opening and having a socket-like opening to receive and to resiliently retain a male signal conducting device, and wherein the cylindrical opening is bounded by a wall that is configured to cooperate with a resilient or hard sheath of a male signal conducting device as a seal.
- a sealed electrical conductor pin including an electrically conductive shaft having first and second ends, a sheath of elastomeric material around a center portion along a length of the shaft, one end of the shaft being of sufficient length to be inserted into a female socket for mechanical engagement and electrical connection therewith, the other end of the shaft being electrically connectable to another device, the sheath being engaged with the center portion of the shaft about the circumference of the shaft along at least part of the length of the sheath, and the sheath having at least one ring with outer diameter larger than the largest diameter of the shaft and larger than other portions of the sheath.
- the ring is configured to be squeezed radially and expand axially in response to engagement with a surface upon insertion into an appropriately sized cavity to make a seal.
- a sealed electrical conductor pin including an electrically conductive shaft having first and second ends, a sheath of hard material around a center portion along a length of the shaft, one end of the shaft being of sufficient length to be inserted into a female socket for mechanical engagement and electrical connection therewith, the other end of the shaft being electrically connectable to another device, the sheath being engaged with the center portion of the shaft about the circumference of the shaft along at least part of the length of the sheath, and the sheath having a consistent outer diameter.
- a signal conducting device including a linearly extending signal conducting member having opposite ends, a resilient sheath surrounding the member along at least part of its length, the sheath including at least one portion that has a first diameter and at least a second portion that has a larger diameter than the first portion, the second portion configured to be resiliently deformed by a wall of a receiving opening into which the signal conducting device may be inserted to provide a seal.
- like reference numerals designate corresponding parts throughout the several views and may be used to designate like or similar parts in more than one embodiment. Also, primed reference numerals may be used to designate parts that are similar to parts designated by the same unprimed reference numeral.
- FIG. 1 is a cross-sectional view of an embodiment of a discrete and individually sealable electrical conductor pin assembly
- FIG. 2 is a cross-sectional view of an embodiment of an electrical conductor socket
- FIG. 3 is a cross-sectional view of individually sealed electrical conductor pins installed in a pin insert, thus forming a pin insert subassembly, and of electrical conductor sockets installed in a socket insert, thus forming a socket insert subassembly;
- FIG. 4 is an exploded isometric view, partly in section of an inline electrical connector assembly in accordance with an embodiment of the disclosure
- FIG. 5 is a cross-sectional view of an inline connector assembly made according to the disclosure.
- FIG. 6 is a cross-sectional view of a bulkhead connector assembly made according to the disclosure.
- FIG. 7 is a cross-sectional view of a connector assembly with dummy plug made according to the disclosure.
- FIG. 8 is a cross-sectional view of another embodiment of a discrete and individually sealable electrical conductor pin assembly having O-ring glands.
- FIG. 9 is a cross-sectional view of yet another embodiment of a discrete and individually sealable electrical conductor pin assembly
- FIG. 10 is a cross-sectional view of another embodiment of a bulkhead connector assembly made with the electrical conductor pin assembly in FIG. 9.
- the present embodiments generally relate to a unique electrical connector having one or more connector pin assemblies that are individually insertable into a discrete pin insert holder to form a watertight seal.
- Embodiments also generally relate to a submersible electrical connector and connector system that has a number of unique benefits including one or more of the ability to be mated and unmated in a harsh environment, operability at high pressures, low manufacturing cost, and flexible configuration.
- the exemplary electrical connector and/or connector system may allow a user to insert one or more of the pin connector assemblies into a separate and distinct pin insert holder in situ, such as in the field, without special skill and/or without the electrical connector being pre-fabricated to have the connector pins integrated into the housing, which may eliminate or reduce cable splicing in the field, or may reduce the need for new mold tooling and the need for overmolding the connector pins integrally with the housing.
- the present disclosure provides one or more individually sealed electrical conductor pins, and an electrical conductor socket, at least one discrete pin insert holder to hold the one or more pins and one or more sockets in various configurations, a housing to contain the insert with pins and/or sockets, and a sealing compound to fill the housing and prevent water intrusion.
- the individually sealed electrical conductor pin can be manufactured in large volume with low tooling cost and utilized on a wide range of different connector configurations without the need for new tooling or with minimal new tooling for each configuration.
