High voltage heater termination

Abstract

A connector assembly is provided that includes an upper element and a lower element in contact with the upper element along a contour-matched interface. The first element and the second element are dielectric and each comprise a recess and a groove, the recesses cooperatively forming a cavity and the grooves cooperatively forming a channel communicating the cavity to exterior surfaces of the upper element and the lower element. A conductive plug is disposed within the cavity and is adapted for engaging a lead wire and a terminal pad. Preferably, the connector assembly further includes a clamping device for securing the connector assembly to a substrate and a spring element disposed within the cavity, wherein the conductive plug is disposed between the terminal pad and the spring such that the spring biases the conductive plug against the terminal pad.

Description

DRAWINGS

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

FIG. 1 is a top view of a substrate having a resistive heating element and terminal pads connected to the resistive heating element in accordance with the teachings of the present disclosure;

FIG. 2 is a cross sectional view, taken along line 2-2 of FIG. 1, illustrating terminal pads in greater detail in accordance with the teachings of the present disclosure;

FIG. 3 is a perspective view of a connector assembly constructed in accordance with the teachings of the present disclosure;

FIG. 4 is a perspective view illustrating an exploded connector assembly and a second, assembled, connector assembly constructed in accordance with the teachings of the present disclosure;

FIG. 5 a is a perspective view of the top of an upper element of a dielectric enclosure constructed in accordance with the teachings of the present disclosure;

FIG. 5 b is a perspective view of the bottom of the upper element of a dielectric enclosure constructed in accordance with the teachings of the present disclosure;

FIG. 6 a is a perspective view of the top of a lower element of a dielectric enclosure constructed in accordance with the teachings of the present disclosure;

FIG. 6 b is a perspective view of the bottom of the lower element of a dielectric enclosure constructed in accordance with the teachings of the present disclosure;

FIG. 7 is a top view of the connector assembly in accordance with the teachings of the present disclosure;

FIG. 8 is a cross-sectional view, taken along line 8-8 of FIG. 7, of the connector assembly in accordance with the teachings of the present disclosure;

FIG. 9 is a cross-sectional view, taken along line 9-9 of FIG. 7, of the connector assembly in accordance with the teachings of the present disclosure;

FIG. 10 is a perspective view of a conductive plug constructed in accordance with the teachings of the present disclosure;

FIG. 11 a is a top view of an alternate embodiment of the conductive plug having an alignment feature and constructed in accordance with the teachings of the present disclosure;

FIG. 11 b is a top view of another alternate embodiment of the conductive plug having an alignment feature and constructed in accordance with the teachings of the present disclosure;

FIG. 12 is a perspective view of a spring constructed in accordance with the teachings of the present disclosure; and

FIG. 13 is a perspective view of an alternate form of a clamping device constructed in accordance with the teachings of the present disclosure.

Claims

1. A connector for connecting a lead wire to a terminal pad comprising: a dielectric enclosure surrounding the terminal pad and defining a cavity open to the terminal pad, the dielectric enclosure comprising: an upper element; anda lower element in contact with the upper element along a contour-matched interface; anda conductive plug disposed within the cavity for electrically connecting the terminal pad to the lead wire.

2. The connector according to claim 1, wherein the dielectric enclosure further comprises a channel extending between the cavity and an exterior surface of the dielectric enclosure for receiving the lead wire.

3. The connector according to claim 1, wherein each of the upper element and the lower element defines a recess, the recesses of the upper and the lower elements forming the cavity.

4. The connector according to claim 3, wherein the recess of the upper element defines a blind hole.

5. The connector according to claim 3, wherein the recess of the lower element defines a through hole.

6. The connector according to claim 3, wherein the dielectric enclosure further comprises opposing grooves between the upper element and the lower element, the opposing grooves extending from the recesses to exterior surfaces of the upper and lower elements, the opposing grooves cooperatively forming a channel for receiving the lead wire.

7. The connector according to claim 6, wherein the lead wire includes wire strands and an insulating sheath around the wire strands, the insulating sheath in contact with the channel.

8. The connector according to claim 1 further comprising a clamping device for securing the connector to a substrate.

9. The connector according to claim 8, wherein the clamping device further comprises an extension adapted for being secured to the lead wire and opposing flanges adapted for being secured to the substrate.

