Note: Descriptions are shown in the official language in which they were submitted.
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PUSH-LOCK ELECTRICAL CONNECTOR
FIELD OF THE INVENTION
100011 This invention relates generally to quick connect/disconnect, multi-pin
electrical
connectors, and is particularly directed to a push-lock electrical connector
incorporating
metal threads, a high strength, secure seal, and an anti-vibration capability.
BACKGROUND OF THE INVENTION
100021 Inli.ne electrical connectors tend to be of two basic types: the screw-
type connector
or the bayonet-type connector. The screw-type connector incorporates mating
threads on the
plug and socket portions of the connector and requires rotation of one or the
other to connect
the sets of electrical cables together in a sealed manner. Connection and
disconnection are
labor- intensive and require the application of a predetermined fastening
torque to achieve an
environmental seal or overcoming of this torque in disconnecting the pair of
connector
members. The fastening torque may undergo unintended loosening when the
connector is
subject to vibration forces resulting in loss of the connector seal and
interruption of the pin
and socket connections. Connection and disconnection of the two threaded
connector
members is also relatively slow and time consuming. The bayonet-type
connection, on the
other hand, is easily and quickly formed or disconnected. However, the coupled
members in
a bayonet connection are more easily separated and the connection broken than
in a threaded
connector. In addition, the bayonet connection is less adapted for the
formation of high
strength, tight seals than the threaded connection. Finally, the threaded and
bayonet
approaches are mutually exclusive, as one cannot be connected to the other
which, in some
cases, is inefficient and wasteful.
[00031 Recent efforts in this area have given rise to the use of segmented
thread
arrangements on each of the two connecting members which can be joined by
pushing one
connecting member onto the other in an axial direction, followed by rotation
of one or both of
the connecting members to place their respective thread arrangements in mutual
engagement.
Thus, this approach includes pushing the two connector members together as in
the bayonet
approach, followed by relative rotation between the two connector members to
provide their
threaded engagement. This combined approach does not afford all of the
advantages of both
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approaches taken individually. For example, rotation of one or both of the
connecting
members is required for connection, while the integrity and strength of the
connection is
limited by the partial thread arrays that must be on both connecting members.
In addition, the
connector's seal is limited because of the hand torque requirement to achieve
the
environmental seal. One approach in this area utilizes plastic segmented
threads that wear
after a few couplings and uncouplings of the pair of connector members or lose
their ability
to "spring back" because the elastic limit of the plastic has been reached.
The present
invention addresses and overcomes these limitations by providing a push-type
connection
resulting in full thread engagement between the two connecting members that
use a standard
thread.
SUMMARY OF THE INVENTION
[00041 Accordingly, it is an object of the present invention to provide a push-
type electrical
connector with a threaded connection coupling the two connector members.
[00051 It is another object of the present invention to provide a tightly
sealed, closed
compartment for the plural conductive elements in an inline electrical
connector.
100061 Yet another object of the present invention is to provide a vibration-
resistant
connection between the male and female connecting members of a push-type
electrical
connector.
[00071 A further object is to provide quick and easy push-type engagement
between the male
and female connecting members of an inline, multi-pin electrical connector,
while securely
maintaining the two connecting members coupled together by means of a threaded
type
connecting arrangement.
[00081 A still further object of the present invention is to provide a sealed
compartment for
the contact elements of an electrical connector where the strength of the seal
can be easily
achieved regardless of the torque used to mate the connector members.
100091 This invention is directed to an in line electrical connector adapted
for quick, locked
connection by merely pushing the male and female connecting members together
in
establishing a threaded, sealed connection between the two connecting members.
The push-
lock electrical connector further includes an anti-vibration feature to
prevent relative
rotational movement between the male and female connecting members to ensure
that
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electrical continuity is maintained. The push-lock electrical connector also
incorporates
metal threads rather than plastic threads to increase reliability and
connector operating
lifetime. The push-lock connector is fully compatible with traditional
threaded electrical
connectors such as of the M12 threaded type.
[00101 An additional related embodiment of this invention contemplates an
electrical
connector having mating male and female connecting members, where either
connecting
member includes an elastic member which allows that connecting member to
receive and to
securely couple to the other connecting member in a secure, electrically
insulated and
electromagnetically shielded manner. In one embodiment, the male connector
member
includes a cylindrical male insulator insert having an outer peripheral
lateral wall forming an
open cylindrical space within which are plural elongated, spaced conductive
pins. The
mating female connecting member includes plural spaced sockets each adapted to
receive a
respective connector pin when the female connecting member is inserted in male
member's
open cylindrical space in establishing electrical contact between the two
connector members.
The lateral wall of the male member forming the open cylindrical space which
is adapted to
receive the female connector member in a tight-fitting manner includes at
least one slot
therein extending longitudinally from the male member's outer end inwardly
Disposed on
the inner surface of the male member's lateral wall and spanning the at least
one slot therein
is a thin layer of an elastic insulating material, such as comprised of
silicone, which allows
for outward lateral expansion of the male member's lateral wall, permitting
the male member
to receive and engage in a tight-fitting manner mating female members having a
range of
diameters. The stretchable material may also be incorporated in the female
connecting
member to accommodate a range of diameter sizes and tolerances in mating male
members,
by elastically undergoing radially inward compression when a conductive pin-
bearing male
connector member is inserted over the female member's socket-bearing end
portion. In the
latter embodiment, the elastic layer may be disposed about the female
connector member or
the female connector member may be substantially comprised of the elastic
electrically
insulating material. In one embodiment, rendering the elastic insulating layer
conductive
allows the layer to also function as an electromagnetic interference (EMI)
shield in the
electrical connector.
