The present invention relates to improvements in the design, construction and manufacture of connectors for a thermocouple system. The present invention particularly relates to a design and method of connector manufacture that is low cost, efficient, has reduced number of assembly parts and assembly steps, and avoids the use of screws.
Connectors are utilized to interconnect a thermocouple probe or sensor member within a thermocouple system. One portion of the connection arrangement is interconnected with a probe member. A second portion of the connection arrangement is connected to a wire that may extend to a strip panel. In turn, the strip panel may be operatively connected via cable or the like to one or more instruments.
It is known to use screws to connect wire leads and screws that secure a cover onto a body of at least one portion of the connector arrangement. It is labor intensive to provide such connections. Also, such construction may not provide for ease of variation of component parts.
In accordance with one aspect, the present invention provides a thermocouple connector arrangement that includes a first connector configured to have a thermocouple probe lead extending therefrom. The first connector has an interior configured to receive an electrical connection terminus of the thermocouple probe lead. A second connector of the arrangement is configured to have an electrical connection lead extending therefrom. The second connector has an interior configured to receive a terminus of the electrical connection lead. The first and second connectors include electrically conductive mating parts that, when mated, provide an electrical conduction path between the thermocouple probe lead and the electrical connection lead. At least one of the first and second connectors includes housing parts that mate in a snap-lock arrangement to secure the housing parts together and to enclose the respective interior. The at least one of the first and second connectors includes structure that engages the respective terminus and secures the respective terminus against removal during the mating of the housing parts and without the use of a threaded fastener.
In accordance with another aspect, the present invention provides a thermocouple connector arrangement that includes a first connector configured to have a thermocouple probe lead extending therefrom, and having an interior configured to receive an electrical connection terminus of the thermocouple probe lead, and a second connector configured to have an electrical connection lead extending therefrom, and having an interior configured to receive a terminus of the electrical connection lead. The first and second connectors include electrically conductive mating parts that, when mated, provide an electrical conduction path between the thermocouple probe lead and the electrical connection lead. At least one of the first and second connectors includes housing parts that mate in a snap-lock arrangement to secure the housing parts together and to enclose the respective interior.
In accordance with another aspect, the present invention provides a thermocouple connector arrangement that includes a first connector configured to have a thermocouple probe lead extending therefrom, and having a portion configured to receive an electrical connection terminus of the thermocouple probe lead, and a second connector configured to have an electrical connection lead extending therefrom, and configured to receive a terminus of the electrical connection lead. The first and second connectors include electrically conductive mating parts that, when mated, provide an electrical conduction path between the thermocouple probe lead and the electrical connection lead. At least one of the first and second connectors includes structure that engages the respective terminus and secures the respective terminus against removal without the use of a threaded fastener.
In accordance with yet another aspect, the present invention provides a thermocouple connector arrangement. The arrangement includes a first connector configured to have a thermocouple probe lead extending therefrom, and having an interior configured to receive an electrical connection terminus of the thermocouple probe lead. The arrangement includes a second connector configured to have an electrical connection lead extending therefrom, and having an interior configured to receive a terminus of the electrical connection lead. The first and second connectors include electrically conductive mating parts that, when mated, provide an electrical conduction path between the thermocouple probe lead and the electrical connection lead. At least one mating part of one of the first and second connectors is a prong that includes a strip of conductive material twisted into a helix.
An example thermocouple system 10 that utilizes a thermocouple connector arrangement 12 in accordance with one aspect of the present invention is shown in
A first connector 16 of the connection arrangement 12 is interconnected with the probe member 14. Specifically, the first connector 16 is configured to have a thermocouple probe lead 18 extending therefrom, and the first connector has an interior configured to receive an electrical connection terminus of the thermocouple probe lead. A second connector 20 of the connection arrangement 12 is connected to an electrical connection lead 22, such an elongate wire cable. Further, the second connector 20 is configured to have the electrical connection lead extending therefrom, and the second connector has an interior configured to receive a terminus of the electrical connection lead. It is to be appreciated that the designations of first and second for the connectors are merely for ease of identification.
In the shown example system 10, the wire cable 22 extends to a strip panel 26. In turn, the strip panel 26 is operatively connected via cable or the like to one or more instruments 28. It is to be appreciated that the shown example system 10 may have different components, structure, etc., and these aspects of the system 10 are not specific limitations upon the present invention.
The first and second connectors 16 and 20 include electrically conductive mating parts that, when mated, provide an electrical conduction path between the thermocouple probe lead 18 and the wire cable (electrical connection lead) 22. The electrically conductive mating parts are described further below. However, it is to be appreciated that the specifics of the electrically conductive mating parts may not be a limitation on the present invention.
In accordance with one aspect, at least one of the first and second connectors 16, 20 includes housing parts that mate in a snap-lock arrangement to secure the housing parts together and to enclose the respective interior. Also in accordance with one another aspect, at least one of the first and second connectors 16, 20 includes structure that engages the respective terminus and secures the respective terminus against removal without the use of a threaded fastener. As a further aspect, the engagement and securing accomplished without the use of a threaded fastener occurs during the mating of the housing parts.
