Patent Application
20070141903
The present invention relates generally to connectors and more particularly to electrical connector assemblies.
Connectors are well known in the art for establishing electrical connection between electronic devices. While many types of connectors are adequate for certain applications, there are situations in which existing connectors do not function as well as described. For example, in many applications where a conductor is already present, there may be a need to add a new connector to connect new devices for new applications. Unfortunately, each new electrical connection is a point of potential failure and interrupting the conductor with numerous electrical connections may significantly increase electrical resistance.
In certain applications, such as where machines are powered, controlled and monitored using electric and electronic technology, electrical conductors may supply power and data to various components and locations, and connectors may be required to convey power and data to attached devices. Attempts have been made to attach connectors to a conductor where both power and data are routed over the same conductor. One such example is disclosed in U.S. Pat. No. 6,179,644 to Adams et al (hereinafter “Adams”). Adams discloses attaching a connector to a conductor that routes power and data signals over separate power and data wires. Unfortunately, the connector of Adams may not provide an adequate electrical connection due to reliance on the precision and penetration of prongs through the conductor sheathing as the connector is assembled.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.
One aspect of the present invention is directed to a connector having a base housing and a top housing. The base housing has a longitudinal axis and includes a base conductor channel, a conductor partition and at least one conductor contact. The base conductor extends along the longitudinal axis and provides a through path for a power and data delivery conductor. The at least one conductor contact has at least one corresponding prong extending transverse the longitudinal axis. The top housing includes a top conductor channel and a connector interface. The top conductor channel corresponds to the base conductor channel. The connector interface is operably connected to the at least one connector pin.
Another aspect of the present invention is directed to a method for attaching a connector to a conductor. The method includes attaching a conductor contact to each of at least one conductor wires, the conductor contact having a prong extending transverse a longitudinal axis of the conductor, positioning the conductor in a base conductor channel of a base housing located along the longitudinal axis, separating each conductor wire with a conductor partition, and attaching a top housing to the base housing such that each prong extends through the top housing to a connector interface.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several exemplary embodiments of the invention and, together with the description, serve to explain the principles of the invention. In the drawings,
Reference will now be made in detail to embodiments of the invention, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
Referring to
The connector 110 may include a connector top housing 120 and a connector base housing 150. The conductor 100 is shown extending from top housing first and second ends 122,124 and corresponding base housing first and second ends 152,154. The conductor 100 may be configured to extend along a longitudinal axis 115. The top and base housings 120,150 may also be configured to extend along this same longitudinal axis 115. A connector interface or a device connector 147 is shown protruding from the top housing 120 transverse the longitudinal axis 115 of the conductor 100. Although a single device connector 147 is shown, there may be additional device connectors 147 extending from the connector 110 to accommodate additional connections to the conductor 110. The device connector 147 may also be configured to receive at least one connector pin 145 that may also extend transverse the longitudinal axis 115 of the conductor 100. While typical device connectors 147 may have three connector pins 145, the total number of connector pins 145 may be more or less than this.
The connector 110 may also be secured such that the top and base housings 120,150 provide a seal about the conductor 100. Although
The circuit board 130 may have circuit board contacts 131 positioned to receive first and second contact prongs 165,175 through the potting layer 140. At least one connector pin 145 may also be attached to the circuit board to be received by the device connector 147. Locating apertures 133 may be configured in the circuit board 130 for receiving locating pins 142 from the potting layer 140 and locating pins (not shown) from the top housing 120. A potting aperture 134 may be located in the circuit board 130 for possible injection of the potting material 135.
Any of a variety of circuit boards 130 may be used with the connector 110. The circuit board 130 may contain a number of circuit board devices 195, such as, but not limited to, processors, transmitters, receivers, contact devices, transistors, etc. For mere electrical conveyance, a circuit board 130 may be omitted. In more complex electrical applications, the circuit board devices 195 may be heat generating such that they may require heat sinks 190, mounted external to the top housing 120, to conductively transfer heat from the circuit board 130.
As is shown in
Removal of the insulation 105 may be accomplished in any of a number of ways such that conductor contacts 160,170 may be attached to the wires. The conductor contact 160,170 may be attached to each corresponding line 101,103 of the conductor 100 in any of a number of ways, such as crimping, welding, soldering, and the like. Each conductor contact 160,170 may have a corresponding prong 165,175 extending transverse the longitudinal axis 115. A conductor partition 180 may positioned in the base housing 150 between the positive and negative lines 101,103 of the conductor 100. Alternatively, connection of the connector 110 to the conductor 100 may occur without removing the insulation 105. This may require that the connector 110 have at least one prong (not shown) that may penetrate the insulation 105 to contact the at least one wire of the conductor 100. This prong (not shown) may assume the shape of a knife-like structure for easier penetration into the conductor 100, and may be configured to penetrate the conductor strands.
Properly securing the top and base housings 120,150 about the conductor 100 may equalize any compressive forces on the individual wires of the conductor 100 and may result in an overall stiffer region of the conductor 100. Having a stiffer region where the conductor contacts 160,170 attach to the conductor 100 may result in a reduction of fretting corrosion between the conductor contacts 160 and the individual wires of the conductor 50.
Ensuring a correct connection may include techniques such as clearly marking the conductor 100 and the conductor contacts 160 with positive or negative markings, color codes or other types of markings so that the correct polarity between the contacts is made. The top and base housings 120,150 and conductor 100 may also be designed such that the conductor 100 may fit into the connector 110 in only one orientation. Alternatively, the top and base housings 120,150 may be configured such that connection to the conductor 100 may be made with the positive and negative lines 101, 103 contacting either conductor contact 160,170, i.e., no initial attempt is made to connect via a certain polarity. In cases such as this, a polarity circuit (not shown) may be located on the connector 70 to sense voltage polarity and may either provide an indication of a correctly polarized connection or automatically reverse the polarity if not initially correct.
The connector 110 may connect to and make electrical contact with a device (not shown) by way of the device connector 147. The device connector 147, as shown here, may be integrated into the top housing 120. The device connector 147 may be connected to the device (not shown) via a mating connector arrangement (not shown) as may be suitable for the task. Alternatively, the device (not shown) may be connected to the connector 110 directly without any intermediate connector, for example by way of a pigtail.
Embodiments of the present application are applicable to electrical systems where it is desired to connect a device (not shown) to a conductor 100. After a conductor 100 is arranged in a certain application, connectors 110 may be attached to the conductor 100 in locations near where devices (not shown) may desirably be located. Insulation 105 may be removed from a portion of the conductor 100 and conductor contacts 160 may be attached to each wire of the conductor 100. The wires of the conductor 100 may be positioned in a conductor base conductor channel 157 with a conductor partition 180 structured between the conductor contacts 160 attached to each wire. The top housing 120 may then be attached to the base housing 150 such that prongs 165 extending from the conductor contacts 160 may be operably received by a connector interface 147. This connection may be made without interrupting electrical continuity of the conductor 100 and may provide improved and consistent connection from the conductor 100 to the connector 110 and associated connector interface 147.
It will be apparent to those skilled in the art that various modifications and variations can be made in the system and method of the present invention without departing from the scope or spirit of the invention. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims and their equivalents.
