Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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This invention relates to electrical connectors
of the type having inser-table and removable contacts. The
invention is more particularly related to a means for the
xemovable securing of an electrical contact retention device
within an integr~l body of dielectric material. Additionally,
a means for molding the integral dielectric insert with a
core pin and core bushing is disclosed.
Electrical connectors generally include a plug and
a receptacle, each of which has an insert of dielectric
material within which electrical contacts are retained. The
prior art under consideration addresses the insert means which
were employed to secure electrical contact retention devices
within a dielectric material and the means of molding these
inserts.
Among the techni~ues often employed was the use of
complex and intricate retaining mechanisms which were
generally comprised of multiple pieces of dielectric material
bonded together. When multiple pieces of dielectric are used,
it is necessary to carefully seal the pieces together in
order to eliminate the lower resistance paths and electrical
breakdowns which occur between contacts along the interface
of the pieces that form the retention clip insert. Examples
of this method are disclosed in U.S. patents No. 3,727,172
and No. 3,638,165. The difficulties encountered with multiple
pieces of dielectric bonded together to form an insert were
partially overcome by minimizing the number of pieces of
dielectric material required to fabricate an electrical
connector insert. This technique is advanced in U.S. patent
No. 4,082,398, assigned to the assignee of the present
invention. Perhaps one of the most significant developments
prior to this disclosure in the field of electrical connector
retention means is found in U.S. patent No. 3,158~424. ~mong
the teachings of this patent is the use of a flange,
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encompassing a full 360, at the rearward edqe of an insert
passageway that is designed to hold an electrical connector
retention clip within the bored section of an insert. This
design, however, contains several drawbacks which become
evident in the manufac-ture of the insert. It is taught that
this insert can be molded with an annular member that is
removable or dissolvable or otherwise disposable from the
molded insert. Among the problems encountered in this method
of manufacture is an inexactness in the length and positioning
of the metal bushing being molded into the insert. After
melting the hushing away from the insert, a standard length
connector retention clip may not seat properly with the result
that the entire insert must be scrapped. Another problem with
this type of manufacturing method is that the metal bushings
have to be cleaned thoroughly prior to molding the bushing
into the insert. If any metal chips have not been cleaned
from the bushings, they become molded into the insert and can
cause electrical breakdowns within the insert. Another ma~or
problem with the use of metal bushings is that oxidation and
static electricity are formed on the bushings. This results
in obvious handling and molding difficulties.
The present invention eliminates the problems
encountered with electrical failures within the inserts as
well as those difficulties common to the manufacturing methods
now employed.
The present inYention resides in an electrical
connector insert for receiving elongated electrical contact
of the type having a retention section defining forward and
rearward facing shoulders, the insert having an axial passage
therethrough from a front face to removably receive a
resilient contact retention clip. The contact is removably
secured within the passage by ~eans of the resilient clip
being received within the passage, the clip being longitudinally
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split to permit diametrical reduction and including resilient
means to engage the rearward facing shoulder of the contact.
The insert includes a dielectric body which has integrally
formed therewith retention means disposed at opposite ends
of the passage for retaining the retention clip within the
insert, the retention means including a first vertical wall
adjacent to the rear face for engaging one end of the clip
and a second vertical ~all adjacent to the front face for
engaging the other end of the clip and the forward facing
shoulder of the contact, constriction means extending axially
inwardly into the passage from the rear face for reducing
the retention clip diameter/ support means adjacent to the
front face for supporting a forward mating section of the
contact, and means defining an opening in one of the vertical
walls for receiving a release tool to diametrically reduce
the clip diameter and thereby permit removal of the clip
through the constriction.
It is an object of this invention to provide a means
for removably securing the contact retention clips of an
electrical connector insert by the use of an integral body.
It is another object of this invention to provide
a simple and economical insert for an electrical connector.
It is another object of this invention to provide
an insert of the type which permits each of its contact
retention clips to be removed for repair and/or for
replacement without damage to insert.
It is still another object of this invention to
provide a clip retention mounting insert which permits the
removal of an electrical contact from the retention clip
while retaining the retention clip within the insert.
