Statement of the Technical Field
The present disclosure relates to electrical interfaces. More particularly, the present disclosure relates to electrical interfaces with floating contacts, contact redundancy and break away retention.
Description of the Related Art
There are many electrical interfaces known in the art. Some of these known electrical interfaces comprise spring fingers, fixed pins and/or pogo pins. These known electrical interfaces suffer from certain drawbacks. For example, a single point of contact is provided between a finger/pogo pin and a mating conductor. During severe shock and/or vibration, the contact between the finger/pogo pin and mating conductor can be lost. Additionally, the finger/pogo pin could be damaged as a result of excessive stress on the fixed points of the electrical interface. In effect, the reliability of such conventional electrical interfaces is not satisfactory for certain applications, such as military applications.
The present disclosure concerns systems and methods for providing an electrical interface between a male plug and a female receptacle. The method comprises: receiving a conductive pin of the male plug in a socket opening of the female receptacle; providing (a) a plurality of first spring loaded floating contact points between an elongate body of the conductive pin and an electrical contact of the female receptacle and (b) at least one second spring loaded floating contact point between a tip of the conductive pin and the electrical contact of the female receptacle, when the conductive pin is fully inserted into the female receptacle; and maintaining at least two of the first and second spring loaded floating contact points when the pin moves within the socket opening as a result of an external force applied to the male plug or female receptacle.
In some scenarios, the electrical contact comprises: a plurality of first elongate spring contacts extending in a first direction parallel to the center axis of the socket opening; and a second elongate spring contact extending in a second direction different than the first direction. The first and second elongate spring contacts are electrically connected to each other via a planar contact provided for connecting the female receptacle's electrical contact to an external circuit.
In those or other scenarios, the plurality of first spring loaded floating contact points is provided by a plurality of first conductive spring contacts respectively applying spring forces on a plurality of conductive retention members. The conductive retention members are slidingly disposed in a support structure of the female receptacle and in direct contact with the elongate body of the conductive pin. The first conductive spring contacts are spaced apart along a periphery of a support structure of the female receptacle. An elastic member applies a retention force on each said first conductive spring contact in a direction towards a center axis of the female receptacle. The elastic member may also provide an environmental seal at least reducing an ingress of contaminants into the socket opening. The second spring loaded floating contact point is provided by a second spring contact that is in direct contact with the conductive pin's tip.
In those or other scenarios, the following events occur as the pin is being inserted into the female receptacle: a first chamfered edge of the conductive pin slides against second chamfered edges of a plurality of conductive retention members disposed in the female receptacle whereby each said conductive retention member is urged from a first position in a direction away from the socket opening; pushing forces are respectively applied by the plurality of conductive retention members on a plurality of first spring contacts so as to cause the plurality of first spring contacts to flex away from the socket opening; and the plurality of first spring contacts respectively apply spring forces in directions towards the socket opening on the plurality of conductive retention members so as to cause each said conductive retention member to return to the first position when the conductive pin is inserted a certain distance into the socket opening.
Embodiments will be described with reference to the following drawing figures, in which like numerals represent like items throughout the figures.
The invention is described with reference to the attached figures. The figures are not drawn to scale and they are provided merely to illustrate the instant invention. Several aspects of the invention are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide a full understanding of the invention. One having ordinary skill in the relevant art, however, will readily recognize that the invention can be practiced without one or more of the specific details or with other methods. In other instances, well-known structures or operation are not shown in detail to avoid obscuring the invention. The invention is not limited by the illustrated ordering of acts or events, as some acts may occur in different orders and/or concurrently with other acts or events. Furthermore, not all illustrated acts or events are required to implement a methodology in accordance with the invention.
The present disclosure concerns electrical interfaces or connectors. The electrical interfaces or connectors solve many drawbacks of conventional electrical interfaces or connectors (such as those discussed in the background section of this document) associated with the following issues: loss of electrical contact during shock and vibration; stresses on Printed Wiring Board (“PWB”) solder joints; stresses on connector pins; complexity and limitations of pogo pins; and/or precision alignment requirements for engagement between the male plug and the female receptacle.
