Note: Descriptions are shown in the official language in which they were submitted.
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In connector systems used in a hostile environment,
such as deep within an oil well, the female or socket ends of
contacts are damaged much more often that the male or pin
contact ends. Also, cleaning of the deep recess of a socket
contact end is much more difEicult than of a pin con-tact end
which may have no recesses. A socke-t device with socket
contact ends at both ends of the connector could be used to
connect two male or pin ends to avoid-the need to reconnect
multiple wires to a new connector whenever it is damaged.
However, if the module with the sockets at either ends is to be
disposed of every time a socket becomes damaged or very dirty,
then the cost would be high. A socket insert assembly which
enabled cleaning and replacement of its sockets modules in the
field, would facilltate the maintenance of connector systems in
the field.
SUMM~RY OF THE INVENTION
The invention provides a connector system comprising:
(a) a pair of receptacle connectors and a separate plug
assembly for mounting with and between said receptacle
connectors; (b) each said receptacle connector having a shell
with a hollow end portion, said shell holding an insulation
member containing a plurality oE spaced pin contacts extending
into said hollow end portionl with the pin contacts arranged in
a predetermined pattern; (c) said plug assembly comprising: (i)
a housing, other than said shells, containing Eirst and second
insulators, each said insulator having an inner end that
substantially abuts the inner end of the other insulator, and
each having an outer end, said insulators forming a plurality
of through holes arranged in a pattern corresponding to the
pattern of said pins; ~ii) a plurality of elongated socket
modules each mounted in a respective one of said through holes
each said socket module having a pair of opposi-te ends with
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holes for receiving the pin con-tacts of said receptacle
connectors; (iii) each said through hole having a wide diameter
portion e~tending Erom the inner end of the insulator for
receiving a socket module, and each said through hole having a
narrow portion near its outer end that is too narrow to pass
the socket module therethrough, said wide diameter portions
being long enough to receive said socket modules, with opposite
ends of each socket module lying in diferent ends o:E said
insulators; (iv) means for releasably holding said first and
second insulators together in said housing with said socket
modules in the insulators to form a self-contained assembly,
said holding means permitting intentional removal of the
insulators from said housing to remove and replace the socket
modules therein; and (d) each end of said plug assembl~ being
slldably insertable into a different one of said connector
hollow ends with the pins of said receptacle connectors
received in the ends of said socket modules said plug assembly
being withdrawable from said receptacle connectors by sliding
the plug assembly out of said connector hollow ends.
The novel features of the inven-tion are set
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orth with particularity in the appended claims. The
invention will be best understood from the following
description when read in conjunction with the
accompanying drawings.
BRIEF DESCRIPTIOM OF THE DRAWINGS
Figure l is an exploded partially sectional view
of a connector system constructed in accordance with
the present invention.
Figure 2 is a view taken on the line 2-2 of
Figure 1.
Figure 3 is a partial perspective and exploded
view of a socket module of the socket insert assembly
of Figure 1.
Figure 4 is a sectional view of the socket
module of Figure 3.
Figure 5 is a view taken on the line 5-5 of
Figuxe 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Figure 1 illustrates a connector system 10 which
can be used in a hostile environment such as deep
within an oil well where part or all of the system is
subjected to dirt under considerable heat and pressure.
The system includes a pair o~ connectors 12, 14 having
male connector ends 16, 18 that must be interconnected
under hostile conditions. In this connnector system,
the connector 12 has an opposite end 20 which is also a
male end and which connects to a socket connector 22 at
the end of a cable, where the connections between the
ends 20, ~2 are under less than hostile conditions, in
as much as a seal applied around the outside 24 of the
connector isolates its opposite ends to protect the end
20 from the extreme hostile environment.
The two male connector ends 16, 18 are
interconnected by a socket insert assembly or apparatus
26. The socket insert assembly includes two insulators
23, 30 that have inner ends 32, 34 that abut one
another, and outer ends 36, 38. Each insulator has a
plurality of through holes ~0, 42 that extend between
its opposite ends. A plurality of soc~et modules 44
lie in the holes. Each socket module has a pair of
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opposite socket ends 46, 48 for receiving pin contacts,
to interconnect a pair of pin contac~s received in its
opposite ends. Each hole 40, 42 of the insulators
includes a wide diameter portion S0, 52 extending from
the inner end of the respective insulator, for
recei~ing the socket module. Each hole also includes a
narxow portion 54, 56 near its outer end, which is too
naxrow to pass a socket module 44, to thereby retain
the socket module i~ place~ However, each narrow
portion 54, 56 is wide enough to pass a pin contact, so
that a pin contact can enter an end of a socket
module~ A socket insert assembly shell 60 surrounds
the two insulators to hold them in, although Lt is
possible to provide other locking means to hold the
lS insulators together.
Each connector includes a group of pin contacts
62, 64 that have middle portions 66 trapped within an
insulation member 68 within the connector and are
preferably sealed thereto. Each pin contact also has
an end 70 that projects from the insulation member into
a hollow connector end 72. The contact end is
surrounded by a largely cylindrical hollow connector
end 74 formed by a shell 76 of the connector. The
socket insert assembly 26 is designed to it into the
hollow shell end 74 of either male connector end 16, 18
to receive the pin contact ends 70 therein. The depth
! D of each hollow connector end is less than the length
L of the soc~et insert assembly. As a result, when one
end of the socket insert assembly is fully inserted
into a male connector end such as 16, the opposite end
¦ o the socket insert assembly projects therefrom and
can be inserted into the other male connector end 18
to contact its pin contacts 64. The length L is less
than 2D, so the ex-treme end of the shells can abut one
another.