10. The connector according to claim 8, wherein the clamping device further comprises ears that flex to provide vertical displacement.

11. The connector according to claim 8, further comprising a U-shape member mounted over the dielectric enclosure and configured to accommodate a dimensional variation of the dielectric enclosure in a direction vertical the substrate.

12. The connector according to claim 11, wherein the U-shape member applies a force against the dielectric enclosure to hold the dielectric enclosure against the substrate.

13. The connector according to claim 1, wherein the conductive plug defines a receptacle for receiving the lead wire.

14. The connector according to claim 13, wherein the conductive plug further comprises a dimple for clamping the lead wire within the receptacle.

15. The connector according to claim 13, wherein the conductive plug is made of a material selected from the group consisting of a stainless steel and a high temperature alloy.

16. The connector according to claim 1, further comprising a spring element disposed within the cavity, wherein the conductive plug is disposed between the terminal pad and the spring such that the spring biases the conductive plug against the terminal pad.

17. The connector according to claim 1, wherein the dielectric enclosure is made of a dielectric material selected from the group consisting of alumina and steatite.

18. A dielectric enclosure defining a cavity open to a first exterior surface and a channel communicating the cavity to at least one second exterior surface, the cavity and the channel providing a conduit for an electrical connection wherein the dielectric enclosure is adapted to receive a terminal pad within the cavity proximate the first exterior surface and to receive a lead wire within the channel proximate the second exterior surface.

19. The dielectric enclosure according to claim 18, wherein the dielectric enclosure comprises an upper element and a lower element defining a contour-matched interface.

20. The dielectric enclosure according to claim 19, wherein each of the upper element and the lower element defines a recess formed on the contour-matched interface, the recesses of the upper and the lower elements forming the cavity.

21. The dielectric enclosure according to claim 19, wherein each of the upper element and the lower element comprise opposing grooves that define the channel.

22. The dielectric enclosure according to claim 18, wherein the dielectric enclosure is made of a dielectric material selected from the group consisting of alumina and steatite.

23. The dielectric enclosure according to claim 18, wherein the dielectric enclosure is coated with a material selected from the group consisting of alumina and steatite.

24. A connector assembly comprising: a first element;a second element in contact with the first element along a contour-matched interface,the first element and the second element each comprising a recess and a groove, the recesses cooperatively forming a cavity and the grooves cooperatively forming a channel communicating the cavity to exterior surfaces of the first element and the second element; anda conductive plug disposed within the cavity and adapted for engaging a lead wire and a terminal pad.

25. The connector assembly according to claim 24 further comprising a clamping device for securing the connector assembly to a substrate.

26. The connector assembly according to claim 24, wherein the conductive plug defines a receptacle for receiving the lead wire.

27. The connector assembly according to claim 26, wherein the conductive plug further comprises a dimple for clamping the lead wire within the receptacle.

28. The connector assembly according to claim 24, further comprising a spring element disposed within the cavity, wherein the conductive plug is disposed between the terminal pad and the spring such that the spring biases the conductive plug against the terminal pad.

29. The connector assembly according to claim 24, wherein at least one of the second element and the conductive plug define an alignment feature to align the conductive plug within the cavity for receiving the lead wire.

30. The connector assembly according to claim 24 further comprising a lead wire, the lead wire comprising an outer protective sheath, an inner insulating sheath disposed within the outer protective sheath, and individual wire strands within the inner insulating sheath, wherein the inner insulating sheath is clamped within the channel of the upper element and the lower element.

31. A heater comprising: a resistive heating element;a terminal pad connected to the resistive heating element; anda connector for connecting the terminal pad to a lead wire, comprising: a first element;a second element in contact with the upper element along a contour-matched interface,the first element and the second element each comprising a recess and a groove, the recesses cooperatively forming a cavity and the grooves cooperatively forming a channel communicating the cavity to exterior surfaces of the first element and the second element; anda conductive plug disposed within the cavity and adapted for engaging the lead wire and the terminal pad.

32. The heater according to claim 31 further comprising a substrate, the resistive heating element and the terminal pad disposed proximate the substrate, wherein the second element is in contact with the substrate along a contour-matched interface.