The electrical interfaces or connectors discussed herein: provide electrical connections with contact point redundancy; allow for blind mating of the male plug and the female receptacle; provide strain relief at cable connections; and/or have environmentally sealed housings. The electrical interfaces or connectors also have a floating contact feature. The floating contact feature minimizes mating alignment errors and/or issues resulting from shock and/or vibration. In this regard, the floating contact feature allows the mating contact to float in at least two directions (e.g., X, Y and/or Z directions). The electrical interfaces or connectors further have a break-away retention feature. The break-away retention feature reliably allows components to break free from each other and/or their mounted position in emergency situations. This break-away retention feature is a requirement in many stationary and mobile applications where personnel safety and equipment survival cannot be compromised. Accordingly, the electrical interfaces or connectors are designed to allow the couplings of a male plug and a female receptacle to disconnect at selectable, predetermined forces.
The male plug generally comprises a housing which supports at least one pin to be inserted into the female receptacle. An exemplary male plug is shown in
Referring now to
Also, the respective placements of the elastic members, spring contacts and retention members need not be the same as that shown in
The housing (or support structure) 102 is provided for housing and/or structurally supporting the elastic members, spring contacts and retention members. In this regard, the housing 102 is formed of rigid or semi-rigid dielectric material, such as plastic. The housing 102 comprises a socket opening (or aperture) 112 in which a pin 402 of a male plug (not shown in
Notably, five (5) floating contact points (spring loaded) are provided by the present solution which results in an electrical interface with extreme contact point redundancy. The extreme contact point redundancy and spring loading ensures that there are a minimum of two (2) points of contact at all times (even in extreme vibration and shock scenarios where the pin 402 moves around in the socket) between the male plug's pin and the female receptacle's electrical contact. In this regard, it should be understood that electrical connections are provided between the following components when the male plug and female receptacle are coupled to each other (in times when the connectors are not subjected to shock and vibration): (A) the pin's tip 420 and the spring contact 110; and (B) the pin's elongate body 422 and each spring contact 106A-106D via a respective retention member 108A-108D. The pin 402, spring contacts 110, 106A-106D and retention members 108A-108D are formed of a conductive material, such as metal (e.g., copper or brass).
The spring contacts 110, 106A-106D are electrically connected to each other via a planar contact 202. The spring contacts 110, 106A-106D can be integrally formed with the planar contact 202 so as to provide a single contact component as shown in
The planar contact 202 is also formed of a conductive material, such as metal (e.g., copper or brass). The planar contact 202 provides a means to electrically connect the female receptacle 100 to external circuitry, such as that disposed on a PWB. In this case, solder and/or a wire can be used to establish this electrical connection.
Each spring contact 110, 106A-106D is designed to allow the pin 402 to float in the socket opening 112. Accordingly, each spring contact 110, 106A-106D protrudes out and away from the planar contact 202. For example, spring contact 110 extends horizontally and protrudes vertically out and away from a center of the planar contact 202. Each spring contact 106A-106D extends vertically and protrudes vertically out and away from a peripheral edge portion of the planar contact. In this regard, the housing 202 comprises a plurality of insert spaces 204 for receiving vertically extending spring contacts 106A-106D. Each insert space 204 has a generally T-Shape. The thinner portion of the insert space has a width 208 that is slightly larger than the width 210 of a spring contact 106A-106D. The wider portion of the insert space has a width 206 that is substantially similar (possibly slightly smaller) or the same as the width of an elastic member 104A-104D so that the elastic member 104A-104D is securely retained in the housing 202 with or without the assistance of an adhesive (e.g., via friction or by being molded in place so that a chemical reaction occurs at the contact surfaces of the housing and elastic members).
Each spring contact 110, 106A-106D is flexible so that when the female receptacle 100 is subjected to shock and/or vibration the electrical connection between itself and the pin 402 is maintained. For example, the spring contact 110 flexes in two (2) opposing vertical directions 212. Similarly, spring contacts 106A and 106C flex in two (2) opposing horizontal directions 214, and spring contacts 106B and 106D flex in two (2) opposing horizontal directions 216. The flexing of the spring contacts facilitates shock and vibration absorption by the female receptacle 100, as well as the elimination of the need for precision alignment for engagement between the male plug and the female receptacle 100. The elimination of the precision alignment requirement is also at least partially facilitated by the provision of an angled surface 114 in the socket opening 112. The angled surface 114 helps guide the pin 402 into proper placement within the socket opening 112 as shown in
During shock and vibration, the pin 402 applies a pushing force on each retention member 108A-108D at respective times. As a result of this pushing force, the retention members slidingly move within the housing 102 in respective directions away from the center axis 300 of the socket opening 112. This movement causes the retention members 108A-108D to respectively apply pushing forces on the spring contacts 106A-106D. In turn, the spring contacts 108A-108D flex away from a surface 306 of the housing 102.