BRIEF DESCRIPTION OF THE DRAWINGS
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100111 The appended claims set forth those novel features which characterize
the invention.
However, the invention itself, as well as further objects and advantages
thereof, will best be
understood by reference to the following detailed description of a preferred
embodiment
taken in conjunction with the accompanying drawings, where like reference
characters
identify like elements throughout the various figures, in which:
100121 Fig. 1 is a longitudinal sectional view of the push-lock electrical
connector of the
present invention mated, or engaged, with a traditional M12 threaded type
electrical
connector;
100131 Fig. 2 is a sectional view of the push-lock electrical connector taken
along site line B-
B in Fig. 1;
100141 Fig. 3 is a sectional view of the push-lock electrical connector taken
along site line A-
A in Fig. 1;
[00151 Fig. 4 is a side elevation view of the male connecting member of the
push-lock
electrical connector;
[00161 Figs. 5 and 6 are perspective views of the end portion of the male
connecting member
of the push-lock electrical connector;
100171 Figs. 7 and 8 are respectively end-on and side elevation views of the
metal cylinder
with resilient tabs incorporated in the inventive push-lock electrical
connector;
[00181 Fig. 9 is a plan view of the metal cylinder with resilient tabs
incorporated in the
inventive push-lock electrical connector prior to being formed into a
cylindrical shape;
[00191 Figs. 10 and 11 are respectively perspective and transverse sectional
views of the
male insulator incorporated in the push-lock electrical connector of the
present invention,
where the sectional view of Fig. 11 is taken along site line c-c in Fig. 10;
100201 Fig. 12 is a perspective view of metal cylinder with anti-vibration
resilient tabs
incorporated in the inventive push-lock electrical connector;
[00211 Fig. 13 is a transverse sectional view of the combination of the outer
metal cylinder
with resilient tabs taken along site line D-D in Fig. 12 and the inner male
insulator taken
along site line C-C in Fig. 10, which combination provides anti-vibration
protection in the
push-lock electrical connector of the present invention;
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100221 Fig. 14 is a longitudinal sectional view of a second embodiment of the
inventive push-
lock electrical connector mated to a traditional M12 threaded type electrical
connector;
[00231 Fig. 15 is a lateral plan view of a portion of the male push-type
electrical connector
illustrated in Fig. 14;
[00241 Fig. 16 is a perspective view of the male connector portion of the push-
lock electrical
connector illustrated in Fig. 14;
100251 Fig. 17 is a perspective view of the metal cylinder employed in the
embodiment of the
invention shown in Fig. 14;
[00261 Fig. 18 is a lateral plan view of the metal cylinder illustrated in
Fig. 17;
[00271 Fig. 19 is an end-on view of the metal cylinder illustrated in Fig. 17;
[00281 Fig. 20 is another perspective view of the metal cylinder employed in
the male
electrical connector of Fig. 14;
[00291 Fig. 21 is a perspective view of the male outer coupling sleeve used
with the metal
cylinder illustrated in Figs 17-20;
[00301 Fig. 22 is a longitudinal sectional view of the combination of the
metal cylinder and
male outer coupling sleeve incorporated in the male electrical connector of
Fig. 14;
[00311 Figs. 23 and 24 are respectively longitudinal sectional and end-on
views of the
tapered ring used in the electrical connector of Fig. 14;
[00321 Fig. 25 is a longitudinal sectional view of another embodiment of the
male insulator
insert used in the electrical connector of Fig. 14, where the male insulator
insert is provided
with a molded seal on an inner surface thereof;
[00331 Fig. 26 is a side elevation view of a push-lock electrical connector
incorporating an
insulator insert in the form of a thin layer of elastic material incorporated
between the mated
male and female connecting members in accordance with another embodiment of
the present
invention;
[00341 Fig. 27 is a longitudinal sectional view of the push lock electrical
connector shown in
Fig. 26;
[00351 Fig. 28 is a perspective view of the inventive male insulator insert
incorporating a pair
of spaced slots disposed in a lateral wall thereat
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100361 Fig. 29 is a side elevation view of the male insulator insert shown in
Fig. 28;
100371 Fig. 30 is a perspective longitudinal sectional view of the male
insulator insert shown
in Fig. 28 having disposed on a portion thereof a thin layer of elastic
insulating material in
accordance with this embodiment of the present invention;
[00381 Fig. 31 is an end-on view of the inventive male insulator insert
illustrating the pair of
end slots therein;
100391 Fig. 32 is a longitudinal sectional view of the male insulator insert
taken along site
line A-A in Fig. 31 illustrating a layer of electrically insulating material
disposed thereon in
accordance with this embodiment of the present invention;
[00401 Figs. 33 and 34 illustrate different perspective views of the elastic
electrically
insulating layer applied to the open end portion of the male insulator insert
in accordance
with one embodiment of the present invention.
100411 Fig. 35 is a longitudinal sectional view of another embodiment of the
present
invention, wherein the female insulator insert is adapted to receive in a
tight fitting manner
male insulator inserts having a range of diameters;
[0042] Fig. 36 is a transverse sectional view of an elastic electrically
insulating layer, or ring,
for use in the female insulator insert illustrated in Fig. 35;
100431 Fig. 37 is a longitudinal sectional view of the inventive female
insulator insert used in
the embodiment of the invention illustrated in Fig. 35; and
[0044] Figs. 38 and 39 are different perspective views of the elastic
electrically insulating
insert shown in Fig. 36 which is adapted for use with the female insulator
insert of Fig. 37.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[00451 With reference to the above described figures, the push-lock electrical
connector 10 of
the present invention will now be described in detail. Push-lock electrical
connector 10
includes a male connecting member 12 and a female connecting member 14, with
the male
connecting member including plural spaced male pins 24a-24d and the female
connecting
member 14 including plural spaced sockets 26a-26d, each adapted for receiving
a respective
male pin in a tight-fitting manner as shown in Fig. 1. Male connecting member
12 further
includes a male overmold 16 coupled on an end thereof to a male insulator
insert 21. Plural
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electrical conductors, or wires, (not shown for simplicity) are disposed in
the first male
overmold 16, with each of the wires connected to a respective one of the male
pins 24a-24d.
