The present invention relates to a kit for use with field communication distribution equipment and, more particularly, to an improved cable connector seal kit that includes torque limiting spacers or stand offs.
The J-1077 A/U distribution box (hereinafter referred to simply as the “J-1077”) is used to interconnect military field telephones and other communication devices in mobile, transportable, and semi-permanent installations. The J-1077 has provisions for connection of one or two 26 conductor-pair cables to a set of 26 pairs of spring post connectors mounted on a panel within the box. The standard cable for use with J-1077 type boxes is designated CX-4566 A/G. As such, the J-1077 can interconnect two 26-pair cables or can terminate a single 26-pair cable and provide connections to the conductors within the cable, such as for telephone sets or test equipment. The J-1077 has been in use for several decades and has proved to be generally rugged and reliable in varied field conditions. Additional information about the J-1077 distribution box can be obtained from Associated Industries of North Hollywood, Calif. (www.associated-ind.com) and from other sources.
The J-1077 distribution box and the standard CX-4566 A/G cable were originally designed for carrying multiple channels of audio frequency telephone signals. Military field communications have evolved beyond voice and teletype communications to high speed data communications for text, numeric, and image date in addition to voice signals. United States military services also make use of an expanded field distribution box or signal distribution panel designated as the J-2317 A/U box (referred to hereinafter simply as the J-2317 box) which has the interconnection capabilities of four J-1077 boxes. The conventional J-2317 box includes four 26-pair cable connectors, designated as connectors A, B, C, and D. Each cable connector terminates at a respective set of binding posts to enable patching of communications devices to 26-pair cables connected to the cable connectors.
A number of shortcomings for the J-1077 and J-2317 boxes have been remedied by the communication equipment disclosed in co-owned U.S. Pat. No. 7,238,063, U.S. Pat. No. 7,445,520, U.S. Pat. No. 7,625,248, U.S. Pat. No. 7,625,249, and U.S. Pat. No. 7,628,659; the entire contents of which patents are incorporated herein by reference.
In order to provide for digital communications between computers and computerized equipment, improved J-1077 type distribution boxes may have some of the insulation displacement connectors interconnected to connectors more appropriate for computer networks or for interconnections between modems. Such connectors can include, but are not limited to, RJ-45 (8P8C), RJ-11, and RJ-12 modular type connectors; BNC type connectors; and other connectors commonly employed for interconnections between computers. Conductors of the cables interconnecting the improved J-1077 boxes and carrying data between computers may be shielded separately from the other conductor pairs to minimize possible interference to and from other signals on other conductor pairs. Data connectors and associated cable conductors would provide some limited computer networking capabilities in addition to more conventional analog voice communications in systems employing J-1077 type distribution boxes. Alternatively, other types of connectors can be connected to selected insulation displacement connectors, such as standard phone connectors, F-type connectors, fiber optic adapters, and other standard types of network, telephone, audio, video, and signal connectors. The insulation displacement connectors and the auxiliary connectors are connected to a pair of box connectors positioned on opposite sides of the box to enable the distribution box to be connected to other boxes. The box connectors have sets of contacts which correspond to the conductors of the insulation displacement connectors and the auxiliary connectors.
A preferred type of box connector is designated U-187 A/G which is referred to as a side mount connector in which a side of the box connector structure is joined to the side wall of the box. It is foreseen that the box connector could alternatively be a U-186 C/G connector which is substantially similar to the U-187 A/G except that the U-186 C/G connector is joined to a side wall of the box by an end of the connector structure.
A preferred type of cable includes a plurality of pairs of cable conductors positioned within a conductive shield and an insulative tubular sheath. The cable may also include an outer “armor” layer which reduces damage from being chewed by animals and from other hazards. Each end of the cable includes a cable connector with a plurality of sets of contacts to which the cable conductors are connected. The cable connector is configured to be compatible with the configuration of the box connector. The conductor pairs, in cooperation with the cable connector, are configured to comply with Category 5E (Cat 5E) specifications. Cat 5E conductor pairs are typically twisted at a twist pitch of three twists per inch (2.54 cm). Preferably, the twist is maintained within the cable connector to within one-half inch (12.7 mm) of the contact terminal set to which the conductors are soldered. The conductor pairs and connector may be configured to specifications more stringent than Cat 5E.