- An embodiment of the invention may be priced to be substantially more affordable than existing submersible electrical connectors, which will allow more devices to use such connectors and help to expand the use of electrical devices and technology in submersed environments.
- the present disclosure provides an electrical connector that may be used to transmit electrical power, or electrical signals, suitable for use in a wide variety of applications that require submersible electrical connections.
- an embodiment of the invention may be used to connect underwater equipment such as lights and cameras for a SCUBA diver. Such underwater equipment can be modified to use these connectors or the equipment can be designed to use these connectors originally by the manufacturer.
- These connectors may also be used for equipment for manned or unmanned underwater vehicles, manned and unmanned surface vessels, sensors, motors, sonar devices, and a multitude of other applications.
- the present invention allows or facilitates the device to be used at high pressures underwater, such as near the bottom of the ocean and/or to be used in harsh conditions, such as in a wet environment.
- the present invention would allow electrical connectivity in these applications at a better price and with more configuration and installation options than existing available connectors.
- an embodiment of an electrical connector A having one or more individually sealed electrical conductor pin assemblies P that include a conductive shaft 1 with first and second terminal ends la, lb and a sheath 2 of electrically non-conductive rubber or other material around the center portion 2c of the shaft.
- the shaft may be generally linear as shown.
- the sheath 2 surrounds the shaft 1 along a length of the shaft, such as along the center portion of the shaft 1.
- the conductor pin assembly P (also referred to as conductor pin, or pin) may be of electrically conductive material, e.g., copper or another metal.
- the sheath 2 may be of a material that is resilient, flexible, elastic, elastomeric, or of similar characteristics such that it is both deformable and tends to try to return or to reacquire its original shape, e.g., as rubber.
- the sheath 2 may be of a material that may be resiliently
- the first end la of the pin P includes a round shaft 3 with smaller diameter than the overall or largest diameter of the pin and with sufficient length to be inserted into a female socket for mechanical engagement and electrical connection therewith.
- the first end la may also include a shoulder 4 with a diameter such that the sheath 2 of rubber or other material may be molded over the pin without escaping to the first end of the pin during the molding process.
- the second end lb of the pin P includes a solder cup 5 for attachment to a wire end, a threaded section 6 used to secure the pin in a pin insert holder 17, shown in FIGs. 3 and 4, for example, and described below, and a second shoulder 7 such that the sheath 2 of rubber or similar material may be molded over the pin without escaping to the second end of the pin during the molding process.
- the pin may use another type of wire connection, such as a crimp connection.
- the pin P instead of a solder cup 5, the pin P may be designed to connect to a printed circuit board with through-hole or surface-mount soldering methods.
- the threaded section 6 may be removed in favor of another method to secure the pin in the pin P insert, such as a press-fit.
- the center shaft 8 of the pin may be knurled, chemically primed, or otherwise treated to improve adhesion of the sheath 2 material to the pin.
- the sheath 2 of rubber or similar material is secured to the pin P by overmolding the sheath material onto the pin.
- a mold is made in such a way that the overmolded material is applied only where needed and with the desired shape.
- the sheath 2 may be made with other methods such as heat-shrink material or separate molding and installation.
- the overmolded material has a shape intended to provide a robust seal and easy installation, as is described below.
- the distal ends 9 of the sheath are made with a diameter similar to the first shoulder 4 and second shoulder 7.
- the center portion of the sheath includes one or more rings 10 with outer diameter larger than the diameter of the pin P, e.g., larger than the maximum diameter of the pin, which in the illustrated embodiment is at the shoulder 4, 7.
- the diameter of the rings is such that the rings are deformed, e.g., compressed, bent, radially compressed and axially expanded, as described herein, when inserted into a properly sized cavity, e.g., by engagement with a wall of the cavity to make a seal.
- the remaining portion of the sheath 2 that is between each of the rings 10 is made with a diameter that is sufficiently reduced to allow each of the plurality of rings 10 to be squeezed radially and expand axially. Due to the direction of insertion of the pin into a cavity, the rings 10 tend to expand axially towards the center of the sheath.
- the plurality of rings is not included and/or the sheath may include other shapes designed to seal the pin from water intrusion.
- an embodiment of the electrical conductor socket S includes a conductive shaft 11 with first and seconds ends 11a, 1 lb.
- the first end 11a includes a solder cup 12 for attachment to a wire end
- the second end 1 lb includes an expandable cavity 13 in which the first end la of shaft 3 of the individually sealed electrical conductor pin P can be inserted.