Each of the male pins 24a-24d is inserted through a respective slot within the
male insulator
21 and extends into an open recess in the outer end of the male insulator.
Coaxially aligned
with and disposed between adjacent portions of an outer male coupling sleeve
20 and the
inner male insulator insert 21 is a metal cylinder 28.
[00461 Female connecting member 14 includes a female overmold 18 attached on
an end
portion thereof to a female insulator insert 23. Disposed about and engaging
an outer surface
of the female insulator insert 23 is a female outer coupling sleeve 22 having
threads 32
located on an inner surface thereof. Plural spaced female sockets 26a-26d are
attached to an
end of the female overmold 18 and are disposed in and extend through
respective slots within
the female insulator insert 23. Electrical leads, or wires, which are not
shown in the figure
for simplicity, are each connected to a respective one of the female sockets
26a-26d. Each of
the female sockets 26a-26d is adapted to receive in tight-fitting engagement a
respective one
of the male pins 24a-24d to establish electrical continuity between the plural
leads in the male
connecting member 12 and the plural leads in the female connecting member 14.
An 0-ring
34 is disposed between and in contact with female insulator 23 and an end
portion of the male
insulator 21 to establish a sealed environment for the male pins and female
sockets. Male and
female insulator inserts 21 and 22 are preferably comprised of plastic, or
another material
having high dielectric properties.
[00471 In one illustrated embodiment, metal cylinder 28 is shown as having
four resilient tabs
30a-30d disposed in a spaced manner about its outer periphery, although the
present
invention is not limited to this number of resilient tabs on the metal
cylinder. Each of the
four resilient tabs 30a-30d is formed by stamping or otherwise deforming the
lateral wall of
the metal cylinder 28, with each of the resilient tabs extending outwardly in
a direction away
from the open end portion of male connecting member 12. The orientation and
the resilience
of each of the four tabs 30a-30d allows the male connecting member 12 to be
inserted, or
"pushed", into the female connecting m.ember 14, whereupon the distal ends of
each of the
four resilient tabs 30a-30d engage the inner threads 32 of the female outer
coupling sleeve 22
as shown in Fig. 1. With the distal ends of each of the four resilient tabs
30a-30d engaging a
portion of the inner threads 32 of the female outer coupling sleeve 22, the
male and female
connecting members 12, 14 are securely coupled together. The resilience of the
tabs 30a-30d
allows their respective distal ends to be displaced radially inwardly upon
contacting the crest
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portions of the threads, with the resilience of the tabs then urging the
distal end of each of the
tabs radially outward so as to engage an immediately adjacent thread portion
during insertion
of the male connecting member 12 into the female connecting member 14. Male
connecting
member 12 is fully inserted in female connecting member 14 when the distal end
portion of
male insulator 21 engages 0-ring 34 to form the above-described seal between
the two
connecting members for sealing the space in which the male pins 24a-24d and
the female
sockets 26a-26d are disposed. Once inserted into the female connecting member
14 and into
engagement with threads 32, it may be necessary to rotate the male connecting
member 12
containing the resilient tabs 30a-30d a partial turn either clockwise or
counterclockwise to
ensure that the distal ends of the tabs engage inner portions of the threads
and not an outer
edge of the threads to ensure secure engagement between the resilient tabs and
the threads.
[00481 Disposed on the inner surface of male insulator 21 are the
aforementioned first and
second seals 36a and 36b as shown in Figs. 1, 5 and 6. Seals 36a and 36b also
provide a seal
for the space within the push-lock electrical connector 10 in which the
connected male pins
24a-24d and female sockets 26a-26d are located. In fact, the first and second
seals 36a, 36b
eliminate the need for 0-ring 34 in providing a sealed environment for the
connected male
pins 24a-24d and female sockets 26a-26d. While the aforementioned seal is
described as
formed by first and second seals 36a, 36b disposed on an inner surface of male
insulator 21,
the aforementioned seals can also be positioned on the outer surface of the
female insulator
23 so as to engage an inner surface of male insulator 21 in forming a seal.
Similarly, while
two seals 36a, 36b are disclosed, the invention is not limited to two seals.
For example, a
higher number of seals could be provided between the male insulator 21 and
female insulator
23 to increase the strength of the seal. Conversely, a single seal could be
used where the
application calls for a seal of reduced strength.
[00491 While the illustrated and described embodiment of the invention
includes a metal
cylinder 28 with resilient tabs 30a-30d disposed in the male connecting member
12 for
engaging threads 32 in the female outer coupling sleeve 22, the metal cylinder
could
alternatively be positioned within the female connecting member 14 for
engaging inner
threads provided for on the male insulator 21. The present invention also
contemplates the
use of a pair of metal cylinders each having a respective set of resilient
tabs, with one metal
cylinder disposed within the male connecting member 12 and the other metal
cylinder
disposed within the female connecting member 14. The metal cylinder disposed
within the
male connecting member 12 would securely engage an inner portion of the female
connecting
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member 14, while the metal cylinder in the female connecting member would
securely
engage an inner portion of the male connecting member. On the two metal
cylinders could
be disposed in mutual engagement to provide a secure, sealed coupling between
the male and
female connecting members 12, 14. In this latter embodiment, neither the male
connecting
member 12 nor the female connecting member 14 would necessarily include inner
threads.