The exploded view of
As can be appreciated by viewing
The portion of the connector body 32 that retains the prongs 34 can be considered to be a first or front portion 72 (
As can be appreciated, a substantial portion of each prong 34 extends from the front end of the body 32 for connection to the other connector 16. However, a rear end portion 76 of each prong 34 extends rearward from the front portion 72 of the body 32. The rear end portion 76 of each prong 34 is located at a respective side of the rear portion 74 of the body 32 (i.e., the rear of the lower body section). These prong end portions 76 are provided for electrical connection to wires of the wire cable 22, which will be described below.
Turning to the rear portion 74 of the body 32, it provides two functions. First, the rear portion 74 is configured to receive a crimp adapter 80 (
Within the shown example, wire cable 22 is elongate and flexible, and the wire cable has two wires 84. It should be noted that the connector could accommodate a wire cable, and included wires, of various size. Turning attention to
Turning back to the second function of the rear portion 74, the portion is configured to provide one half of a snap-lock interconnection between the body 32 and the cap 38. The snap-lock connection is described further below. However, it is to be noted that the rear portion 74 (
The shown example of the cap 38 of the connector 20 is made of two sections 98 and 100. These sections 98, 100 can be made of thermoplastic and are secured together in a manner similar to the manner used for the body 32. As noted above, various techniques can be used. For ease of reference, these sections 98, 100 are referred to as upper and lower sections. The upper section 98 includes a projection 102 (
The cap 38 has an interior 110 that is bounded by the two sections 98, 100 and that provides multiple functions. First, the rear portion 74 (
Within the shown example, each of the resilient retainer means is a spring 112, which is made of resilient metal. Within the shown example, each spring 112 has a general “C” shape and acts as a clip.
The interior of the cap 140 is configured to receive and retain the springs 112. Each of the upper and lower sections 98 and 100 of the cap 38 has a curved seat portion 114 for each spring 112. The seat portions 114 cooperate when the upper and lower sections 98, 100 mate together to provide a seat pocket that cradles the respective spring 112, resists removal of the spring, and yet permits flexing of the spring.
The upper section 98 of the cap 38 has two additional features. First, the upper section 98 has a projection 118 that extends toward the lower section 100 of the cap 38. The projection 118 is configured and located to help retain the wire cable 22 and/or the crimp adapter 80 within the rear portion 74 of the body 32.
Second, the upper section 98 of the cap 38 has at least one (e.g., two) projection 122 that provide a second half of the snap-fit interconnection. Specifically, the projections 122 are located and configured such that the projections will cooperate with the sloped surfaces 88 and the shoulders 90 of the rear portion 74 of the body 32 to snap-lock the cap 38 onto the body. During the mating of the cap 38 onto the body 32, the projections 122 engage and ride along the sloped surfaces 88. As the cap 38 is moved toward a final position mated with the body 32, the sloped surfaces 88 deflect the projections 122 and thus part of the cap outward. However, as the cap 38 reaches the final position, the projections 122 arrive at the edge of the shoulders 90. Subsequently, the projections 122 drop off of the shoulders 90 with a snapping action (i.e., the deflected portion of the cap snaps back). Thus, the projections 122 rest against the shoulders 90.
It should be noted that the snap interlock mating could be accomplished by any other suitable snap interlock structure. This sort of snap interlock is commonly referred to as a one-way connection. It is to be noted that additional snap-lock structures may be utilized. For example, a tapered tip 124 that has a recess 126 is located on the lower section 100 of the cap 38. The tapered tip 124 and the recess 126 interact with a pin-like projection (not visible) on the outer side of the lower body section 42. The tapered tip 124 slides over the pin-like projection and the pin-like projection snaps into the recess 126 as the cap 38 is moved toward a final position mated with the body 32.
Turning to the connection of the wire cable 22 to the shown example connector 20, it is to be noted that the terminus of the wire cable 22 is extended through the cap 38 and the crimp adapter 80 (see
In preparation for connecting the terminus of the wire cable 22 to the connector 20, an end portion of any protective cable covering is removed (e.g., stripped) to expose the wires 84 contained therein. Further, any coverings on the two wires 84 are removed (e.g., stripped) at the terminus ends to expose the bare wires. Next, the bare wire ends are bent to the outer sides and backward, relative to the wire cable 22. Next, the bared wires 84 are laid onto the exposed rear end portions 76 of the prongs 34 extending from the rear of the body 32. As shown in
It is to be appreciated that the springs 112 are within the cap 38. When the cap 38 is attached to the body 32 (e.g., via relative movement to complete the snap interlock), the springs 112 will engage and ride over the rear end portions 76 of the prongs 34. In other words, the rear end portions 76 are received into the springs 112, with each spring squeezing the respective end portion there between. With the wire tips bent over the prong rear end portions 76, the wires 84 are squeezed into pressing contact with the respective prongs 34. Moreover, the springs 112 resiliently maintain the contact between the wires 84 and the prongs 34. Thus, the wires 84 are gripped and pressed against the prongs 34. Thus, electrical connection is established between each respective wire 84 and prong 34. Again, it is to be appreciated that the connector 20 thus has structure to retain (e.g., grasp) the wire cable.