- the expandable cavity 13 is formed by a wall 14w that has one or more slots 14s in the wall that allow the cavity to expand as a pin with diameter larger than the inside diameter of the cavity is inserted into the cavity.
- the electrical conductor socket S also includes a threaded section 15 used to secure the socket into a socket insert 20 (FIGS. 3 and 4).
- a shoulder 16 with diameter larger than the threaded portion 15 is used to limit the depth at which the socket can be installed in a socket insert.
- FIGS. 3 and 4 the electrical connector, such as an inline connector assembly A of the pin insert holder 17 and socket insert holder 20 (also referred to as socket insert 20) is illustrated.
- an embodiment of the pin insert holder 17 (also referred to generally as pin insert 17) includes a discrete body 17a having cavities 18 in which the individually sealed electrical conductor pins P are installed.
- the pin insert holder 17 is separate and distinct (not integral) with respect to the conductor pins P, and each conductor pin P is configured to be individually inserted into a respective pin insert cavity 18 to interface with an interior wall 18W defining the cavity 18 to thereby form a watertight seal.
- the inner diameter, e.g., wall 18w, of the cavity 18 may be made such that a portion of the sheath 2 is compressed or deformed while maintaining engagement with the wall of the cavity 18 as the pin P is installed into the cavity, thus forming a watertight seal between the pin P and the pin insert holder 17.
- the cavity 18 opens on one side of the pin insert holder 17 for receiving the pin P, and the cavity 18 is configured as a through-passage having an opening on an opposite side of the pin insert holder 17 for passage of an opposite end of the pin P, or for a wired connection to the opposite side of the pin P.
- each conductor pin assembly P is a discrete pin assembly that is independent of the other connector pin assemblies, in which each discrete pin assembly P is configured for individual sealing insertion into a respective cavity of the distinct insert pin holder. It is understood, however, that in other embodiments the conductor pin assemblies P may be grouped integrally or sub- assembled together for sealing insertion of each individual pin assembly P into a respective cavity 18 of the discrete pin insert holder 17.
- an embodiment of the socket insert 20 includes an insert body 20a having cavities 21 in which the electrical conductor sockets S are installed with female threading 22 to secure the socket via mating socket threads 15.
- the second end 1 lb of the socket S is disposed within a round cavity 21 that has inner diameter such that when the pins P are inserted into the respective sockets S and engage respective walls 21 w of the cavity, the sheath 2 is compressed or deformed by engagement with the wall of the cavity 21 as the pin is inserted into the cavity, thus forming a watertight seal between the pin P and the socket insert 20.
- the length of the cavity 21 is such that when the pins P are inserted into the sockets S the pin insert 17 is pressed against the socket insert 20.
- the pin and socket inserts 17, 20 are constructed with a non-electrically conductive material such that no electrical connection is formed between the conductor pins P and sockets S when they are installed to the respective inserts 17, 20.
- a guide pin G in the pin insert 17 fits into and cooperates with a guide opening G' in the socket insert 20 to help guide aligning of the pin and socket inserts 17, 20 for proper alignment and insertion of pins P into respective sockets S.
- the pin insert 17 is then installed into the pin insert housing 23, which has a lip or ledge 28 to constrain the position of the pin insert, which may be secured with adhesive or other method.
- the socket insert 20 is then installed into the socket insert housing 24, which also has a lip or ledge 29 to constrain the position of the socket insert, which may be secured with adhesive or other method.
- the pin insert housing 23 and socket insert housing 24 are then substantially filled with a sealing compound 27 such as epoxy, silicone, urethane, or similar compound to fill the housing and seal the solder connections, e.g., of wires 26 to solder cups 5, 12, from water.
- a sealing gland or packing gland may be used to seal the wires or cable without a sealing compound.
- a coupling ring 25 with threading is used to secure the pin insert holder 17 to the socket insert holder 20.
- the coupling ring 25 may be slid along the outside of the socket insert housing 24 to about a flange 25f on the socket insert housing and be tightened at a threaded connection 25t to hold the housings together.
- an embodiment of a bulkhead connector assembly B includes the same components as the inline connector assembly A except that the pin insert housing 23 is substituted for a pin insert housing 30 with bulkhead design.