Each socke~ module 44 has a construction such as
is shown in Figure 5. The socket module includes a
body 80 extending along axis 81/ with a middle portion
} 82 and with arcuate opposite end portions 84. A napkin
spring 86 fits around each end portion to press a pin
contact portion 70 against the inside surface of a body
end portion 84. A hood 88 surrounds the end portion 84
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of the body and the spring 86 to retain them in place.
The hood has an open outer end 90 which is large enough
to pass a pin contact but small enough to prevent loss
of the spring 86.
Most of the socket modules carry noncritical
signals, and have napkin springs which can be deflected
by moderate insertion forces. A minority of the socket
modules carry critical signals, and low contact
resistance then must be assured even when the system is
subjected to severe vibrations, shocks, and other
disturbances. Where critical signals are carried by a
socket module, its napkin spring is stiffer so it
applies at least a 50% greater force against a con~act,
than does a spring of a module carrying noncritical
signals. only a minority of socket modules with
stiffer napkin springs are present in a socket
insertion assembly, to avoid an excessive connector
mating force.
The socket insert assembly 26 (Fig. 1) is
designed to facilitate the clean out and replacement of
a socket module 44 or insulator in the ~ield. To
disassemble the assembly, a snap ring 94 is removed
rom a slot near one end of the shell 60, which can be
easily accomplished with a screw driver blade or
knife. The assembly is then turned so that the'end 38
is lowermost, so that the two insulators may be removed
from the shell 60. The two insulators are then turned
upside down so that the end 36 is lowermost. The top
insulator 30 can then be lifted off of the other one 28
so that ends of a socket modules 44 project from the
inner end 32 of the insulator 28. If one of the socket
modules 44 is damaged or a few of them require
cleaning, they can be lifted out, cleaned, and then
replaced. Altexnately, all of the socket modules can
be placed in a container and cleaned, and the
insulators alld their holes can also be cleaned.
One of the insulators 28 is longer, along the
axis 96, than the other 30. Reassembly of the socket
assembly is accomplished by orienting the longer
insulator 28 with its inner end 32 uppermost, and then
inserting the numerous socket modules in the holes 50
of the larger insulator. When the socket madules are
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dropped into the longer holes 50 of the longer
insulator, their projecting ends are held sufficiently
close in position so that the shorter insulatox 30 can
fit over them. That is, the module axes are
sufficiently parallel to the axes of the insulator
holes. The shorter insulator 30 can be lowered into
position so that lts inner end 34 abuts the inner end
32 of the longer insulator. Thereafter, the projecting
upper ends of the socket modules hold the two
insulators 28, 30 in alignment. It may be noted that
it would be much harder to assemble the socket module
by first inserting the socket modules into the shorter
insulator 30, because then the projecting ends of the
socket modules would not be closely aligned wi~h the
insulator holes; then, it would be difficult to drop
the longer module over them.
The diameter of the hole 50, 52 of the
insulators is at least about 3% greater than the outer
diameter of the socket module 44, to permit slight
movement of the socket modules to accomodate the
precise spacing of the pin contacts that ~hey receive.
In prior connector systems wherein each half is
hermeticall~ sealed, only very slight misali.gnment of
mating contacts can be tolerated. However, in the
present socket modules both ends of a module are free
and the modules can "float" within the insulator, and
the spring which engages an inserted pin contact allows
more than prior socket deflection. This allows a much
greater degree of contact misalignment without
degrading the contact arrangement, and provides an
automatic cleanin~ action on both the pin and socket
contacts during mating and unmating, and even by reason
of axial float while the contacts are mated.
After assémbling the two insulators with the
socket modules therein, the two insulators as a unit
are dropped into the shell 60. The longer insulator 28
has two different outside portions 100, 102 of
different diameters, the portion 102 nearest the inner
end 32 of the insulator being of larger diameter. This
forms a ledge 104 at the intersection of these
di~ferent diameter portions. The shell has two
different outside diameters to form an inside shoulder
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106 on which the ledge 104 rests. The insulators are
freely slidable into the shell, until the ledge 104
rests on the shoulder 106, ~o prevent the insulators
from moving further towards a first end 108 of the
shell. The snap ring 94 is then installed around a cut
away portion 110 at the outer end of the short
insulator and into a groove 112, ~o prevent the
insulators from moving towards a second end 113 of the
shell. The assembly and reassembly o the socket
insert assembly is relatively easy and, as mentioned
above, can be performed rapidly in the field without
any tools except for a screwdriver, knife, or tha like.
Thus, the invention provides a connector system
which includes a socket insert assembly that can
connect the male ends of a pair of connectors. The
socket insert assembly includes individual socket
modules that can be easily removed for replacement or
cleaning in the field.
Although particular embodiments of the invention
have been described and illustrated herein, it is
recognized that modifications and variations may
readily occur to those skilled in the art and
conse~uently, it is intended that the claims he
interpreted to cover such modifications and
equivalents.