100501 Referring to Fig. 9, there is shown a plan view of metal cylinder 28 in
a flat
configuration which is the form of the metal cylinder as originally
manufactured. Metal
cylinder 28 is then subjected to a rolling process to provide its cylindrical
shape. Formed
within metal cylinder 28 are the aforementioned four resilient tabs 30a-30d.
Because the
resilient tabs 30a-30d each form a portion of a thread and are adapted for
engaging a threaded
surface characterized with a given pitch, or slope, the pitch of the array of
the four resilient
tabs is given by the ratio A/B. Similarly, the pitch of each of the individual
resilient tabs is
given by the ratio a/b as shown in the encircled portion of Fig. 9. In the
present case, the
pitch of the array of the four resilient tabs and the pitch of the individual
resilient tabs are
equal, or A/B = a/b.
[00511 Referring to Fig. 10, there is shown a perspective view of male
insulator insert 21.
Fig. 11 illustrates a sectional view of the male insulator insert 21 taken
along site line C-C in
Fig. 10. Along site line C-C, the male insulator insert 21 has an undulating
outer surface 42
having a series of alternating upraised portions, or peaks, 42a and sunken
portions, or valleys,
42b.
[00521 Fig. 12 is a perspective view of metal cylinder 28 illustrating a pair
of resilient tabs
30a and 30c disposed in a spaced manner about the outer periphery of the metal
cylinder.
Also formed in the lateral surface of metal cylinder 28 are first and second
inwardly
extending arms 45a and 45b. Arms 45a and 45b may be formed in metal cylinder
28 by
conventional means such as by stamping similar to the manner in which the
resilient tabs
30a-30d are formed in the lateral wall of the metal cylinder. The distal ends
of the inwardly
extending resilient arms 45a and 45b are adapted to engage respective sunken
portions 42b
disposed on opposed sides of an adjacent upraised portion 42a in the outer
surface 42 of the
male insulator 21as shown in Fig. 13. In this manner, the first and second
inwardly extending
arms 45a and 45b prevent relative rotation between the outer metal cylinder 28
and the inner
male insulator 21caused by vibration, and thus provide an anti-rotation
function in preventing
a change in the relative positions of these two connector components caused by
environmental vibrations or physical shock experienced by the mated connector
components.
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100531 As shown in Figs. 2, 3 and 10, male insulator 21 includes an inwardly
extending rib
40 on its inner periphery adapted for insertion in a generally U-shaped
recessed portion 23a
within female insulator 23. With inner rib 40 disposed within recessed portion
23a of female
insulator 23, the four male pins 24a-24d are respectively aligned with the
four female sockets
26a-26d during assembly of the connector to ensure proper electrical
connections are made
within the mated male and female connecting members 12, 14.
[00541 Referring to FIG. 14, there is illustrated a longitudinal sectional
view of another
embodiment of a push-lock electrical connector 50 in accordance with the
principles of the
present invention. Connector elements common to the first embodiment of the
present
invention shown in FIG. 1 and the second embodiment shown in FIG. 14 are
provided with
the same element identifying number. Components of the push-lock electrical
connector 50
shown in FIG. 14 which are different than corresponding components in the push-
lock
electrical connector 10 shown in FIG. 1 are provided with different element
identifying
numbers. For example, metal cylinder 52 in the push-lock electrical connector
50
embodiment shown in FIG. 14 differs from the corresponding metal cylinder 28
in the
embodiment shown in FIG. 1. The male insulator insert 64 in the push-lock
electrical
connector 50 embodiment shown in FIG. 14 also differs from the male insulator
insert 21 in
the embodiment shown in FIG. 1 as described in the following paragraphs.
[00551 Referring to Figs. 15-19, there is shown a second embodiment of the
metal cylinder
52 in accordance with the present invention. Metal cylinder 52 includes four
generally
linearly slots 54a-54d disposed in a spaced manner about its lateral,
cylindrical surface. The
space between each pair of adjacent slots defines a respective resilient arm
of the metal
cylinder 52. Thus, adjacent slots 54a and 54b define a first resilient arm.
56a, while adjacent
slots 54b and 54c define a second resilient arm 56b. Similarly, adjacent slots
54c and 54d
define a third resilient arm 56c, while adjacent slots 54d and 54a define a
fourth resilient arm
56d. Disposed adjacent a respective distal end of each of the four resilient
arms 56a-56d is a
respective linear projection on its outer surface. Thus, a first linear
projection 58a is disposed
on the outer surface and adjacent to the distal end of the fourth resilient
arm 56d, while a
second linear projection 58b is disposed on the outer surface of the first
resilient arm 56a
adjacent its distal end. Similarly, disposed on the outer surface of the
second resilient arm
56b on its outer surface and adjacent to its distal end is a third linear
projection 58c, while a
fourth linear projection 58d is disposed on the outer surface of the third
resilient arm 56c
adjacent its distal end. The four linear projections 58a-58d are each disposed
on a respective
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outer surface of the first through fourth resilient arms 56a-56d at an
inclined angle relative to
a plane orthogonal to the longitudinal axis X-X' as shown in FIG. 18. Inclined
angle a equals
the inclined angle of the threads 32 disposed on the inner surface of female
outer coupling
sleeve 22. The four linear projections 58a-58d are in common alignment about
the outer
periphery of a metal cylinder 52 and are disposed at the aforementioned
inclined angle a.