It is still another object of this invention to
minimize the number of pieces required to fabricate an
electrical connector insert.
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It is yet another object of this inven-tion to
provide a molding means which is immediately reusable and
re~uires no tooling be-tween uses.
It is an additional object of this invention to
provide a molding means which manufactures an integrally
molded dielectric insert that requires no tooling after the
removal from the molding means.
Brief Descript'ion of the Drawings
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Figure 1 is a partia1 cross-sectional diagrammatic
view of an integrally molded dielectric insert designed to
removably secure both a contact retention clip and a pin
contact;
Figure 2 is a partial cross-sectional diagrammatic
view of the molded insert of Figure 1 with a contact retention
clip seated in the assembled position;
Figure 3 is a cross-sectional view of an electrical
pin contact engaged by a contact retention clip mounted within
the molded insert;
Figure 4 is a partial cross-sectional diagrammatic
view of an alternative embodiment of the invention which is
molded to house an electrical socket contact;
Figure 5 is a schematic illustration of a separated
core pin and bushing utilized in molding the clip retention
insert used for a pin contact as in Figure l;
Figure 6 is the mated view of the core and bushing
of Figure S;
Figure 7 is a schematic illustration of a separated
core pin and bushing utilized in molding the clip retention
insert used for a socket contact as in Figure 4;
Figure 8 is the mated view of the core and bushing
of Fi'gure 7;
Figure 9 is a,molded dielectric insert, wi-th reten-
tion clip and pin contact mounted, assembled in a t~pical
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electrical connector plug; and
Figure 10 is a molded dielectric insert with
reten-tion clip and socket contact mounted and assembled in
a typical electrical connector plug such that the plugs in
Figures 9 and 10 are ~atable.
Detailed Description
Referring now to the drawings, Figure 1 illustrates
a portion of an electrical connector insert that discloses one
embodiment of the invention. The insert lO consists of a body
molded from a dielectric material. Generally, the dielectric
insert is made from a thermoplastic resin, although other
materials such as thermosetting materials may be used. Some
examples of preferable materials are: polyester *(Valox),
polyarylsulfone *(B 360 Astrel), polyethersulfone *(Torlon),
polymides (Nylon), acetates *(Delrin), and polycarbonates
*(Lexan). The polyester material sold under the name `'Valox`'
is preferred along with polyarylsulfones and polyethersulfones.
The foregoing materials have acceptable mechanical strength
and electrical insulation characteristics which serve to
increase the dielectric separation between adjacent contacts.
The insert 10 has a plurality of passages 15
therethrough from a front face 11 to a rear face 13, the
front face 11 being defined as that section of insert 10 which
faces toward an engaged connector assembly and the rear face
13 as that side of the insert 10 opposite to front face 11.
Extending axially forwardly from rear face 13 of insert 10
and into passage 15 and radially inwardly from (i.e.,
perpendicular to) the interior wall of passage 15 are at
least two retention clip shoulder housings 17 (only one being
shown). Each of the housings are equiangularly spaced around
the passage to define a constriction to the passage. Each
shoulder housing 17 includes a vertical wall 19 which faces
vertical wall 22 of the axially separated sleeve abutment 21.
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That portion of passage 15 betwcen vertical wall 19 of
shoulder housing 17 and vertical wall 22 of sleeve abutment
21 forms a cavity 23 within which contact retention clip 29
is removably secured. Further, each shoulder housing 17
includes a concave surface which is coaxial to the passage,
the pair of concave surfaces being disposed in confronting
(i.e., superposing) relation. As shown, each concave surface
includes a pair of flat, substantially horizontal, plate-like
surfaces 17a which laterally angle away from a central axial
line 17b to intersect the wall 17c of passage 15. The
angular separation between the shoulder housings provide a
rearward means whereby a flat bladed tool may enter for
removing the contact clip by diametrical reduction thrGugh
the constriction. mese concave surfaces could also be semi-
circular in shape. As shown best in FIGURE 2, each of the
walls 19, 22 are substantially perpendicular to the interior
wall of passage 15. Vertical wall 19 of shoulder housing 17
may be angled rearwardly from an edge to form a lip (not shown)
in the shoulder housing that will provide a recess for engaging
the rear end face of retention clip 29~ It should be noted
that this lip would provide additional means for resisting
axial cable forces imposed on contacts from pulling the clip
outwardly of its cavity. Sleeve abutment 21 includes a contact
support bore 25 which communicates with the cavity formed
within the integrally dielectric insert. Vertical wall 22 of
sleeve abutment 21, rather than presenting a surface
perpendicular to the interior wall passage 15, could be angled
forwardly (relative to the wall of passage 15) to form a
second lip (not shown) to engage the forward end face of
retention clip 29.
