Patent Application
20170170615
Electrical cable assemblies typically include at least one electrical conductor, and an electrical insulator that surrounds the electrical conductor. The at least one electrical conductor typically defines a first end for electrical connection to a mating member, and a second end for electrical connection to a mounting member. The mating and mounting members can be placed in electrical communication with respective complementary electrical devices. The at least one electrical conductor can be configured to carry electrical power or data signals between the complementary electrical devices.
In accordance with one embodiment, an electrical cable assembly can include a plurality of stranded electrically conductive fibers of wire extending from a first end to a second end. The electrical cable assembly can also include an electrical insulator surrounding the plurality of strands of wire, such that each of the first and second ends extends out from the electrical insulator. The fibers of wire of at least one of the first and second ends can be shaped so as to define at least one keyed surface, and fused to each other while shaped so as to define a solidified shape having the at least one keyed surface, prior to electrically connecting the at least one of the first and second ends to a mating member or mounting member, respectively.
The foregoing summary, as well as the following detailed description of example embodiments of the application, will be better understood when read in conjunction with the appended drawings, in which there is shown in the drawings example embodiments for the purposes of illustration. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown. In the drawings:
Referring to
The electrical cable 24, and thus the electrical cable assembly 22, can include a plurality of stranded electrically conductive fibers of wire extending from the first end 24a to the second end 24b. For instance, the stranded electrically conductive fibers of wire can be braided with each other between the first end and the second end. The electrical cable 24, and thus, the electrical cable assembly 22, can further include an electrical insulator 32 that surrounds the plurality of strands of wire 33, such that each of the first and second ends 24a and 24b extends out from the electrical insulator 32. The fibers of wire of at least one of the first and second ends 24a and 24b are shaped so as to define at least one keyed surface 34, and fused to each other while shaped so as to define a solidified shape 36 having the at least one keyed surface 34, prior to electrically connecting the at least one of the first and second ends 24a and 24b to the respective mating member 26 or mounting member 28. For instance, the fibers of wire can be ultrasonically bonded, welded, or soldered to each other at one or both of the first and second ends 24a and 24b so as to fuse the fibers of wire to each other. For instance the first end 24a can be shaped so as to define the at least one keyed surface 34 prior to electrically connecting the first end 24a to the mating member 26. Alternatively or additionally, the second end 24b can be shaped so as to define the at least one keyed surface 34 prior to electrically connecting the second end 24b to the mounting member 28.
The electrical cable assembly 22, and in particular the mating member 26, can include at least one electrically conductive contact member 37 that defines at least one contact surface 38. For instance, the electrical cable assembly 22 can include a first at least one contact surface 38 in electrical communication with the mating member 26, and a second at least one contact surface 38 in electrical communication with the mounting member 28. The keyed surfaces 34 are configured to be placed in contact with the respective ones of the contact surfaces 38, thereby establishing an electrical connection between at least one or both of the first and second ends 24a and 24b, and the mating member 26 or mounting member 28, respectively. For instance, the keyed surfaces 34 are configured to be placed in contact with the respective ones of the contact surfaces 38, thereby establishing an electrical connection between the first end 24a and the mating member 26, and an electrical connection between the second end 24b and the mounting member 28. For instance, each of the keyed surfaces 34 can be sized and shaped to be placed in surface contact with the respective contact surfaces 38 prior to placing the keyed surfaces 34 in contact with the respective contact surfaces 38. Thus, when the keyed surfaces 34 are placed in contact with the respective contact surfaces 38, the keyed surfaces 34 and the contact surfaces 38 are in surface contact with each other. Because the keyed surfaces 34 permit surface contact only when the respective first and second ends 24a and 24b are in one or more predetermined orientations with relative to the respective contact surfaces 38 in order to be placed in surface contact, the surfaces can be referred to as keyed. The keyed surfaces 34 can be flat surfaces, or alternatively shaped surfaces as desired. Similarly, the contact surfaces 38 can be flat surfaces or alternatively shaped surfaces as desired, so as to correspond with the shape of the keyed surfaces 34.
