Patent Application
20100210151
This invention relates to insertable and removable contacts for electrical connector assemblies. More particularly, the present invention relates to improvements to pin-and-socket and brush type contacts.
Electrical connector assemblies generally include a plug and receptacle. A common type of plug and receptacle connector utilizes pin (plug) and socket (receptacle) terminals. Such pin-and-socket contacts are of the male and female type, wherein an electrical interconnection is made between the contacts by inserting the male pin into the female socket. Another type of plug and receptacle connector assembly utilizes a pair of brush type terminals. Sometimes referred to as bristle brush bunch contacts, or B3 contacts, such brush type contacts are hermaphroditic, wherein each of the contacts includes a bundle of wires. An electrical connection is made between the contacts by intermeshing the bundled wires of one contact with the bundled wires of the other.
Because of their different configurations, pin-and-socket type contacts and brush type contacts each have different operating characteristics with different benefits and drawbacks. Among the different operating characteristics are the contacts' ability to fit in high-density connector assemblies, i.e., size; to carry the appropriate amount of current; and to stay coupled during shock and vibration conditions. For example, pin-and-socket type contacts are typically larger in size (12 gauge and larger) and carry larger electric current (50 amperes to 500 amperes) while brush type contacts are typically smaller in size (22 gauge and smaller) and carry smaller electric current (5 amperes and smaller). Accordingly, pin-and-socket type contacts are typically used as power terminals and brush-contacts are typically used as digital signal terminals. Pin-and-socket type contacts often come loose, however, under sever shock and vibration conditions where brush type contacts can maintain good electrical contact during such conditions. Accordingly, there remains a need for contact assemblies that can be used in high-density connector assemblies while providing for large current applications and that remain coupled even under severe shock and vibration conditions.
Accordingly, to solve at least the above problems and/or disadvantages and to provide at least the advantages described below, a non-limiting object of the present invention is to provide a device of and method for an electrical contact that includes a plurality of axially-aligned electrically conductive wires, each wire being in electrical contact with at least one other wire at a peripheral surface thereof; an electrically conductive inner sleeve disposed around the plurality of wires and having at least one slot extending axially from a leading end that is adapted to allow the inner sleeve to expand radial; an outer shell disposed around the inner sleeve for protecting at least a leading end of the plurality of wires and the inner sleeve; and an attaching portion disposed at a terminal end of the plurality of wires, the inner sleeve, and the outer shell, the attaching portion being in electrical contact with at least the plurality of wires and the inner sleeve and being adapted to place at least the plurality of wires and the inner sleeve in electrical contact with a first electronic device
These and other objects of the invention, as well as many of the intended advantages thereof, will become more readily apparent when reference is made to the following description, taken in conjunction with the accompanying drawings.
Reference will now be made in detail to non-limiting embodiments of the present invention by way of reference to the accompanying drawings, wherein like reference numerals refer to like parts, components and structures.
Turning to the figures,
As
The pin/brush contact 102 and the socket/brush contact 104 also each include a second attaching portion 112 extending from a rear end of the collar portion 106 for electrically attaching each of the contacts to an electronic device via an electrical wire or a trace on a PCB. The second attaching portion 112 and the first attaching portion 110 are in electrical contact so that current can flow from the wires 108 to the electronic device to which the second attaching portion 112 is attached. The second attaching portion 112 may be provided in substantially any attachment style, such as crimp, solder, PC tail, or wire wrap. In the illustrated embodiment, the pin/brush contact 102 and the socket/brush contact 104 are each provided with a crimping second attaching portion 112. The crimping second attaching portion 112 includes an inspection hole 114 through which the end surfaces of an electrical wire can be inspected after being inserted into the bore 116 of the second attaching portion 112.
As
The cylindrical sleeve 200 includes a bore 202 of sufficient diameter to allow radial spreading of the wires 108 of each of the contacts 102 and 104 as they intermesh with each other (See, e.g.,
As
The inner sleeve 302 is formed of conductive material and is in electrical contact with at least the second attaching portion 112 of the socket/brush contact 104 so that current can flow from the inner sleeve 302 to the electronic device to which the second attaching portion 112 is attached. Accordingly, the collar portion 106, the second attaching portion 112, and the inner sleeve 302 may be integrally formed from the same piece of conductive material, such as a copper based alloy. They may also be formed from separate pieces of conductive material and mechanically attached by substantially any suitable means.