Also shown in FIGVRE 1- are a plurality of "half-
mooned" openings 27 which are formed during the molding of
the integral insert. Each openlng 27 communicates with cavity
23 and includes an arcuate wall 27a and a su~stantially flat
chordal surface 27b, each arcuate wall 27a forming a coaxial
continuation of the interior wall of passage 15. These
openings 27 are generally symmetrically disposed at 180 to
one another around the array of the contact support hores 25.
Further and relative to passage 15, the pair of openings 27
at one passage end are substantially in register with the
pair of shoulder housings 19 at the other passage end such
that the angular extension of each arcuate wall 27a is
substantiall~ angularly co-extensive with the angular extension
of each shoulder housing 19. Thàt is, arcerate wall 27a
forming opening 27 is substantially angularly coextensive with
the angular extension of the shoulder housing 17 formed around
the passage wall and between the intersection of flat surfaces
17a with the passage wall. These openings 27 provide a
forward means whereby a tool, such as a pair of flat blades,
may be received to diametrically reduce clip 29 and remove
the clip rearwardly of insert 10. Openings 27 also provide
a means through which the visual inspection of the forward
seating and alignment of contac-t retention clips 29 is possible.
The shoulder housings 17 do not form a complete
360 lip at the rear face 13 of insert 10. Rather, shoulder
housings 17 are in axial alignment with openings 27 and form
a partial lip along the rear face 13 of insert 10. The flat
surfaces 17a serve to diamatrically reduce clip 29 for its
entry into cavity 23 from rear face 13. As well as allowing
entry of the clip into the cavity, the passage wall between
(i.e., separating) each of the shoulder housings 17 provides
a rearward means whereby a bladed tool may be received into
the passage cavity to diametrically reduce clip 29 and to
then remove the clip rearwardly of the insert. Depending upon
the angular position of the clip within the cavity,
removability may be required from the front face or from the
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rear face. As will be discussed, an interior longitudinal
rib 32 may be provided to orient the angular position OL the
clip within the cavity. An additional benefit of this design
is the capability of examining the insert vertical wall 19
of shoulder housing 17 through the openings 27.
Figure 2, another partial view of the electrical
connector insert 10, shows a contact retention clip 29
installed within the cavity 23 section of the passage 15. It
will be noted that clip 29 is not a completely enclosed
cylinder, but ra-ther has an opening along one full side. This
opening permits a clip of resilient material to be slightly
compressed in order to slide the clip between the shoulder
housings 17 (only one shown in drawings) into the clip cavity
23. Once in place, the retainer clip 29 returns to its rest
condition and is restricted in its lateral movement within
the insert 10 by means of vertical wall 19 and the sleeve
abutment 21. The fingers 31 of retention clip 29 are sections
of the clip's 29 wall which point downwardly and forwardly
forming a cone like configuration within the cavity 23.
In Figure 3 the method by which a pin contact 33 is
removably secured within the body of insert 10 is illustrated.