- the bulkhead pin insert housing 30 is designed to be installed into a hole, e.g., of a bulkhead, and sealed with an O-ring placed in an O-ring gland 31 so that the wires or cable 26 may be passed into a watertight enclosure.
- the assembly method is also similar as described above and the bulkhead housing 30 also may be sealed by filling with a sealing compound 27.
- the housing or shell may also include O-ring seals to provide redundant seals to increase reliability of the connector.
- an embodiment of the connector assembly includes a dummy plug 32 used to seal the connector pins P from water when a mating connector is not available or is not desired to be used.
- the dummy plug 32 is made of non-conductive material and includes one or more cavities 33 positioned to accept the pins P and with diameter such that the pin sheath P compresses and forms a seal with the cavity 33.
- the bulkhead housing 30 holds the socket insert 20 instead of the pin insert 17 and the plug housing 24 holds the pin insert 17 instead of the socket insert 20.
- This method may be used in situations where the polarity of a connector is chosen for safety. For example, if active power is applied to a bulkhead connector, it may be desirable to use a bulkhead connector with sockets so that a person is less likely to make contact with the electrical conductors and harm themselves or cause damage to the equipment.
- FIG. 8 another embodiment of an individually sealed electrical conductor pin assembly P' is shown.
- the conductor pin assembly P' is substantially similar to the above- referenced conductor pin assembly P, except that one or more seals, such as O-ring seals 135, are utilized to provide a sealing interface with the internal cavity of the insert housing.
- one or more seals such as O-ring seals 135, are utilized to provide a sealing interface with the internal cavity of the insert housing.
- the sheath 102 is formed between the shoulders 104, 107, and includes one or more seal glands 137 configured to receive one or more seals 135, such as an O-ring seal.
- the sheath 102 is made of a non-electrically conductive rigid material, such as acetal, PEEK, PTFE, PC, ABS, HDPE, LDPE, PVC, PPS, or ceramic, and the sheath 102 is molded to form the O-ring gland 137.
- the gland dimensions may be designed to suit a standard or custom O-ring shape and material.
- the rearward seal 135 (located toward the rearward shoulder 107) is configured to provide a sealing interface within the cavity of the pin insert holder, and the forward seal 135 (located toward the forward shoulder 104) is configured to provide a sealing interface within a cavity of the socket insert holder.
- FIGS. 9 and 10 another exemplary embodiment of an individually sealed electrical conductor pin assembly P" is shown.
- the conductor pin assembly P" is substantially similar to the above-referenced conductor pin assemblies P, P', except that the sheath 202 is rigid or resilient and is configured to interface with an elastic interior wall of the cavity of the pin insert holder to form the watertight seal. Consequently, the same reference numerals but indexed by 200 are used to denote structures corresponding to similar structures in the corresponding conductor pin assemblies.
- the foregoing description of the conductor pin assemblies P, P' ' are equally applicable to the conductor pin assembly P' ' except as noted below.
- conductor pin assemblies P, P', P" may be substituted for one another or used in conjunction with one another where applicable.
- the sheath 202 may be made of a suitable rigid material, such as acetal, PEEK, PTFE, PC, ABS, HDPE, LDPE, PVC, PPS, ceramic, or may be made of a suitable resilient or elastic material, such as NBR, EPDM, FKM, Buna-N, chloroprene, TPE, polyurethane, urethane, or other suitable non-conductive materials.
- the sheath 202 may have an outer surface (e.g., cylindrical surface) having a consistent outer diameter along a length thereof. In this manner, the pin assembly P" including shaft 201 and sheath 202 may be at least partially slidably inserted into a cavity of the pin insert holder 217 (shown in Fig. 10) having the resilient internal walls and/or body.
- FIG. 10 An exemplary electrical connector, such as a bulkhead connector A", which utilizes the connector pin assembly P" is shown in Fig. 10.
- the body of the pin insert holder 217 and/or the internal walls of the cavities 218 are made of an elastic or resilient non-conductive material, and the cavities 218 are formed with a diameter slightly smaller than the diameter of the sheath 218 on the pin, such that when the pin P" is slidably inserted into the pin insert holder 217, the material of the pin insert holder 217 conforms to the pin P" to form a watertight seal.
- the socket insert holder 220 is configured to receive the electrical conductor sockets S" within cavities 221 in a similar manner as described above.
