The present description may be directed to interconductor connectors, and especially to interconductor connectors configured for resisting physical separating forces.
Some electrical systems such as, by way of example and not by way of limitation, sensor systems with flat wire construction may require data cable connections. The data cables may be significantly larger and stiffer than the conducting elements of the flat wire sensor system. Mechanical loads applied to a data cable may be transmitted to the electrical connection between the data cable and the flat wire structure, thereby weakening the electrical connection.
There is a need for an apparatus and method for connecting a flat wire conductor with a second conductor such as a data cable without transmitting mechanical loads between the flat wire conductor and the second conductor.
An apparatus for establishing a substantially unitary connecting structure including a generally flat conductor member carrying a first plurality of first electrical conductors and a second conductor member carrying a second plurality of second electrical conductors includes: (a) an electrical connecting structure configured for receiving the second conductor member to establish electrical connection between at least one first electrical conductor of the first plurality of first electrical conductors and at least one second electrical conductor of the second plurality of second electrical conductors; (b) a generally inflexible support structure; and (c) at least one connecting member traversing the flat conductor member and cooperating with the electrical connecting structure and the support structure for capturing the flat conductor member between the connecting structure and the support structure in an installed orientation.
A method for establishing a substantially unitary connecting structure including a generally flat conductor member carrying a first plurality of first electrical conductors and a second conductor member carrying a second plurality of second electrical conductors; includes: (a) in no particular order: (1) providing an electrical connecting structure configured for receiving the second conductor member to establish electrical connection between at least one first electrical conductor of the first plurality of first electrical conductors and at least one second electrical conductor of the second plurality of second electrical conductors; (2) providing a generally inflexible support structure; and (3) providing at least one connecting member; and (b) orienting the at least one connecting member to traverse the flat conductor member and to cooperate with the electrical connecting structure and the support structure to effect capturing the flat conductor member between the connecting structure and the support structure in an installed orientation.
It is, therefore, a feature of the described embodiment to provide an apparatus and method for connecting a flat wire conductor with a second conductor such as a data cable without transmitting mechanical loads between the flat wire conductor and the second conductor.
Further features of embodiments of the present invention may be apparent from the following specification and claims when considered in connection with the accompanying drawings, in which like elements may be labeled using like reference numerals in the various figures, illustrating embodiments of the invention.
A flat conductor member 16 may support at least one first electrical conductor in a manner known to one skilled in the art of electrical wiring installation. A second conductor member 18 may support at least one second conductor in a manner known to one skilled in the art of electrical wiring installation. Second conductor member 18 may be embodied in a substantially cylindrical cable configured for insertion into a generally cylindrical electrical connection structure 12, as illustrated in
Electrical connection structure 12 may present a plurality of connecting pin structures 20 for effecting electrical connection between electrical conductors supported in flat conductor member 16 and second electrical conductor member 18, in a manner known to those skilled in the art of electrical wiring installation.
A support structure 22 may be situated and configured for supporting flat conductor member 16. Support structure 22 may be inflexible. Electrical connection structure 12 and flat conductor member 16 may each have generally equal widths in a plane substantially perpendicular with the plane of
Connecting members 24 may be configured for traversing flat conductor member 16 and interacting with at least one of fastening structure 14 and support structure 22 to capture flat conductor member 16 between electrical connecting structure 12 and support structure 22 in the installed orientation illustrated in
Connecting members 24 may each be embodied in a threaded fastener 26 configured for passing through support structure 22, through flat conductor member 16 and through fastening structure 14 for threaded engagement with nut members 28. Bushing members 29 may surround threaded fasteners 26 substantially where threaded fasteners 26 traverse flat conductor member 16. Threaded fasteners 26 may be countersunk within support structure 22 to present a substantially planar face for resting upon or may be affixed to a generally planar-faced host structure 30. Host structure 30 may include, by way of example and not by way of limitation, an aircraft structural piece such as a fuselage.
An adhesive layer 32 may be situated between support structure 22 and host structure 30. An electrically insulating layer 34 may be situated between flat conductor member 16 and support structure 22. An adhesive or sealant layer 36 may be situated upon flat conductor member 16 and extend between flat conductor member 16 and electrical connection structure 12. If adhesive or sealant layer 36 may be installed, connecting pins structures 20 may pierce adhesive or sealant layer 36 to effect electrical connection with first conductors supported in flat conductor member 16 (not shown in detail in
Mechanical loads from electrical connection structure 12 may be transmitted through the relatively stiff bolted interface between fastening structure 14 via connecting members 24 to support structure 22. The mechanical loads may not pass through connecting pin structure 20 so that minimal mechanical load may be transmitted from electrical connecting structure 12 load to the electrical connection between flat conductor member 16 and second conductor member 18. Further, no additional support such as a mechanical attachment to a connection box or other enclosure may be necessary to avoid transmitting mechanical loads to the electrical connection between flat conductor member 16 and second conductor member 18.