The keyed surfaces 34 are configured to be fused to the respective contact surface 38 after the keyed surfaces 34 have been placed in contact with the respective contact surfaces 38. For instance, the keyed surfaces 34 can be ultrasonically bonded, welded, or soldered to the respective contact surface 38 so as to fuse the keyed surface 34 to the contact surfaces 38. Accordingly, the electrical cable 24 can be attached to the mating member 26 and the mounting member 28 without the use of crimp sleeves. Further, the mating member 26 can be sized as desired to attach to any desired first electrical component so long as the respective contact surface 38 is configured to fuse to the first end 24a. Furthermore, the fused keyed surfaces 34 and contact surfaces 38 produce higher tensile pull out forces than crimped sleeves, and exhibit a better temperature rise than crimp sleeves. Additionally, the electrical cable 24 can have different sizes but still configured to attach to the same mating member 26 and mounting member 28.
The electrical cable assembly 22 can further include an electrically insulative material 43, such as a first shrink wrap that can be configured as a shrink tube, that can surround and thus overlap at least a portion of the electrical insulator 32, and can surround the first end 24a. The first shrink wrap can further surround the respective contact surface 38 that is in electrical communication with the mating member 26. The electrical cable assembly 22 can further include an electrically insulative material 43, such as a second shrink wrap that can be configured as a shrink tube, that can surround and thus overlap at least a portion of the electrical insulator 32, and can surround the second end 24b, and further surrounds the respective contact surface 38, for instance that is in electrical communication with the mounting member 28. The shrink tubes can be placed over the electrical cable 24, such that they are aligned with the first and second ends 24a and 24b, the respective contact surfaces 38, and overlap at least a portion of the electrical insulator, and heat can be applied to the shrink tubes to cause them to shrink and seal over the first and second ends, the contact surfaces 38, and the overlapped portion of the electrical insulator.
In accordance with one embodiment, one or both of the contact surfaces 38, for instance the contact surface 38 in electrical communication with the mating member 26, can define a receptacle 40 that is configured to receive the respective one of the first and second ends 24a and 24b, for instance the first end 24a, so as place the respective keyed surface 34 in contact with the respective contact surface 38. Thus, the at least one keyed surface 34 of the first end 24a is configured to be received by the receptacle 40 and subsequently fused to the at least one contact surface 38. It should be appreciated that the mating member 26 is in electrical communication with the respective at least one contact surface 38 prior to connection of the corresponding at least one keyed surface 34 with the contact surface 38.
The mating member 26 can define an electrical receptacle 42 that is configured to receive a complementary electrical contact, for instance of the first complementary electrical device 30 so as to place the mating member 26, and thus the electrical cable 24, in electrical communication with the first complementary electrical device 30. Thus, the electrical receptacle 42 can be sized to receive the power rail 31, thereby placing the mating member 26 in electrical communication with the power rail 31, and also placing the electrical cable 24 in electrical communication with the power rail 31. For instance, the mating member 26 can include first and second electrical conductors that, in turn, define first and second arms 44 that cooperate with each other so as to define the receptacle 42 of the mating member 26. The mating member 26 can be substantially U-shaped, such that the first and second arms 44 are monolithic with each other. Alternatively, the first and second arms 44 can be separate from each other, and attached to each other as desired. The respective at least one contact surface 38 can be placed in contact, or otherwise placed in electrical communication, with one or both of the first and second arms 44. For instance, the respective at least one contact member 37 can be monolithic with the first and second arms 44. The mating member 26 can further include an electrically conductive shroud 46 having first and second shroud arms 48a and 48b that are disposed adjacent and outboard of the first and second arms 44, respectively, such that each of the first and second arms 44 is disposed between the first and second shroud arms 48a-b. Thus, when the first and second arms 44 deflect away from each other as they receive the complementary electrical contact in the receptacle 42, the first and second arms 44a-b can abut the first and second shroud arms 48a-b, respectively, so as to provide structural support to the first and second arms 44 and increase the normal force against the received electrical contact. Thus shroud 46 can be substantially U-shaped, such that the shroud arms 48a-b are monolithic with each other. The shroud arms 48a-b can be resiliently deflectable away from each other. The shroud 46 can further be electrically conductive. The at least one contact member 37 can extend through the shroud 46 in a rearward direction, which can be along the longitudinal direction L.