- the body of the socket insert 220 and/or the internal walls of the cavities 221 are made of an elastic or resilient non-conductive material
- the cavities 211 may have an inner diameter slightly smaller than the diameter of the sheath 218 on the pin, such that when the pin P" is inserted into the socket cavity 211, the material of the socket insert holder 220 stretches and conforms to the pin P", thus forming a watertight seal between the pin and the socket insert.
- the pin P" has length such that when the pins are inserted into the sockets the pin insert is pressed against the socket insert.
- the pin insert holder 217 and/or the socket insert holder 220 may be at least partially disposed within a pin insert housing and/or socket insert housing, as described above with reference to FIG. 5.
- the pin insert holder 217 and/or the socket insert holder 220 may at least partially extend from the respective housings so that the outer portion of the housing is exposed to the water. In this manner, when used under water, the external water pressure will exert a compression force on the pin insert holder 217 and/or socket holder 220 to compress the resilient or elastic material of the insert holder 217, 220, thus enhancing the sealing ability with the pin P" .
- the pin P" may utilize a relatively hard sheath material with a uniform diameter to improve its manufacturability, while also providing satisfactory sealing performance of the electrical connector by utilizing a resilient or elastic holder material that compresses to further enhance sealability when external water pressure is applied via submersion of the connector.
- the socket assemblies could have sheaths and or sealing surfaces configured to be individually sealable with the socket insert holder, or both the pins and sockets could have individual sealing functions as described above.
- the individually sealed electrical conductor pin may have overmolded material in other areas, such as at a distal end of the pin. This may allow the pin to be inserted into a cavity that is substantially open at first and second openings. When the pin is inserted into the first opening, any liquid contained in the cavity would be ejected out of the second opening. When completely inserted the overmolded material at the distal end of the pin would form a high pressure watertight seal so that both the first and second openings are sealed from liquid intrusion. This method may be used for a connector designed to be connected when fully submersed.
- the individually sealed electrical conductor pin may be made to transfer signals of non-electrical type.
- the pin may be designed to transfer optical signals from a fiber optic element.
- the pin may be designed to transfer fluid such as air or oil.
- the individually sealed electrical conductor pin is made with multiple layers of coaxial conductive and non-conductive materials with each layer of conductive material exposed at the first and second ends. This allows multiple electrical connections to be made with a single sealed pin.
- the center portion of the pin has a sheath similar to the preferred embodiment, but there may also be sheaths of rubber or similar material between the exposed surfaces of each conductive layer such that a seal can be formed between each conductive layer of the pin.
- the sheath of the pin assembly and/or the internal wall or body defining the cavities of the pin insert holder may be made of any suitable rigid or resilient material as discussed above.
- a resilient, elastic or soft material is one that is able to recoil or spring back toward its original shape after bending, stretching, or being compressed, preferably without plastic deformation.
- Exemplary resilient materials may include, but are not limited to, NBR, EPDM, FKM, Buna-N, chloroprene, TPE, polyurethane, and urethane.
- a rigid or hard material is one that is not easily able to bend or forced out of shape without plastic deformation.
- Exemplary rigid materials may include, but are not limited to acetal, PEEK, PTFE, PC, ABS, HDPE, LDPE, PVC, PPS, and ceramic.
- An electrical connector has been described herein having one or more connector pins for use in harsh environments, such as underwater connections.
- the one or more connector pins may each have a conductive shaft and a sheath at least partially surrounding the shaft.
- Each connector pin assembly is configured to be inserted into a cavity of a discrete pin insert holder, and is configured to interface with an internal surface of the holder defining the cavity to form a watertight seal between the pin and holder.
- the connector pin assemblies may protrude from the pin insert holder to be received within corresponding sockets, such that the electrical connector may be mated or unmated in the harsh environment.
- the sheath may be a rigid material configured to sealingly interface with a resilient material of the holder.
- the sheath may be a resilient material configured to sealingly interface with a rigid material of the holder.
- the connector pin assembly may include seals to facilitate sealing between the pin and holder.
- an electrical connector for submersible electrical connection includes: one or more connector pin assemblies, each connector pin assembly having an electrically conductive shaft and a sheath at least partially surrounding the shaft; a discrete pin insert holder having one or more cavities configured to receive the one or more connector pin assemblies; wherein each of the one or more connector pin assemblies is configured for individual insertion into the respective one or more cavities of the discrete pin insert holder; and wherein each of the one or more connector pin assemblies is configured to sealingly interface with a corresponding internal surface defining each of the cavities to form a watertight seal.