Engagement of two opposed linear projections 58a and 58c with the inner
threads 32 of
female outer coupling sleeve 22 is shown in the sectional view of Fig. 14. The
perspective
view of Fig. 16 of male insulator insert 64 shows first and second molded
seals 36a and 36b
disposed on the inner surface of the male insulator sleeve so as to engage an
outer concentric
surface of female insulator insert 23 as in the previously described
embodiment.
[00561 As shown in Figs. 17, 18, 20 and 22, metal cylinder 52 includes a pair
of end tabs 60a
and 60b which are disposed on respective opposed end portions of the metal
cylinder and
extend outwardly along the length of the cylinder. Also shown in FIG. 21 is a
perspective
view of the male outer coupling sleeve 62 incorporated in the second
embodiment of the
push-lock electrical connector 50 shown in Fig. 14. Male outer coupling sleeve
62 includes a
cylindrical aperture, or slot, 66 extending therethrough. Disposed on opposed
end portions of
cylindrical aperture 66 are first and second opposed slots 68a and 68b. With
metal cylinder
52 inserted in the cylindrical aperture 66 of male outer coupling sleeve 62,
each of the
opposed slots 68a, 68b within the male outer coupling sleeve is adapted to
receive a
respective one of the opposed end tabs 60a, 60b on the end of the metal
cylinder. Each of the
end tabs 60a, 60b is adapted for outward displacement so as to be positioned
within and
engage a respective one of the opposed slots 68a and 68b for securely
connecting these two
components together. In some cases, conventional means such as weldments may
also be
used to securely connect these two components. Thus, metal cylinder 52 and
male outer
coupling sleeve 62 are securely coupled together so that manual engagement and
rotational or
linear displacement of the male outer coupling sleeve results in a
corresponding rotational or
linear displacement of the inner metal cylinder attached thereto.
[00571 Referring again to Fig. 14, there is shown a tapered ring 72 disposed
about and
securely attached to the outer surface of male insulator insert 64 adjacent to
one end of the
male insulator insert. That end of the male insulator insert 64 includes an
enlarged circular
flange 64a disposed about the cylindrical opening at the end of the male
insulator insert. A
longitudinal sectional view of the tapered ring 72 is shown in FIG. 23, while
an axial, or end-
on, view of the tapered ring is shown in Fig. 24. Tapered ring 72 includes a
circular aperture
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72a extending through the ring and an outer tapered surface 72b, and it is
attached to the
outer surface of male insulator insert 64 by conventional means such as
weldments.
Similarly, it is recognized that tapered ring 72 does not need to be a
separate part, but could
be integrated into male insulator insert 64 by conventional manufacturing
methods like
molding or die-casting.
100581 As shown in Fig. 14, metal cylinder 52 is disposed in cylindrical
spaces formed
between an outer surface of male insulator insert 64 and respective inner
surfaces of male
outer coupling sleeve 20 and female outer sleeve coupling 22. As described
above, metal
cylinder 52 is fixedly attached to the inner cylindrical surface of male outer
coupling sleeve
20. In assembling push-lock electrical connector 50, metal cylinder 52 is
inserted into the
cylindrical spaces disposed about male insulator insert 64 as described above.
When male
connecting member 12 is fully inserted into female connecting member 14 and
male outer
coupling sleeve 20 is displaced leftward in the direction of arrow 80 shown in
Fig. 14, the
distal, or leading, end of metal cylinder 52 engages the tapered surface 72b
of circular ring 72
and is urged radially outward toward threads 32 disposed on the inner surface
of female outer
coupling sleeve 22. Disposed on the outer surface of metal cylinder 52
adjacent its distal end
are the aforementioned linear projections 58a-58d, where only two of these
projections 58a
and 58c are shown in the sectional view of Fig. 14. With the distal end of
metal cylinder 52
deflected radially outward by tapered ring 72, the metal cylinder's outer
projections 58a-58d
are displaced radially outward and into engagement with the inner threads 32
of female outer
coupling sleeve 22, as shown for the case of linear projections 58a and 58c in
Fig. 14. In this
manner, all of the linear projections 58a-58d disposed on the outer lateral
surface of metal
cylinder 52 are inserted into the inner threads 32 of female outer coupling
sleeve 22.
Disposed about male insulator insert 64 and in end-abutting contact with male
overmold 16
and male outer coupling sleeve 20 is a short coiled spring 82 which urges male
outer coupling
sleeve leftward in the direction of arrow 80 so as to maintain the distal end
of metal cylinder
52 in contact with tapered ring 72 so that the metal cylinder's distal end
remains outwardly
biased so as to maintain the metal cylinder's linear projections 58a-58d in
secure engagement
with the inner threads 52 of female outer coupling sleeve 22. With metal
cylinder's linear
projections 58a-58d engaging the female outer coupling sleeve's inner threads
32, the
combination of male coupling sleeve 20 and metal cylinder 52 may be threadably
tightened
on the electrical connector to compress 0-ring seal 34, as desired. Coiled
spring 82 facilitates
engagement of the metal cylinder's plural outer projections 58a-58d with the
female outer
12
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coupling sleeve's inner threads, but is not essentially for proper operation
of the inventive
push-lock electrical connector 10.
[00591 Referring to Fig. 25, there is shown a longitudinal sectional view of
another
embodiment of a male insulator insert 76, wherein the open, cylindrical end of
the male
insulator insert is provided with an enlarged end flange 76a and a tapered
portion 76b which
are formed integrally with the male insulator insert. Thus, tapered portion
76b of the male
insulator insert 76 shown in Fig. 25 replaces the tapered ring 72 described
above and
illustrated in Figs. 14, 23 and 24. Disposed on the inner surface of the open
end portion of
the male insulator insert 76 is a molded flexible seal 78 which adheres to the
inner surface of
the male insulator insert and includes spaced upraised ring-like portions 78a
and 78b which
form seals between the male insulator insert 76 and the female insulator
insert which is
shown as element 23 in Fig. 14. Molded flexible seal 78 is placed on, adheres
to, and
conforms with the contours of the inner surface of the open end portion of
male insulator
insert 76.