The electrical cable assembly 22 can include an electrically insulative housing 50 that surrounds the mating member 26 and can include a mounting member, such as a mounting plate 51, that is configured to be mounted onto a panel or other suitable support member. For instance, the housing 50, for example the mounting plate 51, can define at least one securement member configured to attach to the panel or other suitable support member. The securement member can be configured as one or more apertures 52 configured to receive hardware 75 that attaches the housing 50 to the panel or support member. Alternatively or additionally, the housing 50 can include a securement member configured as one or more latches 55 (see
As described above, the at least one keyed surface 34 of the second end 24b is configured to be placed against the respective contact surface 38 that is in electrical communication with the mounting member 28, and subsequently fused to the respective contact surface 38. For instance, the keyed surfaces 34 can be ultrasonically bonded, welded, or soldered to the respective contact surface 38 so as to fuse the keyed surface 34 to the contact surfaces 38 in the manner described above. It should be appreciated that the mounting member 28 is in electrical communication with the respective at least one contact surface 38 prior to connection of the at least one keyed surface 34 of the second end 24b with the contact surface 38. The second end 24b and the respective contact surface 38 can each be planar or alternatively shaped as desired. In accordance with the illustrated embodiment, the mounting member 28 can be configured as a plate, such as a fusion lug, having a surface that defines the respective contact surface 38. Thus, the mounting member 28 can be monolithic with the respective at least one contact surface 38. The mounting member 28 can define a securement member 56 that is configured to secure the mounting member 28 to the underlying substrate. For instance, the securement member 56 can be configured as one or more through holes configured to receive hardware that secures the mounting member 28 to the underlying substrate. The mounting member 28 can be placed against at least one contact pad of the underlying substrate when mounted to the substrate so as to place the mounting member 28, and thus the electrical cable 24, in electrical communication with the electrical traces of the substrate.
It should be appreciated that the electrical cable assembly 22 can include a single cable 24 as illustrated in
Referring now to
The latch arm 60 can be elongate along a direction that includes 1) a first directional component in the rearward direction, and 2) a second directional component in an direction perpendicular to the rearward direction. The direction perpendicular to the rearward direction can be along the transverse direction T. Thus, the latch arm 60 can be oblique to both the longitudinal direction L and the transverse direction T. In accordance with one embodiment, the mating member 26 can include first and second latch arms 60 that are spaced from each other along the transverse direction T and are both configured to interfere with the housing 50 after the mating member 26 has been inserted into the channel 62 of the housing 50, so as to prevent removal of the mating member 26 from the housing 50 in the rearward direction. For instance, the latch arms 60 can extend out from the at least one shroud 46, which can include first and second shrouds 46a and 46b. In particular, the at least one shroud 46 can include a base 47, such that the shroud arms 48a-b extend out from the base 47 in the forward direction. The arms 44 can extend through the base 47. The latch arms 60 can extend out from the base 47. For instance, a first one of the latch arms 60 can extend out from an upper surface of the base 47, and a second one of the latch arms 60 can extend out from a lower surface of the base 47. The second directional component of the first one of the latch arms 60 can be in the upward direction. The second directional component of the first one of the latch arms 60 can be in the downward direction. The latch arms 60 can be monolithic with the shroud 46. Alternatively or additionally, the latch arms 60 can extend out from one or both of the first and second arms 44. The latch arms 60 can further be monolithic with the at least one of the first and second arms 44. The latch arms 60 can be flexible, for instance elastically flexible.