- Embodiments of the present disclosure may include one or more of the following additional features, alone or in any combination:
- Each of the one or more connector pin assemblies may be a discrete connector pin assembly, each discrete connector pin assembly may be individually insertable into the discrete pin insert holder independently of other ones of the discrete connector pin assemblies. [98] The one or more connector pin assemblies may be at least partially slidably inserted into the respective one or more cavities of the discrete pin insert holder.
- the sheath may be made of a non-conductive rigid material.
- the sheath may have a uniform outer diameter.
- the internal surfaces defining the one or more cavities may be made of a non-conductive resilient material.
- Each of the one or more cavities may have a diameter that is less than an outer diameter of the sheath, such that upon insertion of the sheath into the cavity the internal surface of the cavity conforms to the outer diameter of the sheath to form a watertight seal.
- the pin insert holder may be made of a resilient material, and may be configured to compressingly engage the one or more connector pin assemblies when submersed under water and acted upon by external water pressure, thereby enhancing the sealing between the connector pin assembly and the pin insert holder.
- the electrical connector may further include a socket insert holder, the socket insert holder having one or more cavities configured for holding one or more sockets.
- At least a portion of the electrically conductive shafts and at least a portion of the sheaths of the one or more pin assemblies may protrude outwardly from the pin insert holder, the protruding portions being configured to be received in the one or more cavities of the socket insert holder.
- the socket insert holder may made of a resilient material, and may be configured to compressingly engage the protruding portions of the one or more sheaths when submersed under water and acted upon by external water pressure, thereby enhancing the sealing between the connector pin assembly and the socket insert holder.
- the sheath may include one or more seal glands, and the connector pin assembly may include one or more seals disposed within the one or more seal glands.
- At least one of the one or more seals may be configured to be inserted into a
- At least one other of the one or more seals may be configured to be inserted into a corresponding cavity of a socket insert holder to form a watertight seal between the connector pin assembly and the socket insert holder.
- the sheath may be made of a non-conductive resilient material.
- the sheath may have a portion having an external diameter that is greater than an external diameter of another portion of the sheath, and the greater diameter portion of the sheath may be resilient and may be configured to be deformed in response to cooperating engagement with the internal surface of the cavity of the pin insert holder to thereby form a watertight seal.
- the internal surface defining the cavity may be made of a non-conductive rigid material, and the greater diameter portion of the sheath may be configured to be compressed radially and expand axially in response to engagement with the internal surface upon insertion into the cavity.
- the sheath may be a cylindrical layer overlying and surrounding at least a portion of a length of the electrically conductive shaft, the sheath having a plurality of raised toroidal rings, such that when the connector pin assembly is inserted into one of the cavities, at least one of the plurality of toroidal rings is compressed to form a watertight seal.
- the electrical connector may further include a socket insert holder, the socket insert holder having one or more cavities configured for holding one or more sockets, wherein at least a portion of the electrically conductive shafts and at least a portion of the sheaths of the one or more pin assemblies protrude outwardly from the pin insert holder, the protruding portions being configured to be received in the one or more cavities of the socket insert holder; and wherein at least one of the plurality of raised toroidal rings is on the protruding portion of the sheath, such that when the connector pin assembly is inserted into one of the cavities of the socket insert holder, the at least one toroidal ring on the protruding portion of the shaft is compressed to form a watertight seal between the connector pin assembly and the socket insert holder.
- the connector pin assembly may have axially spaced apart shoulders, the sheath being disposed between the shoulders, and wherein the shoulders are configured to act as stops to restrict axial forward or reward movement of the sheath during insertion or removal of the connector pin assembly, or when acted upon by external water pressure when in use.
- the connector pin assembly may have threads for engaging corresponding threads of the pin insert holder for fixedly connecting the connector pin assembly to the pin insert holder.
- the connector pin assembly may have a connector for connecting an electrical wire.
- the electrical connector may further include a socket insert holder having one or more sockets disposed in one or more corresponding cavities, wherein the corresponding cavities and sockets disposed therein are configured to receive respective protruding portions of the one or more connector pin assemblies.
- the sheath may be made of acetal, PEEK, PTFE, PC, ABS, HDPE, LDPE, PVC, PPS, ceramic, NBR, EPDM, FKM, Buna-N, chloroprene, TPE, polyurethane, or urethane.