Cable connectors with the military designation U-185 B/G and U-187 A/G are used to connect 26-pair Cat 3 and Cat 5E cables with each other and with the J-1077 or J-2317 box. Typically, both ends of the cables will have U-185 B/G connectors which are compatible with both the U-187 A/G and U-186 C/G box connectors. The U-185 B/G connector is a “genderless” type of connector and may be connected to another U-185 B/G connector to thereby connect one cable to another cable. The cable may also be provided at one end with another type of connector, such as a standard type of multi-contact cylindrical connector designated MS-27467 or AE167, often referred to as a barrel or Cannon connector.
The cable connectors are designed to provide a weatherproof encasement for a contact array board assembly having the standard military designation of MX-3227/G. The MX-3227/G includes a circuit board that enables electrical contact through the cable to the field communication box. The MX-3227/G is installed in each of the mating halves of a pair of cable connectors by fasteners that extend inboard from the outside surface of the connector. The connection posts on the inward-facing surfaces of the circuit boards are evenly sized, but the inner surfaces of the cable connector shells are stepped. When properly installed, the board fits flat within the rim of its respective cable connector shell, with one side floating over the stepped down portion of the shell. In the field, technicians install or replace the boards by inserting screw-type fasteners through the outside of the housing and into the connection posts without benefit of any torque specifications. This inevitably results in over tightening of the connector to the board on the floating side of the board, causing a crooked installation. When two misaligned connectors are matingly engaged, this leaves open contacts or connection points and causes the field communication device to malfunction.
The U-185/U-187 connector system was designed and built in the early 1960's to be rugged and reliable. In use, however, the connectors can rarely be fully closed and locked. Field personnel address this issue by forcing the mating parts together, which exerts pressure on the existing gaskets and on the MX-3227/G circuit boards when they are forced together. When the connector cannot be fully closed, the compressed gaskets will force the connectors apart, causing loss of a positive seal, allowing entry of moisture and dirt, and may result in intermittent or continuous interruption of circuit continuity between the cable and the box. This creates a perceived need for active line retorque of the fasteners on the MX-3227/G insert in order force the parts together, which may result in damage to the insert.
Over tightening and failure to achieve full connector closure thus result in misalignment of the MX-3227/G contact array boards and damage from excessive gasket pressure, which result in poor electrical connections between the cable and the box, which negatively affects the performance and reliability of the field data distribution system. Because the U-185 B/G and U-185 A/G cannot be locked in a fully closed position, these connectors are not fully utilized, which results in waste of the substantial cache of cables and equipment that utilize the U-185 B/G and/or U-185 A/G.
Thus there is a need for a cable connection system for 26 pair Cat 5E cables and field communication boxes that enables them to be connected in a fully closed and locked position with the MX-3227/G contacts properly aligned for full contact, and without excessive torque or damage to the MX-3227/G insert. In addition, there is a need for such a cable connection system that would enable the military to utilize its existing cache of cables and equipment that employ the U-185 B/G and/or U-185 A/G connectors.
The present invention provides a greatly improved universal sealing solution kit with torque limiting standoffs or spacers for U-185 B/G and U-185 A/G connectors that allows for a full close of these connectors in a deployed situation without causing damage to the contact array board.
Embodiments of the present disclosure relate to a low torque outer gasket and compression inner gasket for providing stable gasket pressures within each connector interface and reducing the force required to obtain a fully closed and locked engagement of the connector parts. An array of torque limiting standoffs or spacers is sized for installation between the contact array board and the connector housing of the U-185 B/G and U-185 A/G to establish a predetermined position and pressure against the circuit boards so that all of the contact points will be aligned and engaged.
In one embodiment, the outer gasket includes a series of ribs
In one embodiment, the kit includes an array of torque limiting standoffs or spacers sized for respective use with the U-185 B/G and U-185 A/G connector housings with either Cat 3 or Cat 5E cables.
Various objects and advantages of the universal seal kit with torque limiting standoffs will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention.
The drawings constitute a part of this specification, include exemplary embodiments of the present invention, and illustrate various objects and features thereof.
As required, detailed embodiments of the universal seal kit with torque limiting standoffs are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the device, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the apparatus in virtually any appropriately detailed structure.