The housing 50 can define one or more pockets sized to receive respective ones of the latch arms 60. The housing 50 can further define a retention wall 65 that at least partially defines the pockets. The retention wall 65 can define the retention surface 73. Thus, as the mating member 26 is inserted into the channel 62, the latch arms 60 compresses and rides along the housing until the latch arms 60 are aligned with the pocket, at which point the latch arms 60 decompress and are inserted into the pocket. Interference between the latch arms 60 and the respective retention wall 65 prevents removal of the mating member 26 from the channel 62 along the rearward direction.
Referring now to
A method can be provided for constructing the electrical cable assembly 22 as described above. The method can include the steps of shaping the fibers of wire of the at least one of the first and second ends 24a and 24b of the electrical cable 20 so as to define at least one keyed surface 34, and, after the shaping step, fusing the fibers of wire of the at least one of the first and second ends 24a and 24b to each other so as to define the solidified shape having the at least one keyed surface 34. The fusing step can be performed prior to electrically connecting the respective at least one of the first and second ends to the mating member 26 or the mounting member 28, respectively. It should be appreciated that the method can include any one or more steps so as to construct the electrical cable assembly 22 as described herein.
Referring now to
As described above, the mating member 26, can include at least one electrically conductive contact member 37 that defines at least one contact surface 38. For instance, the first and second electrical conductors 41a and 41b can include respective first and second electrically conductive contact members 37a and 37b. The first and second electrically conductive contact members 37a and 37b can be disposed adjacent each other along the lateral direction A and abut each other. Furthermore, each of the first and second electrical conductors 41a and 41b can include an attachment member at the respective first and second electrically conductive contact members 37a and 37b. The attachment member of the first electrical conductor 41a can be configured to attach to the attachment member of the second electrical conductor 41b so as to attach the first electrical conductor 41a to the second electrical conductor 41b.
For instance, as illustrated in
Alternatively, as illustrated in
With continuing reference to
The first and second shroud arms 48a and 48b of the first and second shroud members 46a and 46b can define respective inner surfaces that face each other along the lateral direction A, and outer surfaces that face away from each other along the lateral direction A. At least one or both of the first and second shroud arms 48a and 48b of at least one or both of the first and second shroud members 46a and 46b can define respective ribs 70 that project out from the respective outer surfaces. The ribs 70 can define a first portion 70a that extends substantially along the longitudinal direction L, and a second portion 70b that is rearward of the first portion 70a with respect to the longitudinal direction L that extends from the first portion 70a along a direction that includes a directional component in the transverse direction T. For instance, the second portion 70b of the ribs 70 of the first shroud member 46a can extend away from the second shroud member 46b along the transverse direction. Similarly, the second portion 70b of the ribs 70 of the second shroud member 46b can extend away from the first shroud member 46a along the transverse direction T. The ribs 70 are configured to be received by a window cut-out in the housing 50 when the shroud 46 is inserted in the housing 50.
Referring now to
Referring now to
In accordance with one embodiment, the at least one pivot member 80 can include first and second pivot members 80a and 80b that are spaced from each other along the transverse direction T. Each of the first and second pivot members pivot members 80a-b that are configured to be received in respective seats of the housing body 53. The first and second pivot member 80a and 80b are spaced from each other along the transverse direction T so as to define the axis of rotation. The latch 55 can be spaced from the respective electrical conductors 41a and 41b along the transverse direction T. The latch 55 can further be spaced from the shroud 46 along the transverse direction T. For instance, the latch 55 can be disposed above the electrical conductors 41a and 41b and the shroud 46 along the transverse direction T. The head 55b can define an outer surface 82 that is configured to be received in an aperture 69 that extends through the respective power rail 31. For instance, the aperture 69 can extend through the power rail 31 along the lateral direction A. The aperture 69 can have any size and shape as desired. For instance, the aperture 69 can be cylindrical in shape. Similarly, the head 55b can have any size and shape as desired, such that the head 55b is sized to be received in the aperture 69 such that the head 54 is rotatable in the aperture 69. The power rails 31 can be mounted to a complementary power bus 91, which can be configured as a printed circuit board or a power rail. The power rails 31 can be oriented parallel to each other, and orthogonal to the complementary power bus 91.