[00601 Having thus disclosed in detail several embodiments of the invention,
persons skilled
in the art will be able to modify certain of the structures shown and to
substitute equivalent
elements for those disclosed while continuing to practice the principles of
the invention. For
example, while the above discussed embodiments of the present invention are
described as
having four (4) resilient arms each have a respective outwardly directed
thread-engaging
member, the present invention is not limited to this specific arrangement and
may have more
or less of these structural members as the application and composition of
these components
may dictate. In addition, while cylindrical member is described as disposed
radially within
the threads of the other connector member, the cylindrical resilient member
may also be
disposed radial outside of the other connector m.ember and urged radially
inward to engage
the threads of the other connector member. It is, therefore, intended that all
such
modifications and substitutions be covered as they are embraced within the
spirit and scope
of the present invention as described in the claims.
[00611 Referring to Figs. 26 and 27, there are respectively shown side
elevation and
longitudinal sectional views of a push lock electrical connector 90
incorporating an improved
male insulator insert 100 with an elastic electrically insulating layer 126 in
accordance with
this embodiment of the present invention. Figs. 28 and 29 are respectively
perspective and
side elevation views of the inventive male insulator insert 100. Fig. 30 is a
perspective
sectional view of the inventive male insulator insert incorporating the
elastic insulating layer
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therein. Figs 31 and 32 are respectively end-on and longitudinal sectional
views of the
inventive male insulator insert 100 in accordance with this embodiment of the
present
invention. Figs. 33 and 34 are different perspective views of the inventive
elastic
insulating layer for incorporation in a male insulator insert for use in a
push lock electrical
connector in accordance with the present invention.
100621 The inventive push lock electrical connector 90 includes a male
connecting member
92 and a female connecting member 94. Male connecting member 92 includes an
outer male
coupling sleeve 93, while female connecting member 94 includes an outer female
coupling
sleeve 95. Disposed within the outer male coupling sleeve 93 is a male
insulator insert 100 in
accordance with the present invention. Disposed within the outer female
coupling sleeve 95
is a female insulator insert 102 which also may be configured in accordance
with the present
invention in another embodiment. The use of an elastic electrically insulating
material may
be incorporated in either the male insulator insert 100 or in the female
insulator insert 102,
but is not incorporated in both simultaneously. The elastic electrically
insulating layer
disposed in the male insulator insert 100 is shown as element 126 in Fig. 27
and is described
in detail in the following paragraphs. Male insulator insert 100 is securely
attached to a male
overmold 98 by means of first and second recessed portions 101a and 101b
disposed on the
outer end portion of the male insulator insert. Similarly, female insulator
insert 102 is
securely attached to a female overmold 98 by means of third and fourth
recessed portions
102a and 102b. As in the previously described embodiments, male insulator
insert 100 is
generally cylindrical and is provided with plural receptacles, or slots, three
of which are
shown as elements 118a, 118b and 118c and are adapted to receive and retain
first, second
and third conductive pins 106a, 106b and 106c, respectively.
100631 As shown in the various figures, male insulator insert 100 is provided
with a generally
cylindrical body 103 having the aforementioned spaced recessed portions 101a,
101b at a first
outer end thereof, and an enlarged end flange 107 on an inner end of the
cylindrical body.
Disposed within male insulator insert 100 is a generally circular base 113
having five spaced
apertures therein, where three of these apertures are shown as elements 115a-
115c in Fig. 28.
Each of the five apertures is adapted to receive and support a respective
conductive pin as
shown for three male pins 106a-106c in the sectional view of Fig. 27. In the
illustrated male
insulator insert 100, there is shown an axially positioned center aperture
115b and three of
four outer apertures 115a, 115c, 115d., where the fifth outer aperture is not
shown in any of
the illustrated views for simplicity.
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100641 Disposed about and attached to the outer lateral wall of male insulator
insert's
cylindrical body 103 is a metal cylinder 110 as shown in Fig. 27. Disposed on
a portion of
the outer surface of metal cylinder 110 are outer threads which are adapted to
securely
engage inner threads on the inner surface of outer female coupling sleeve 95,
where the inter-
engaging threads are shown as elements 122 in Fig. 27. it is in this manner
that the male
connecting member 92 is securely attached to female connecting member 94.
[00651 Female insulator insert 102 is inserted through a circular aperture
within outer female
coupling sleeve 95 in a tight-fitting, secure manner, which allows for free
rotation of outer
female coupling sleeve about the outer surface of female insulator insert 102.
With female
insulator insert 102 inserted in the open end portion of the male insulator
insert 100 as shown
in Fig. 27, rotation of the outer female coupling sleeve 95 about the metal
cylinder 110, with
their mutually engaging inter-locking threads 122, allows for secure coupling
between male
connecting member 92 and female connecting member 94. An outer lateral portion
of female
insulator insert 102 is provided with a flange 102a extending radially outward
from. the
female insulator insert's outer wall. Flange 102a is adapted to engage and
compress a
generally circular 0-ring seal 130 disposed between this flange and the
aforementioned end
flange 107 disposed on the inner edge portion of the male insulator insert 100
as shown in
Fig. 27. Further rotation of the outer female coupling sleeve 95 relative to
the male insulator
insert 100 further compresses 0-ring seal 130 in forming a tighter seal
between the male and
female connecting members 92 and 94.