A flat conductor member 116 may support at least one first electrical conductor in a manner known to one skilled in the art of electrical wiring installation. A second conductor member 118 may support at least one second conductor in a manner known to one skilled in the art of electrical wiring installation. Second conductor member 118 may be embodied in a substantially cylindrical cable configured for insertion into a generally cylindrical electrical connection structure 112, as illustrated in
Electrical connection structure 112 may present a plurality of connecting pin structures 120 for effecting electrical connection between electrical conductors supported in flat conductor member 116 and second electrical conductor member 118, in a manner known to those skilled in the art of electrical wiring installation.
A support structure 122 may be situated and configured for supporting flat conductor member 116. Support structure 122 may be inflexible. Electrical connection structure 112 and flat conductor member 116 may each have generally equal widths in a plane substantially perpendicular with the plane of
Connecting members 124 may be configured for traversing flat conductor member 116 and interacting with at least one of fastening structure 114 and support structure 122 to capture flat conductor member 116 between electrical connecting structure 112 and support structure 122 in an installed orientation (see
Connecting members 124 may each be embodied in a threaded fastener 126 configured for passing through countersunk apertures 148 in support structure 122, through apertures 144 in flat conductor member 116 and through apertures 140 in fastening structure 114 for threaded engagement with nut members 128. Bushing members 129 may surround threaded fasteners 126 substantially within apertures 144 via which threaded fasteners 126 traverse flat conductor member 116. Bushing members 129 may be compressible or non-compressible. Countersunk apertures 148 may be provided for receiving threaded fasteners 126 within support structure 122 in order to present a substantially planar face for resting upon or may be affixed to a generally planar-faced host structure 130 in an installed orientation (see
An adhesive layer 132 may be situated between support structure 122 and host structure 130. An electrically insulating layer 134 may be situated between flat conductor member 116 and support structure 122 generally between threaded fasteners 126 in an installed orientation (see
A reinforcing member 152 configured generally as a grommet or similar structure may be provided within at least one of apertures 140, 142, 144, 146148 for reinforcement in an installed orientation (see
A flat conductor member 216 may support at least one first electrical conductor in a manner known to one skilled in the art of electrical wiring installation. A second conductor member 218 may support at least one second conductor in a manner known to one skilled in the art of electrical wiring installation. Second conductor member 218 may be embodied in a substantially cylindrical cable configured for insertion into a generally cylindrical electrical connection structure 212, as illustrated in
Electrical connection structure 212 may present a plurality of connecting pin structures 220 for effecting electrical connection between electrical conductors supported in flat conductor member 216 and second electrical conductor member 218, in a manner known to those skilled in the art of electrical wiring installation.
A support structure 222 may be situated and configured for supporting flat conductor member 216. Support structure 222 may be inflexible. Electrical connection structure 212 and flat conductor member 216 may each have generally equal widths in a plane substantially perpendicular with the plane of
Connecting members 224 may be configured for traversing flat conductor member 216 and interacting with at least one of fastening structure 214 and support structure 222 to capture flat conductor member 216 between electrical connecting structure 212 and support structure 222 in an installed orientation (see
Connecting members 224 may each be embodied in a threaded fastener 226 configured for passing through countersunk apertures 248 in support structure 222, through apertures 244 in flat conductor member 216 and through apertures 240 in fastening structure 214 for threaded engagement with nut members 228. Spacer members 227 may surround threaded fasteners 226 between fastening structure 214 and an upper layer of apparatus 210, such as flat conductor member 216 or, if installed, an adhesive or sealant layer 236. Threaded fasteners 226 may traverse flat conductor member 216 via apertures 244. Countersunk apertures 249 may be provided for receiving threaded fasteners 226 within support structure 222 in order to present a substantially planar face for resting upon or may be affixed to a generally planar-faced host structure 230 in an installed orientation (see
An adhesive layer 232 may be situated between support structure 222 and host structure 230. An electrically insulating layer 234 may be situated between flat conductor member 216 and support structure 222 and may be generally coextensive with flat conductor member 216, for at least a portion of the length of flat conductor member 216. If electrically insulating layer 234 may be included in interconductor apparatus 210, apertures 246 may be provided to accommodate traversal by threaded fasteners 226. An adhesive or sealant layer 236 may be situated upon flat conductor member 216 and extend between flat conductor member 216 and electrical connection structure 212. If adhesive or sealant layer 236 may be installed, connecting pins structures 220 may pierce adhesive or sealant layer 236 to effect electrical connection with first conductors supported in flat conductor member 216 (not shown in detail in
Method 300 may continue with orienting the at least one connecting member to traverse the flat conductor member and to cooperate with the electrical connecting structure and the support structure to effect capturing the flat conductor member between the connecting structure and the support structure in an installed orientation, as indicated by a block 310. Method 300 may terminate at an END locus 312.
It is to be understood that, while the detailed drawings and specific examples given describe embodiments of the invention, they are for the purpose of illustration only, that the apparatus and method of the embodiments of the invention are not limited to the precise details and conditions disclosed and that various changes may be made therein without departing from the spirit of embodiments of the invention which is defined by the following claims:
This invention was made with Government support under FA8650-04D-3446 awarded by the United States Air Force. The Government has certain rights in this invention.
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