Throughout this process, each elastic member 104A-104D provides a retention force on the respective retention member 108A-108D (via spring contact 106A-106D) in a direction towards a center axis 300 of the female receptacle 100, i.e., the elastic members force the retention members toward the center of the female receptacle 100. The inward force applied by the elastic members ensures that the yield strength of the material (e.g., copper or brass) forming the spring contacts 106A-106D is not exceeded during times when (A) the pin 402 is being inserted into the female receptacle 100 and/or (B) the female receptacle 100 is subjected to shock and vibration. If this yield strength is exceeded, then the spring contacts 106A-106D may experience permanent deformation such that they do not spring back to their rest positions. In effect, the elastic members 104A-104D provide (A) structural support for the spring contact 106A-106D and (B) an inward force to ensure that the retention member 108A-108D are in contact with pin regardless of whether there is shock and vibration.
The elastic members 104A-104D are formed of an elastomer or other rubber. The elastic members 104A-104D have the same durometer. The present solution is not limited in this regard. In some scenarios, the elastic members 104A-104D have different durometers. Adjustments in durometers allow the retention forces of the elastic members 104A-104D to be tuned in accordance with a particular application. For example, each elastic member 104A-104D has a different durometer so that it reacts to different frequencies of shock and vibration as compared to that to which the other elastic members react. The tuning also facilitates one to define a breakaway force at which the male plug and female receptacle would disconnect from each other. This breakaway force feature of the present solution is valuable in scenarios where equipment damage is undesirable as a result of certain events (e.g., when a pulling force of greater than about fifty (50) pounds is applied to the coupled male plug/female receptacle).
In some scenarios, the spring contacts 106A-106D have the same spring rates. In other scenarios, the spring contacts 106A-106D have different spring rates. The adjustment of spring rates allows the spring contacts to have the same or different natural frequencies selected in accordance with a particular application.
As shown in
Referring now to
As the pin 402 is inserted into the socket opening 112, a chamfered edge 404 of the pin 402 slides against the chamfered edges 406 of the retention members 108A-108D. This sliding causes the pin 402 to urge the retention members 108A-108D in respective outward directions 450 away from the center axis 300 of the female receptacle 100. In turn, the retention members 108A-108D apply pushing forces on the spring contacts 106A-106D, whereby the spring contacts 106A-106D flex in a direction out and away from the pin 402. Once the pin 402 is inserted a certain distance into the socket opening 112, the retention members 108A-108D automatically move in an opposing direction 452 towards the center axis 300 of the female receptacle 100.
Notably, the pin 402 has an end portion with a generally hour glass shape, i.e., the diameter of proximal end portion 408 is smaller than the diameter of distal end portion 410. The decrease in the pin's diameter facilitates the automatic movement of the retention members 108A-108D towards the center axis 300 of the female receptacle 100. This movement is also facilitated by the inward forces respectively applied by (A) the spring contacts 106A-106D to the retention members 108A-108D and/or (B) the elastic members 104A-104D to the spring contacts 106A-106D.
As shown in
Notably, the male plug can be decoupled from the female receptacle even when in a position that is angled relative to the female receptacle. This is at least partially possible since the pin 402 floats in the socket opening 112 and/or since an angled surface 114 is provided at the entrance of the socket opening. The angled surface 114 acts as a guide for directing the pin 402 into proper placement within the socket opening 112.
The present solution is not limited to the chamfered pin and retention member configuration shown in
It should be noted that the housing 102 has a plurality of apertures 302 formed in a sidewall 304 thereof. Each aperture 302 is aligned with a portion of a respective insert space 204. In some scenarios, the apertures are shaped so as to ensure that the retention members 108A-108D are retained in the socket opening 112 and/or protrude only a certain distance into the socket opening 112 when the pin 402 is not inserted therein. For example, each aperture 302 may have an inner dimension (e.g., width and/or height) that is smaller than an outer dimension (e.g., width and/or height).