[00661 As also shown in Fig. 27 and as discussed above, the inner end portion
of female
insulator insert 102 is adapted for tight fitting engagement with the inner
surface of the open
end portion of the male insulator insert 100. Female insulator insert 102 is
provided with
plural spaced female sockets, where three of the sockets are shown as elements
I 24a, 124b
and 124c in Fig. 27. Thus, socket 124a is adapted to receive conductive pin
106a in a tight-
fitting manner, and female sockets 124b and 124c are adapted to receive
conductive pins
106b and 106c, respectively. It is in this manner that the male and female
connecting
members 92, 94 are electrically connected to each other.
00671 The cylindrical body portion 103 of male insulator insert 100 is
provided in
accordance with the present invention with at least one elongated, linear
slot. In the
embodiment shown in Figs. 28 and 29, first and second elongated, linear slots
105a and 105b
are shown disposed on opposed portions of the male insulator insert's
cylindrical body. Each
of the first and second elongated slots 105a, 105b extends inwardly from the
end flange 107
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toward the opposite end of the cylindrical body 103 to, and slightly beyond,
base member
113 which is attached to the inner surface of the cylindrical body. Also
disposed on the inner
surface of cylindrical body 103 and aligned generally parallel to the opposed
ends of the
cylindrical body is a non-continuous, generally circular seal flange 120. Seal
flange 120 is
discontinuous because of its intersection with the first and second slots
105a, 105b within the
cylindrical body 103. In the embodiment shown in the figures, seal flange 120
is comprised
of two spaced sections each forming generally a one-half circle within
cylindrical body 103,
with adjacent ends of the two half circles separated by either the first slot
105a or the second
slot I05b. As in the case of end flange 107, the seal flange 120 is preferably
formed
integrally with the cylindrical body 103 such as in a molding process. Seal
flange 120 forms
a circumferential seal with the outer surface of the female insulator insert
102 disposed within
the open end portion of male insulator insert 100.
100681 In accordance with this embodiment of the present invention, first and
second slots
105a, 105b within the end of the insulator insert's cylindrical body 103 allow
the two semi-
cylindrical portions of the cylindrical body formed by the two slots to flex
outwardly to
facilitate insertion of a female insulator insert 102 into the open end
portion of the male
insulator insert 100. This flexure allows the male insulator 100 to receive
female insulator
inserts having a wide range of diameters. Specified tolerances in the
manufacture of mating
members of push lock connectors result in a range of values for various
connector
components, such as the male and female insulator inserts. These variations in
size over an
acceptable, specified range are present even in individual manufacturing runs
and arise
because of the precision limits inherent in the manufacturing process.
Incorporating a
tolerance range in size for various connector parts and components facilitates
manufacture
and assembly of the connectors and substantially reduces the costs of
manufacture and
assembly. While the cylindrical body 103 of male insulator insert 100 is
described and
illustrated as having first and second spaced slots 105a, 105b, the present
invention is not
limited to only a pair of slots, as the present invention may have additional
elongated, linear
slots to form additional flexible peripheral sections of the cylindrical body
depending upon
the type of material that the connector is comprised of and the extent of
flexibility desired in
the male and female insulator inserts 100. As stated above, male insulator
insert 100 may
also be provided with a single elongated, linear slot.
[00691 To accommodate the first and second slots 105a, 105b in the male
insulator insert's
cylindrical body 103, while continuing to provide a high degree of electrical
insulation for the
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conductive pins in the male insulator insert 100 and the conductive pin
receiving slots 118a,
118b and 118c within the female insulator insert 102, an elastic electrically
insulating layer
126 is applied to the inner surface of the open end of the male insulator
insert's cylindrical
body in accordance with this embodiment of the present invention. Elastic
insulating layer
126 is deposited on the inner surface of the open end portion of male
insulator insert 100
which terminates in end flange 107 as shown in Figs. 27, 30, 31 and 32.
Elastic insulating
layer 106 is deposited by conventional means such as spraying, dipping or
other conventional
means. The present invention is formed in a two mold process where a first
mold is used to
form the male insulated insert 100, with the second mold process involving the
positioning of
an insulating material in the space between a second mold's outer surface and
the male
insulator insert's inner surface. Elastic insulating layer 126 includes an
outer angled enlarged
portion 126a adapted to intimately engage and be securely attached to an inner
portion of the
insulator insert's end flange 107. Elastic insulating layer 126 further
includes an enlarged
intermediate circular portion 126c extending radially inward so as to securely
engage and
attach to the seal flange 120 disposed on the inner surface of male insulator
insert 100. Thus,
the inner circular portion 126c of elastic insulating layer 126 serves not
only to electrically
insulate the electrically conductive members of the push-lock connector 90,
but also serves as
a seal between the male and female insulator inserts 100, 102. Elastic
insulating layer 126
further includes an inner flange 126d adapted for positioning within an
annular slot within an
inner portion of the male insulator insert's cylindrical body 103 to form an
inner seal
between the male insulator insert 100 and the female insulator insert 102
disposed within the
open end of the male insulator insert. In a preferred embodiment, the male and
female
insulator inserts 100, 102 are comprised of a semi-rigid thermoplastic
material such as of
polycarbonate plastic, while the elastic electrically insulating layer 126 is
preferably
comprised of a thermoplastic, or thermosetting, elastomer.
100701 Disposed on an outer portion of elastic insulating layer 126 and
positioned within the
first and second slots 105a and 105b of the male insulator insert 100 are
first and second
elongated, linear flanges 126e and 126f as shown in the perspective views of
Figs. 33 and 34.