The aperture 69 can extend through the power rail 31 along a central axis that extends in the lateral direction A. Further, it should be appreciated that the head 55b can define a central axis along the lateral direction A. Each of the central axes can be oriented substantially in the lateral direction, depending on whether play exists in the aperture 69. The central axis of the head 55b can be coincident with the central axis of the aperture 69. It is recognized that when the head 55b of the latch 55 is disposed in the aperture 69, the housing 50 can define a moment of force about an axis that extends substantially in the lateral direction A that can tend to move the housing 50 toward or away from the power rail 31 as the housing pivots about an axis. The axis can be defined by the central axis of the aperture 69, the central axis of the head 55b, both central axes, or another axis in the lateral direction A, for instance when the aperture 69 is sized greater than the head 55b such that the head 55b is eccentrically movable within the aperture 69. Thus, the axis can extend through the aperture 69 in the lateral direction A. The axis can further extend through the head 55b in the lateral direction A. For instance, the housing 50 can tend to pivot about the central axis, as the head 55b rotates within the aperture 69. Accordingly, the housing 50 can include an anti-rotation member 86 that can be configured as an anti-rotation wall 88. The wall 88 can be disposed such that the arms 44 and the shroud 46 are disposed between the wall 88 and the latch 55 along the transverse direction T. The power rail 31 can include a slot 90 that is sized to receive the anti-rotation wall 88. The anti-rotation wall 88 can define first and second opposed surfaces 92a and 92b that face respective opposed first and second surfaces 94a and 94b of the power rail 31 that define the slot 90. Thus, the first surface 92a of the anti-rotation wall 88 can contact the first surface 94a of the power rail 31 to prevent the housing 50 from pivoting about the central axis in a first direction. The second surface 92b of the anti-rotation wall 88 can contact the second surface 94b of the power rail to prevent the housing 50 from pivoting about the central axis in a second direction opposite the first direction. It should be appreciated that a method of preventing rotation about an axis that extends along the lateral direction A can include the step of inserting the anti-rotation wall 88 in the slot 90.
Thus, during operation, a force can be applied to the latch 55 that causes the head 55b to move from a first position along a direction away from the power rail 31 as the latch 55 pivots about the axis of rotation in a first direction. It should be appreciated that a force can be applied to the grip portion 55a that causes the latch 55 to pivot about the axis of rotation in the first direction. Alternatively, the head 55b can define a beveled leading surface that cams over a front edge of the power rail 31, which causes the latch member to pivot about the axis of rotation in the first direction. When the head 55b is aligned with the aperture 69, the latch 55 can pivot about the axis of rotation in a second direction opposite the first direction, thereby causing the head 55b to be inserted in the aperture 69. For instance, it should be appreciated that the latch 55 can be spring biased to return to the first position along the second direction. In particular, the latch 55 can include a spring member 55d that extends from the grip portion 55a and biases against the housing body 53 so as to provide the spring force. Alternatively, a force can be applied to the grip portion 55a that causes the latch 55 to pivot about the axis of rotation in the second direction. As the housing 50 and the power rail 31 are moved toward each other until the head 55b is aligned with the aperture, the anti-rotation wall is inserted into the slot 90. Once the head 55b is disposed in the aperture 69, interference between the head 54 and the power rail 31 prevents translation of the housing 50 with respect to the power rail 31. When it is desired to remove the housing 50 from the power rail 31, a force can be applied to the grip portion 55a that causes the latch 55 to rotate about the axis of rotation in the first direction, thereby removing the head 55b from the aperture 69. Once the head 55b has been removed from the aperture 69, the housing 50 can be removed from the power rail 31, which removes the power rail 31 from the receptacle 77.
A method can further be provided for selling the electrical cable assembly as described herein. The method can include the steps of teaching to a third party one or more up to all of the method steps described herein, and selling to the third party the electrical cable assembly 22. The method can further include the step of teaching to the third party the step of receiving the power rail 31 in the receptacle 42 of the mating member 26. The method can further include the step of teaching to the third party the step of securing the mounting member 28 to the substrate.