The present solution is not limited to the housing and/or elastic member architecture shown in
The female receptacle 500 is substantially similar to the female receptacle 100 of
The elastic member 502 is designed to have a plurality of purposes: (A) provide structural support for the spring contacts 506; (B) provide an inward force to ensure that the retention members 508 are in contact with the pin 800 regardless of whether the female receptacle 500 is being subjected to shock and vibration; and/or (C) provide an environmental seal for preventing or reducing the ingress of contaminants (e.g., dirt, dust, sand, water, etc.) into the female receptacle 500.
Notably, the elastic member 502 has a generally U-cross sectional shape with slits 600 formed in a surface 602 thereof. The slits 600 allow the pin 800 to pass therethrough when a downward force is applied thereto, while at least reducing the amount of contaminants entering the female receptacle 500. A schematic illustration is provided in
In this scenario, the elastic member 502 has a single durometer. The ability to provide a plurality of elastic members with different durometers may not be possible here. However, the spring contacts 506 can have the same or different spring rates. Adjustments of the spring rates allows the spring contacts to have the same or different natural frequencies selected in accordance with a particular application. If effect, the spring contacts 506 can be selectively designed so that they react to the same or different frequencies of shock and vibration, i.e., the natural frequencies of the spring contacts can be tuned. The tuning facilitates one to define a breakaway force at which the male plug and female receptacle would disconnect from each other. This breakaway force feature of the present solution is valuable in scenarios where equipment damage is undesirable as a result of certain events (e.g., when a pulling force of greater than about fifty (50) pounds is applied to male plug/female receptacle).
The present solution is not limited to the particular architecture of the elastic member shown in
Notably, various components shown in
Referring now to
As shown in
The female receptacle 1004 comprises a housing 1010 with a plurality of socket openings 1012 formed therein. Each socket opening 1012 is sized and shaped for receiving a respective pin 1006.
An insert space 1102 is provided which allows a contact retainer 1014 to be inserted and retained in the housing 1010. The retention of the contact retainer 1014 is at least partially achieved via engagement of protrusions 1104 formed on a sidewall 1106 of the insert space 1102 and protrusions 1108 formed on a sidewall 1110 of the contact retainer 1014. An adhesive or other coupling means may also be employed for securely coupling the contact retainer 1014 to the housing 1010.
The contact retainer 1014 comprises a dielectric support structure 1112 and an elastic member 1114. The elastic member 1114 is disposed in and structurally supported by the dielectric support structure 1112. The elastic member 1114 has a plurality of apertures 1014 formed therethrough. Each aperture 1014 is sized and shape to receive a respective socket support structure 1016. Each socket support structure 1016 is designed to receive respective retention members 1018 and spring contacts 1020, 1022, as well as provide structural support to these components and retain these components in a particular relative configuration as shown in
Notably, the overall structure of each socket (i.e., defined by socket support structure 1016, retention members 1018 and spring contacts 1020, 1022) is similar to that shown in
In some scenarios, the male plug and the female receptacle are designed to allow for decoupling thereof. In other scenarios, the male plug and the female receptacle are designed so that they cannot be decoupled from each other. In this case, mating mechanical coupling means may be provided for securely coupling the male plug and female receptacle together. Such a mechanical coupling means can include, but is not limited to, snap couplers and/or locking tabs (e.g., protrusion 1302 of
Referring now to
Once the pin is fully inserted into the socket opening, a plurality of floating contact points is provided as shown by 1714. These floating contact points include: a plurality of first spring loaded floating contact points (e.g., contact points 460 of
In some scenarios, the plurality of first spring loaded floating contact points is provided by the first conductive spring contacts respectively applying spring forces on the conductive retention members slidingly disposed in a support structure (e.g., housing 102 of
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Numerous changes to the disclosed embodiments can be made in accordance with the disclosure herein without departing from the spirit or scope of the invention. Thus, the breadth and scope of the present invention should not be limited by any of the above described embodiments. Rather, the scope of the invention should be defined in accordance with the following claims and their equivalents.
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