Additionally illustrated is a contact retention clip 29 mounted
within the cavity 23 of passage 15, beiny restricted from
rotational movement within the cavity 23 by means of the key
32 which extend axially along the wall of cavity 23 and engage
the retention clip 29. More precisely, connector pin 33 enters
through the rear face 13 of insert 10 and passes between the
opposed shoulder housings 17. As connector pin 33 passes
between the fingers 31 of retention clip 29, the enlarged
section 37 pushes the fingers 31 out away from the center
of the cavity, permitting the enlarged section 37 complete
entry. When the forward wall 39 of enlarged section 37 is
contiguous with the abutment 21, the fingers 31 will return
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to their rest position, engaging the rear wall 41 of the
enlarged section 37. This will restrict lateral movement
of the connector pin 33 within the insert 10. The ter-
minal element 35 of connector pin 33 passes into and
through the contact sleeve 25 in a close fitting relation-
ship and extends beyond the front face 11 of insert 10
a sufficient distance to properly engage a socket contact.
The shoulder housing 17 is in a spaced relationship to
connector pin 33 and a tool can enter into the passage 15
therebetween. This tool will release connector pin 33 by
forcing the fingers 31 away from their rest position, that
is to say away from the rear wall 41 of enlarged section
37 and against the walls of clip 29. When this is accom-
plished, the connector pin 33 can be easily withdrawn from
the insert 10.
Flgure 4 is an alternative embodiment of the in-
sert 10' which is designed to receive and removably secure
a socket contact 43. The principal difference lies in a
socket ~ore 45 which rests between the front face of con-
tact sleeve 25' and the abutment 21'. The contact reten-
tion clip 29' is removably mounted within the cayity 23' of
insert 10' and restricted from lateral movement within the
cavity 23' by abutment 21' and the vertical insert edge
19' of shou]der housiny 17'. Whereas abutment 21' would
be the same surface as the rearward face 47l of the contact
sleeve 25' in the assembly employed for a contact pin 33,
as displayed in Figures 1 throuyh 3, the abutment 21' is
now a separate entity. The rear face 47' oE contact sleeve
25' can be sloped rearwardly from the walls o~ socket bore
45 to serve as a guide for a penetrating connector pin
terminal element 35. A socket contact is remoyabl~ secured
by a retention clip 29' within the insert 10' with the
same technique as depicted in Figure 3. The insert 10'
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with a retention 29' and a connector socket 43 can be
seen in this configuration in Figure 10.
Figure 5 illustrates a core pin 53 and a core
bushing 61. The core pin 53 includes, at its forward edge,
axial projection 55, at least two indented flat sides
57 and two shoulder forms 59 protruding from the rearward
portion of the flat sides 57 and contiguous with the rear
base section 51 of core pin 53. Core busing 61 includes
an axial bore 63, which is matable with the axial projec-
tion 55 and side fins 65 which have flat internal walls
and curved exterior walls and are matable with the flat
sides 57 of the core pin 53. In the mated condition of
Figure 6, the rearwardly facing edges of the side fins 65
will abut the forward edge of shoulder forms 59. The com-
bination of the side fins 65 with the flat sides 57 will
form a shaft like section of the mold which forms the con-
tact retention clip cavity 23 in insert 10. In this align-
ment there will be an open area 69 around the axial pro-
jection 55 which has only partially penetrated bore 63.
This open area 69 forms the front face 11 and the abutment
21 of the passage 15. The axial projection 55 forms the
contact sleeve 25 of insert 10. The shoulder forms 59
form a shoulder housing mold area 67. This corresponds to
the shoulder housing 17. The rearward edges of side fins
65 control the angle/ if any, of the shoulder housing's
vertical inward edge 19. Those sections of the side fins
65 which are in a spaced relationship adjacent to axial
projection 55 form the openin~ 27 seen in the inserts
front face 11. Upon completion of the molding process
the core pin 53 and core bushing 61 can be separated and
withdrawn from the insert 10. Core pin 53 is drawn out
through the rear face 13 of insert 10. Core bushing 61
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is drawn from the front face 11 of the insert 10 and leaves
the opening 27.
Several modifications can be incorporated within
the core pin 53 and core bushing 61 in order to fabricate
an insert with features that will enhance the retention
clip mounting and securing capabilities of the insert 10.