Referring now to
The electrical power rails 31 can be mounted to the complementary electrically conductive substrate 97 in accordance with any suitable embodiment as desired, such as a screw, pin, rivet, solder, weld, or the like. For instance, each of the electrical power rails 31 can include a mating portion 31a and a mounting portion 31b. The mating portion 31a can be received in the housing receptacle 77 and the 42 of the mating member 26 in the manner described above. The mounting portion 31b can flare out with respect to the mating portion 31a, and can be secured to the electrically conductive substrate 97. For instance, the mounting portion 31b can flare out in opposite directions from the mating portion 31a.
As described above, the electrical assembly 20 can include at least one electrical cable assembly 22 that can be placed in electrical communication with a common electrically conductive substrate 97. The common electrically conductive substrate 97 can be configured as a complementary electrical power bus 91 as illustrated in
Referring now to
The at least one electrical conductor 104 can include a mating portion 104a and a mounting portion 104b. The mating portion 104a is configured to be mated to the electrical power rail 31. For instance, the mating portion 104a at least one electrical conductor 104 can extend into the housing receptacle 106, such that when the power rail 31 is received in the housing receptacle 106, the power rail contacts the mating portion 104a. In one example, the electrical connector 100 includes a pair of electrical conductors 104, such that the mating portion 104a of the electrical conductors 104 are disposed on opposite sides of the housing receptacle 106 with respect to a transverse direction T that is perpendicular to the longitudinal direction L. The mounting portion 104b is configured to be mounted to the substrate 97 in the manner described above.
As illustrated in
Referring now to
For instance, the housing 112 can include a divider wall 117 that is disposed in the housing receptacle 116, and is configured to be received in the housing receptacle 77 when the electrical cable assembly 22 is mated to the interposer 110. The at least one electrical conductor 114 can include a mating portion 114a and a mounting portion 114b. The mating portion 114a is configured to be mated to the electrically conductive member 26 of the cable assembly 22. For instance, the mating portion 114a can extend 104 can extend along one side of the divider wall, such that the mating portion 114a is placed in contact with the electrically conductive member 26. In one example, the mating portion 114a is placed in contact with a respective arm 44 of the electrically conductive member 26. In one example, the electrical connector 100 includes a pair of electrical conductors 104, such that the mating portion 104a of the electrical conductors 104 are disposed on opposite sides of the divider wall 117 with respect to a lateral direction A that is perpendicular to the longitudinal direction L. The arms 44 of the electrically conductive member 26 can be placed into contact with respective ones of the mating portions 104a when the divider wall 117 is received in the housing receptacle 77.
Referring now to
With continuing reference to
The foregoing description is provided for the purpose of explanation and is not to be construed as limiting the invention. While various embodiments have been described with reference to preferred embodiments or preferred methods, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Furthermore, although the embodiments have been described herein with reference to particular structure, methods, and embodiments, the invention is not intended to be limited to the particulars disclosed herein. For instance, it should be appreciated that structure and methods described in association with one embodiment are equally applicable to all other embodiments described herein unless otherwise indicated. Those skilled in the relevant art, having the benefit of the teachings of this specification, may effect numerous modifications to the invention as described herein, and changes may be made without departing from the spirit and scope of the invention, for instance as set forth by the appended claims.
This claims the benefit of U.S. Patent Application Ser. No. 61/912,892 filed Dec. 6, 2013, U.S. Patent Application Ser. No. 61/931,962 filed Jan. 27, 2014, and U.S. Patent Application Ser. No. 61/969,719 filed Mar. 24, 2014, the disclosures of each of which are hereby incorporated by reference as if set forth in their entireties herein.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2014/068779 | 12/5/2014 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 61912892 | Dec 2013 | US | |
| 61931962 | Jan 2014 | US | |
| 61969719 | Mar 2014 | US |