- the electrically conductive shaft may be an elongated cylindrical shaft made of copper, copper alloy, aluminum, aluminum alloy, or other similar metal or metal alloy.
- the pin insert holder may be made of acetal, PEEK, PTFE, PC, ABS, HDPE, LDPE, PVC, PPS, ceramic, NBR, EPDM, FKM, Buna-N, chloroprene, TPE, polyurethane, or urethane.
- the electrical connector may further include a socket insert holder for holding one or more sockets, and wherein the socket insert holder may be made of acetal, PEEK, PTFE, PC, ABS, HDPE, LDPE, PVC, PPS, ceramic, BR, EPDM, FKM, Buna-N, chloroprene, TPE, polyurethane, or urethane.
- a discrete connector pin assembly for an electrical connector, the discrete pin assembly including: an elongated electrically conductive shaft having first and second opposite end portions, the second end portion having a connector for connecting an electrical wire; and a non-conductive sheath at least partially surrounding the electrically conductive shaft between the first and second opposite end portions; wherein the discrete connector pin assembly is configured to be independently inserted into a cavity of a pin insert holder that is separate and distinct from the discrete connector pin assembly, such that the second end portion of the shaft is configured to extend into the cavity of the pin insert holder upon insertion, and the opposite first end portion is configured to protrude from the pin insert holder, and wherein the sheath is configured to engage and cooperate with an internal wall defining the cavity to form a watertight seal.
- an electrical connector kit includes: one or more individual connector pin assemblies, each connector pin assembly having an electrically conductive shaft and a non-conductive sheath at least partially surrounding the shaft; and a discrete pin insert holder separate and distinct from the one or more connector pin assemblies, the discrete pin insert holder having one or more cavities configured to receive the one or more connector pin assemblies.
- the electrical connector kit may further include one or more of: one or more sockets for receiving the one or more connector pin assemblies; a socket insert holder having one or more cavities for holding the one or more sockets and configured to receive the one or more connector pin assemblies; one or more wires for connecting to the one or more connector pin assemblies and/or the one or more sockets; solder for connecting the one or more wires to the one or more connector pin assemblies and/or the one or more sockets; a pin insert housing for at least partially containing the pin insert holder; a socket insert housing for at least partially containing the socket insert holder; and a sealing compound for filling at least a portion of the pin insert housing and/or the socket insert housing.
- a method of making an electrical connector includes: forming a connector pin assembly, including providing an electrically conductive shaft and applying a non-conductive sheath on at least a portion of the shaft; forming a pin insert housing separate and distinct from the connector pin assembly, the pin insert housing having a cavity configured to receive the connector pin assembly; inserting the connector pin assembly into the cavity through an opening on one side of the pin insert holder, wherein the connector pin assembly is configured to interface and cooperate with an internal surface of the cavity to form a watertight seal.
- the step of applying the sheath may include overmolding a rigid or resilient material around the shaft between axially spaced apart shoulders of the shaft.
- the step of forming the pin insert holder may include casting, molding, and/or machining.
- a signal conducting device includes an elongate shaft, the shaft having first and second terminal ends, a sheath surrounding the shaft along a length of the shaft, the sheath including a portion having an external diameter that is greater than the external diameter of another portion of the sheath, and wherein the greater diameter portion of the sheath is resilient and is configured to be deformed in response to engagement with another structure with respect to which the signal conducting device is at least partly inserted to cooperate with such another structure to form a seal.
- a pin insert assembly including: a signal conducting device, and a body having at least one through cavity therein, the signal conducting device at least partly extending into the through cavity, at least part of the cavity having an interior wall configured to engage at least one greater external diameter portion of the sheath to form a seal.
- a socket insert assembly including: an insert body having a cylindrical opening in the body, a signal conducting socket mounted in the opening and having a socket-like opening to receive and to resiliently retain a male signal conducting device, and wherein the cylindrical opening is bounded by a wall that is configured to cooperate with a resilient sheath of a male signal conducting device as a seal.
- a socket insert assembly includes: an insert body having a cylindrical opening in the body, a signal conducting socket mounted in the opening and having a socket-like opening to receive and to resiliently retain a male signal conducting device, and wherein the cylindrical opening is bounded by a wall that is configured to cooperate with a resilient sheath of a male signal conducting device as a seal.