It is to be appreciated that a portion of the body 32 does extend into the hollow interior 110 of the cap 38. This may be further appreciated upon viewing
Some of the features of the present invention should now be apparent. First, the two parts (e.g., the body and the cap) 32 and 38 of the connector 20 were connected without the use of any threaded fasteners, such as a screw, a bolt, or the like. Second, the terminus ends of the wires 84 are connected to the prongs 34 without the use of any threaded fasteners, such as a screw, a bolt, or the like. Also, the connection of the wires 84 to the prongs 34 occurs simultaneously with the connection of the cap 38 to the body 32.
Turning to consider the overall construction of the connector 16, the connector has two housing parts 138 and 140. The first housing part 138 is referred to as a body, and in the shown example the body is made by two sections 142 and 144. For ease of reference, the sections are referred to as upper and lower sections 142 and 144. Similar to the body 32, the two sections 142 and 144 of the example body 138 can be made of thermoplastic that are secured together by suitable means.
In the shown example, the lower body section 144 has a series of projections 150 and one recess 152, and the upper body section 142 has a series of recesses 154 and one projection 156. The respective projections and the recesses mate when the upper and lower body sections 142 and 144 are coupled together. It is to be noted that in one example, the projections 150 and 156 have structure that aid in securing the upper and lower sections 142 and 144 together. For example, the structure may be raised material, e.g., in an elongate pyramidal shape, which flows upon occurrence of an ultrasonic welding procedure. As can be appreciated by viewing
The portion of the body 138 that retains the jack springs 132 and inserts 134 can be considered to be a first or front portion 172 of the body, and the end into which the prongs can be inserted can be considered to be the front end of the body. Such a front portion 172 would include the entire upper body section 142 and the front of the lower body section 144. A portion 174 of the lower section 144 does extend to the rear and could naturally be considered a rear portion 174 of the body 138.
A rear end portion 176 of each insert 134 extends rearward from the front portion 172 of the body 138. The rear end portion 176 of each insert 134 is located at a respective side of the rear portion 174 of the body 138 (i.e., the rear of the lower body section). These insert end portions 176 are provided for electrical connection to an electrical connection terminus of the thermocouple probe lead. The constructions and functions to connect the terminus of the thermocouple probe lead are very similar to the connection between the terminus of the wire cable and the prongs associated with the connector 20. As such, most of the details need not be presented at length herein. It is sufficient to state that terminus ends are laid adjacent to the insert rear end portions 176, with the electrically conductive tips bent across the insert end portions. Also, in the shown example, the connector has structure to support the thermocouple probe in a static position relative to the connector.
The rear portion 174 includes at least one (e.g., two) sloped surface 188 and at least one (e.g., two) drop-off shoulder 190. Each sloped surface 188 tapers upward as the sloped surface extends toward the front of the body 138. Each shoulder 190 is located near the front-most terminus of the respective sloped surface 188. In the shown example, the sloped surfaces 188 and shoulders 190 have a very similar or identical structure as the sloped surfaces 88 and shoulders 90 of the connector 20, and thus have very similar or identical functions.
As mentioned, the shown example the cap 140 is very similar or identical to the cap 38 of the plug connector 20. As such, functions of the body and cap 138 and 140 are similar to the functions of the body and cap 32 and 38 of the connector 20. Also, in view of the fact that the example cap 140 is very similar or identical to the cap 38 of the plug connector 20, identical reference numerals are used for identifying structural details and the previously presented descriptions are to be understood as being applicable.
Similar to the plug connector 20 discussed above, the body and cap 138 and 140 are configured to snap together in a one-way type of connection without the use of screws. Also, similar to the plug connector 20 discussed above, electrical connections can be secured without the use of screws. Specifically, because of the presence of the springs 112 within the cap 140, upon insertion of the cap onto the body 138, the springs press the electrical terminus (e.g., contacts) of the probe 14 to the rear end portions 176 of the inserts 134.
It is to be also noted that either the plug connector or the jack connector may be utilized with a cable or may be utilized with some other components such as a probe extension. Specifically, the connectors are not limited to the shown example uses, and it is contemplated that the plug connector or the jack connector may be reversed with regard to connections to the wire cable 22 and the thermocouple probe 14.
It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying, or eliminating details without departing from the scope of teachings contained in this disclosure. In particular, the discussion and drawings are presented herein by way of example only and other variations are contemplated and considered within the scope of the invention.
Benefit of priority is claimed from Provisional Patent Application Ser. No. 60/524,141, filed Nov. 21, 2003.
Number | Date | Country | |
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60524141 | Nov 2003 | US |