Like the inner sleeve 302, the outer sleeve 300 may also be formed integrally with the collar portion 106 and the second attaching portion 112 from a single piece of conductive material. And, the outer sleeve 300 may be formed separate from the collar portion 106 and the second attaching portion 112 using substantially any material, including a dielectric material. The outer sleeve 300 extends forward of the leading edges of the wires 108 to prevent the wires from being damaged or splayed as the socket/brush contact 104 is inserted through an insulating housing. The outer sleeve 300 is preferably made out of a more resilient material than the inner sleeve 302, such as stainless steel, as its primary function is to protect the mated contacts from damage during mating and from the elements, such as moisture. When formed separately, the outer sleeve 300 may be mechanically attached to the collar portion 106 and the second attaching portion 112 by substantially any means.
As
The inner sleeve 302 includes an inwardly protruding annular rib 408 at the rear end 406 that is adapted to engage a corresponding annular groove (not shown) on the first attaching portion 110 of the socket/brush contact 104 so as to resist axial forces applied to the inner sleeve 302 when the pin/brush contact 102 is installed therein and removed therefrom. An annular groove 410 is disposed around the outer circumferential surface of the inner sleeve 302 and may be adapted to similarly engage a corresponding inwardly protruding annular rib (not shown) disposed in the bore 306 of the outer sleeve 300 when the outer sleeve 300 is installed around the inner sleeve 302. The leading end 402 of the inner sleeve 302 includes a rounded, or chamfered, portion 412 at an inside surface thereof, i.e., at the bore 308, to guide the cylindrical sleeve 200 of the pin/brush contact 102 into the bore 308 of the inner sleeve 302 as the pin/brush contact 102 and the socket/brush contact 104 are mated together. In a preferred embodiment, the inner sleeve 302 includes two forward slots 400 disposed on opposite sides of the inner sleeve 302 and three rear slots 404 disposed equidistant from each other around the circumference of the inner sleeve 302.
As illustrated in
When intermeshed, the wires 108 of the pin/brush contact 102 and socket/brush contact 104 provide redundant current paths because there are typically between 14 and 70 points of contact per mated pin/brush contact 102 and socket/brush contact 104. Those redundant current paths allow the pin/brush contact 102 and socket/brush contact 104 to remain coupled during severe shock and vibration conditions, greatly reducing current discontinuities. Accordingly, the pin/brush contact 102 and socket/brush contact 104 provide a well-defined and controlled impedance path during such conditions.
In addition, by providing for the flow of electrical current between the pin/brush contact 102 and socket/brush contact 104 via the electrical contact between the cylindrical sleeve 200 of the pin/brush contact 102 and the inner sleeve 302 of the socket/brush contact 104 and the electrical contact between the wires 108 of the pin/brush contact 102 and socket/brush contact 104, a larger area of electrical contact area is provided in a smaller amount of total space, i.e., the contact ratio is improved for the contacts. The increased contact ratio results in a lower electrical resistance, a lower voltage drop, and a lower temperature across the contacts. Thus, the present invention provides contacts that are suitable for carrying large amounts of electrical current and are resistant to severe shock and vibration conditions, which allows more freedom of design when manufacturing high-density electrical connectors.
In an alternative embodiment of the present invention, an insulating layer (not shown) may be disposed between the wires 108 and the cylindrical sleeve 200 of the pin/brush contact 102 and between the wires 108 and the inner sleeve 302 of the socket/brush contact 104 to form a coaxial connector. In that alternative embodiment, an insulating layer (not shown) may also be disposed between an inner portion and outer portion of the collar portion 106 and second attaching portion 112 to maintain electrical separation between the current flowing through the wires 108 of the pin/brush contact 102 and socket/brush contact 104 and the current flowing through the cylindrical sleeve 200 of the pin/brush contact 102 and the inner sleeve 302 of the socket/brush contact 104. Accordingly, the features of the present invention may also be utilized in a novel coaxial connector.
The foregoing description and drawings should be considered as illustrative only of the principles of the invention. The invention may be configured in a variety of shapes and sizes and is not intended to be limited by the preferred embodiment. Numerous applications of the invention will readily occur to those skilled in the art. Therefore, it is not desired to limit the invention to the specific examples disclosed or the exact construction and operation shown and described. Rather, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