- a sealed electrical conductor pin includes: an electrically conductive shaft having first and second ends, a sheath of elastomeric material around a center portion along a length of the shaft, one end of the shaft being of sufficient length to be inserted into a female socket for mechanical engagement and electrical connection therewith, the other end of the shaft being electrically connectable to another device, the sheath being engaged with the center portion of the shaft about the circumference of the shaft along at least part of the length of the sheath, and the sheath having at least one ring with outer diameter larger than the largest diameter of the shaft and larger than other portions of the sheath.
- the ring is configured to be squeezed radially and expand axially in response to engagement with a surface upon insertion into an appropriately sized cavity to make a seal.
- a signal conducting device includes: a linearly extending signal conducting member having opposite ends, a resilient sheath
- the sheath including at least one portion that has a first diameter and at least a second portion that has a larger diameter than the first portion, the second portion configured to be resiliently deformed by a wall of a receiving opening into which the signal conducting device may be inserted to provide a seal.
- an electrical conductor pin for use in harsh environments including: a conductive shaft with first and second ends; a cylindrical layer of soft non-conductive material extending over part of the length of the shaft, with a plurality of raised toroidal rings, such that when the pin is inserted into a cavity, the plurality of rings is compressed and forms a watertight seal between the sheath and the cavity.
- the individually sealed electrical conductor pin further including a pin insert with cavities in which to install the pin with inner diameter such that the sheath of soft non-conductive material is compressed sufficiently to form a watertight seal between the sheath and the cavity.
Landscapes
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Connector Housings Or Holding Contact Members (AREA)
Abstract
L'invention concerne un connecteur électrique ayant une ou plusieurs broches de connecteur pour une utilisation dans des environnements hostiles, tels que des connexions sous-marines. L'une ou plusieurs broches de connecteur peuvent chacune avoir un arbre conducteur et une gaine entourant au moins partiellement l'arbre. Chaque ensemble broche de connecteur est configuré pour être inséré dans une cavité d'un support d'insert de broche discret, et est configuré pour s'interfacer avec une surface interne du support définissant la cavité pour former un joint étanche à l'eau entre la broche et le support. Les ensembles broches de connecteur peuvent faire saillie à partir du support d'insert de broche pour être reçus à l'intérieur de douilles correspondantes, de telle sorte que le connecteur électrique peut être accouplé ou non dans l'environnement hostile.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US201762459271P | 2017-02-15 | 2017-02-15 | |
US62/459,271 | 2017-02-15 |
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WO2018152207A1 true WO2018152207A1 (fr) | 2018-08-23 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/US2018/018187 WO2018152207A1 (fr) | 2017-02-15 | 2018-02-14 | Connecteur électrique submersible pouvant être accouplé par voie humide |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN109301622A (zh) * | 2018-10-17 | 2019-02-01 | 辽宁瑞邦石油技术发展有限公司 | 一种碳纤维潜油导电杆 |
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US3344391A (en) * | 1964-02-14 | 1967-09-26 | Elastic Stop Nut Corp | Waterproof electrical connections |
US3792416A (en) * | 1972-04-03 | 1974-02-12 | Hughes Aircraft Co | System, method and seal for pressure-sensitive wire and interface sealing of electrical connector assemblies and associated contacts |
DE19515151A1 (de) * | 1995-04-25 | 1996-11-07 | Gisma Steckverbinder Gmbh | Druckwasserdichte Unterwasser-Steckverbindung |
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2018
- 2018-02-14 WO PCT/US2018/018187 patent/WO2018152207A1/fr active Application Filing
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
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US3344391A (en) * | 1964-02-14 | 1967-09-26 | Elastic Stop Nut Corp | Waterproof electrical connections |
US3792416A (en) * | 1972-04-03 | 1974-02-12 | Hughes Aircraft Co | System, method and seal for pressure-sensitive wire and interface sealing of electrical connector assemblies and associated contacts |
DE19515151A1 (de) * | 1995-04-25 | 1996-11-07 | Gisma Steckverbinder Gmbh | Druckwasserdichte Unterwasser-Steckverbindung |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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CN109301622A (zh) * | 2018-10-17 | 2019-02-01 | 辽宁瑞邦石油技术发展有限公司 | 一种碳纤维潜油导电杆 |
CN109301622B (zh) * | 2018-10-17 | 2023-11-07 | 辽宁瑞邦石油技术发展有限公司 | 一种碳纤维潜油导电杆 |
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