Referring now to the drawing figures, the reference numeral 1, (
Referring to
Referring to
Referring to
Referring to
The circuit board 120 and support blocks 124, 126, and 130 support a plurality of conductive contact members 134. Each contact member 134 includes a straight solder lug 136 with means such as an aperture 138 to receive a stripped end of a conductor 83 of a conductor pair 81. At an end opposite the aperture 138, a resilient contact pad 140 is formed. The illustrated contact pad 140 has a wide V-shaped ridge 142. When a cable connector 79 is joined with a box connector 56 or another cable connector 79, the ridges 142 of mutually engaging contacts 134 snap past one another to help retain the connectors together. The circuit board 120 is preferably a multi-layer circuit board with one or more internal ground plane layers (not shown) to form a shield in cooperation with the conductive shell 94. The solder lugs 136 of the contact members 134 extend through holes (not shown) in the circuit board 120 and are retained therein against the support blocks 124, 126, and 130. Each contact member 134 corresponds to a conductor 83. Each contact member 134 is replicated at opposite ends of the assembly 94 with internal traces (not shown) interconnecting the pairs of contacts 134. The patterns of contact members 134 at opposite ends of the contact array board assembly 94 are mirror images of one another so that when a cable connector 79 is connected to another cable connector or to a box connector 56, the signals are channeled to the correct conductor pairs 81.
The structure of the cable member 77 and the connectors 79 cooperate to enable the enhanced cable assembly 75 to comply with, or exceed, specifications of Category 5E (“Cat. 5E”), also known as Telecommunication Industry Association TIA/EIA-568-B standards. Cat. 5E incorporates the older Category 5 standards which enable cables to carry signals up to 100 MHz, including 100 Base-T and 1000 Base-T signals. Cat. 5E is enhanced from Category 5 with improved “far end” crosstalk performance.
In the illustrated enhanced cable assembly 75, the twist of the conductor pairs 81 is maintained within the cable connector 79 to within one half inch (12.7 mm) of their soldered connection to the solder lugs 136 of the contact members 134. This is illustrated as distance D in
An embodiment of a seal kit with torque limiting standoffs or spacers 200 is depicted in
The bottom of the circuit board 122 of the MX 3227/G (
As shown in
The inner gasket 204 is preferably formed of low compression set silicone or other similar flexible, resilient and compressible material and is sized to fit around the perimeter margin of the circuit board 120 and to be received within the inner channel 218. The compressibility of the inner seal 204 holds the inner seal in place and eliminates the need to apply glue or other adhesive composition to the inside of the channel 218. Such an adhesive-free installation serves to insure that the seal 204 will not be forced upwardly, out of the channel 218 by application of excess adhesive.
The outer seal or gasket 206 is generally rectangular in overall shape and is sized and shaped to fit within the outer channel 220 in the connector assembly 202. The outer gasket 206 preferably includes a series of spaced ridges or ribs 222 that enhance the compressibility of the gasket 206.
In use, a technician selects an inner seal 204 from the seal kit 200 and fits it around the outer perimeter margin of the circuit board 120 of an MX-3227/G contact array board assembly 94. The technician selects an outer seal or gasket 206 and fits it onto the U-187 A/G shell 216, urging it into the outer channel 220. This provides a seal between the perimeter margin of the board 120 and the inner wall of the shell 216. The ribs 222 enable the gasket 206 to fit easily into the channel 220 with light compression.
The technician selects a pair of appropriate torque limiting spacers 208, 210, 212 or 214 from the array in the kit 200 in accordance with the type of connector to be sealed, e.g. U-185 B/G or U-187 A/G and cable type, e.g. Cat 3 or Cat 5E. The technician installs the spacers on the receiver posts 207 of the MX-3227/G contact 94 and urges the board assembly 94 into the shell 202 within the outer gasket until the inner seal 204 is received within the inner channel 218 as shown in
When a cable connector 79, such as the U-185 B/G connector shown in
In this manner, a kit 200 including the combination of inner and outer seals 204 and 206 and a variety of torque limiting standoffs 208, 210, 212 and 214, allows for a connector 79 and/or 202 to be sealed and fully closed and locked in position in deployed situations. The need for active line re-torque is greatly diminished. Damage to the MX3227 inserts is minimized because force on the MX-3227/G contact array board 94 is controlled. This serves to enhance the reliability, longevity, and capacity of the U185/U187 connectors.
It is to be understood that while certain forms of the cable connector seal kit with torque limiting spacers have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown.
This application claims the benefit of U.S. provisional patent application Ser. No. 61/539,214, filed Sep. 26, 2011, under 35 U.S.C. §119(e).
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