For example, the vertical inward edge 19 of shoulder housing
17, if angled rearwardly towards the passage walls, would
provide a lip like structure which would act to positively
engage the contact retention clip 29. This result can be
obtained by bevelled the edges of the side fins 65 which
abut shoulder ~orm 59. The beveled section would extend
above and behind the shoulder forms 59 when the core pin and
bushing are mated. Another method of increasing the con-
tact retention clip 29 mounting capability of insert 10
could be achieYed by forming a groove in one of the sections
of the core pin 53 or bushing 61 which form the clip reten-
tion cavity 23. This groove would extend along the length
of the member on which it was cut, axially from a point cor-
responding with the forward edge oE core pin 53 to a point
corresponding with the forward edge of protrusions 59. This
will leave a protruding key within the ca~ity 23 integral
with insert 10 which would align with the contact reten-
tion clip 29 when assembled. Such a design would allow a
fixed location of the retention clip fingers 31 relatiye
to the enlaryed section 37 of the pin contact 33. These
features can similarly be incorporated in the core and pin
bushings presented in Figures 7 and ~ which are employed
in molding an insert 10' used with socket contact 43.
These core pins 53 and core bushings 61 can be multiply
mounted in an endless variety of configurations as dictated
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by the number of contacts required and the dimensions of
the plug in which the inserts are mounted.
Figure 7 illustrates a core pin 53' and a core
bushing 61' which are utilized in the molding of an in-
tegral dielectric insert 10'. The core pin 53' includes a
base portion 51' from which extends a shaft like portion
which terminates in its forward end with axial projection
55'. At least two sides of the shaft like extensions are
indented and flat 57'. In additian, a portion of this
shaft has a reduced diameter which results in stepped sides
73. Also protruding from the flat sides 57' and in a con-
tiguous relationship with the base 51' are shoulder forms
59'. The core bushing 61' includes at least two extending
side fins 65' which are flat along their inside walls and
curved along their outside walls, an axial bore 63' and
a cone 71 which has its wide base in
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point having the axial bore 63'. The core pin 53' and core
bushing 61' mate with the axial projection 55' penetratin~ the
core 71 through axial bore 63'. Side fins 65' will abut the
shoulder forms 59' and be aligned with and contiguous to the
flat sides 57' of core pin 53'. This will provide a cavity 23'
in the completed insert 10'. With this mated alignment there
will be an open area 69' around the axial projection 55' which
will form the front face 11' and the rearward face 47' of
contact sleeve 25'. The axial projection 55' results in the
contact sleeve 25'. The cone 71 creates a tapering extension
with a cone-shaped mouth on the rearward face 47'. The cone
shaped mouth can serve as a guide for the introduction o~ a
pin contact terminal element 35. The steps 73 of core pin 51'
form within the insert 10' a socket bore 45 which closely
receives a socket contact. The vertical wall created by the
different dimensions of step 73 and core pin 53' provides an
abutment 21' within insert 10'. The section of the flat sides
57' contiguous with side fins 65' forms cavity 23' designed to
receive a retention clip 29'. The protrusions 59', along wi.th
the portions of side fins 65' contiguous with the protrusions
59', form the shoulder housing 17' and. vertical inward edge
19' of insert 10'. It should be noted that the modifications
which can be introduced to core pin 53 and core bushing 61 are
am~ng the modifications which can be effected on core pin 53'
and core bushing 61'.
Figure 9 illustrates an insert 10 that contains a
plurality of connector pins 33 secured by retention clips 29.
The insert 10 is mounted in a typical electrical connector
plug assembly 77. Also shown are a rear moisture sealing
grommet 79, an interfacial seal 91, a sealing gasket 93, a
connector shell 81, a retaining nut 83 and a retaining ring
95.
Figure 10 illustrates an integral dielectric insert
10' with connector socket 43 and contact retention clip 29' in
a conventional socket assembly 77' which is matable with the
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conventional pin connector assembly of Figure 9. Also shown
are a rear moisture sealing grommet 79', a connector shell
81', a retaining nut 83', a retaining ring 95', a coupling nut
85, a wave washer 87 and a snap ring 89.
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