First and second slot-spanning flanges 126e and 126f provide an insulating
layer bridging
adjacent portions of the male insulator insert 100 which form the first and
second slots 105a
and 105b within the cylindrical body 103 of the male insulator insert. The
elasticity of the
insulating layer 126 allows it to continue to span the first and second slots
105a and 105b as
they increase in width when a female insulating insert 102 larger in its outer
diameter than the
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male insulator insert's inner diameter is inserted in the open end portion of
the male insulator
insert. Thus, electrical insulation is maintained around the entire periphery
of the open end
portion of the male insulator insert 100 which engages and encloses the female
insulator
insert 102. Upon removal of an oversized female insulator insert 102 from the
open end
portion of the male insulator insert 100, the diameter of the open end portion
of the male
insulator insert assumes its original reduced diameter as the facing lateral
portions of the
cylindrical body 103 assum.e their original relative positions. As indicated
above, the elastic
electrically insulating layer 126 is preferably comprised of silicone, but may
be of virtually
any electrically insulating plastic elastomer composition, such as
polyurethane or a low
durometer epoxy. The thickness of each of the elastic insulating layer's first
and second slot-
spanning flanges I 26e, 126f is preferably on the order of the thickness of
the male insulator
insert 100, which is typically in the range of .007-.008 inch. While the
elastic insulating layer
126 has been described primarily in terms of being an electrical insulator, it
may also be
comprised of a material capable of providing electromagnetic interference
(EMI) protection.
Conductivity of the elastic electrically insulating layer 126 may be provided
by introducing
electrically conductive particles such as of carbon powder in the elastic
insulating layer to
provide an EMI shielding capability. This approach for providing electrical
insulating and/or
EMI shielding protection could also be used between the male and female
connecting
members in a coaxially connector.
[00711 Persons skilled in the art will be able to modify certain of the
structures and materials
illustrated and disclosed in the latest embodiment of the present invention to
substitute
equivalent elements and materials for those disclosed while continuing to
practice the
principles of the invention. For example, while only two spaced slots are
disclosed in the
cylindrical body of the male insulator insert, a single slot or more than two
slots may be
provided and the same process as disclosed above may be used to fill the
single slot or the
additional slots with electrically insulating or electromagnetic shielding
materials.
[00721 Referring to Fig. 35, there is shown a longitudinal sectional view of
another
embodiment of a push lock connector 138 in accordance with the present
invention. In Fig.
35, components of push lock connector 38 which are the same as, and perform
the same
function as, a corresponding component in the push lock connector 90
illustrated in Figs. 26-
34 have been provided with the same identifying numbers. The difference
between the
embodiment of the invention illustrated in Figs. 26-34 and the embodiment now
described is
in the male and female insulator inserts as well as in the elastic
electrically insulating layer
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attached to an insulator insert. In the embodiment shown in Figs. 35-39, the
female insulator
insert 102 is provided with, and is attached to, the elastic electrically
insulating layer, or ring,
140. As in the previously described embodiments, the embodiment of the push
lock
connector 138 shown in Figs. 35-39 and described in the following paragraphs
is also
provided with male and female connecting members 92, 94, outer male and female
coupling
sleeves 93and 95, and male and female overmolds 96 and 98.
[00731 In the embodiment illustrated in Fig. 35, the elastic electrically
insulating layer 140 is
in the form of a cylindrical ring having an inner aperture 140b as shown in
Figs. 36, 38 and
39. The elastic electrically ring 140 is adapted for tight-fitting positioning
within an annular
slot, or recess, 142 on the outer surface of the female insulator insert 102
as shown in Fig. 37.
The inner portion of the outer surface of the elastic electrically insulating
ring 140 is provided
with a radially, outwardly extending portion 140a which is adapted for tight-
fitting
engagement with the inner surface of the male insulator insert 132, as shown
in Fig. 35. The
compressible and elastic composition of the electrically insulating ring 140
allows for the use
of male insulator inserts 132 having a range of inner diameters, where the
range arises from
manufacturing tolerances in producing the various components of the push lock
connector
138. As in the case of the previously described embodiment, the elastic
electrically insulating
material of ring 140 is preferably comprised of a material such as silicone, a
polyurethane or
a low durometer epoxy, or any electrically insulating material capable of
undergoing
compression upon the application of an inwardly directed radial force, and is
also capable of
expanding outwardly to assume its original shape and size upon the removal of
the radial
compressive force. The thickness of the elastic electrically insulating ring
140 is also similar
to the previously described elastic electrically insulating layer attached to
the male insulator
insert, i.e., on the order or .007-.008 inch. Elastic electrically insulating
ring 140 is also
provided with a curvilinear recessed portion 140c as shown in Figs. 38 and 39,
which is
adapted for tight-fitting engagement with an inwardly extending alignment rib
disposed on
the inner surface of female insulator insert 134. The female insulator
insert's alignment rib is
linearly aligned with the inwardly extending alignment rib 109 of the
previously described
male insulator insert 100, which is illustrated in Figs. 28 and 31, to
facilitate connection of
the male and female connecting members.
[00741 While particular embodiments of the present invention have been shown
and
described, it will be obvious to those skilled in the relevant arts that
changes and
modifications may be made without departing from the invention in its broader
aspects.
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'Therefore, the aim in the appended claims is to cover all such changes and
modifications that
fall within the true spirit and scope of the invention. The matter set forth
in the foregoing
description and accompanying drawings is offered by way of illustration only
and not as a
limitation. The actual scope of the invention is intended to be defined in the
following claims
when viewed in their proper perspective based on the prior art,
