US3419844A - Electrical connector - Google Patents

Description

Dec. 31, 1968 E. SCHMUED 3,419,844

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INCL/NED PLANE J? 4 I v 110/ me United States Patent 3,419,844 ELECTRICAL CONNECTOR Edgar Schmued, 5051 Palos Verdes Drive N., Rolling Hills Estates, Calif. 90274 Filed July 12, 1965, Ser. No. 471,334 2 Claims. (Cl. 339-48) ABSTRACT OF THE DISCLOSURE A multi-pin connector formed of a pair of mutually connectable terminal blocks in which lead wires are embedded, the terminal ends of the lead wires in one block being electrically joined with the terminal ends of the lead wires in the other block by ball shaped pellets of electrically conductive metal wire positioned and insulated from each other in an intermediate cavity provided between the two terminal blocks.

My invention relates to electrical connectors and more particularly to an improved pressure electrical connector that is substantially invulnerable to severe vibration and shock. My invention is directed principally to electrical connectors of the multi-pin type in which plug or pinconnector terminals are joined or coupled together by means of female connectors, i.e., split sleeves of relatively ductile electrical conducting metal such as brass, copper or like material; the male pins of one connector being inserted through one end of corresponding female connector and the male pins of the other connector being inserted through the opposite ends thereof to form multiple electrical joints.

While these connectors work well enough in stationary equipment, vast numbers of multi-pin connectors are currently being employed in missiles, rockets and advanced aircraft, for example, wherein reliability of each and every system is of paramount importance. A split-second interruption in a single circuit can abort or cause a vital mission to end in disaster. Frequently such failures can be traced to a multipin connector in which the female connector sleeve has spread apart or fractured due to extreme vibration and shock during launch and subsequent operation, causing a short or break in a circuit that is vital to the operation or guidance of the vehicle. Moreover, such vehicles are occasionally subjected to extremely high G-loads under which forces of destructive proportions are exerted upon the vehicle systems and components.

It is therefore a primary object of my invention to provide a pressure connector that is reliable and substantially invulnerable to severe vibrations and shock over prolonged periods.

It is another object of my invention to provide a pressure connector for use in aerospace vehicles and the like, which can be hermetically sealed against the intrusion of moisture and corrosive chemicals and may easily be internally pressurized for use in unusual environmental conditions.

It is still another object of my invention to provide a pressure electrical connector that is ideally suitable for use in aerospace vehicles, yet relatively simple in construction and economical to manufacture.

Briefly, the pressure connector of my present invention, in one preferred form, comprises a pair of mutally connectable terminal blocks, each electrically connected at one end thereof to a plurality of conductors to be joined. Corresponding leads for the conductors are embedded in the terminal blocks, the leads terminating in an internally disposed chamber that is defined between the terminal blocks when mutually connected together.

Positioned in the chamber are a plurality of resilient connectors, one disposed between each of the distal or terminal ends of the terminal block leads, in electrical conduction contact therebetween, and means for retaining and insulating each of the resilient connector means from one another.

My invention will be more easily understood, and other objects and advantages more readily seen, by reference to the ensuing detailed description and appended drawings in which:

FIGURE 1 is a side elevational view in cross-section showing a preferred form of my invention,

FIGURE 2 is a fragmentary enlarged view showing the plate, aperture and resilient connector of my present invention,

FIGURE 3 is a plan view showing the plate, apertures, resilient connectors, and indexing notch of my invention, and

FIGURE 4 is a side elevational view of a modified form of my invention.

A preferred form of my invention is shown in FIG- URE l in which two groups 5 of electrical wires or conductors 6 bundled together in a cable sheath, or by harness straps (not shown), are joined together at their distal ends in terminal blocks 9 and 10 respectively. Each terminal block is formed of a body 11 cast or molded of epoxy resin or other suitable dielectric potting material having embedded therein a plurality of lead wires 12. In all respects, terminal blocks 9 and 10 are identical.

For convenience and ease of assembly the terminal blocks 9 and 10 are adapted to be assembled and fastened together in overlapping relationship as shown, the faying or mutually connectable surfaces 13 thereof being ac curately planed and ground to sufiicient flatness to form a void-free, flush interface at their joint.

Wire leads 12, joined with appropriate conductors 6 of each bundle 5, are arranged in predetermined relationship in their respective terminal blocks, being cut to appropriate lengths and bent at right angles so that their distal ends are coterminus along a common plane ad acent to the faying or interfacial surfaces 13 of the termlnal blocks.

A recess or cavity 15 is provided in the faying surfaces 13 of each terminal block, being formed or machined therein in any convenient manner, and aligned with each other to define a unitary internally disposed chamber 16 between the terminal blocks when assembled and fastened together.

The cavities 15 extend a desired distance into each body 11, exposing along the aforementioned common planes the terminal ends 14 of the prealigned lead wires 12 for interconnection. If desired, the ends 14 of the terminal block leads 12 in the chamber 16 maybe somewhat fiattened and soldered to increase their contact area, or may be provided with standard terminals (not shown) if desired.

In the chamber 16, intermediate the aligned lead wire terminals 12 of each terminal block 9 and 10, I provide a flat insulating wafer or plate 17, fabricated of a durable dielectric material, the dimensions and shape around the edges being such as to produce a sliding fit within the chamber 16. Preferably, the thickness of plate 17 is slightly less than the depth of chamber 16 to provide a small clearance therein.

A plurality of apertures 19 are provided through plate 17 each of the apertures 19 being prearranged and located to correspond with the aligned terminal ends 14 of the terminal block leads 12 as shown.

In each aperture 19, I mount a ball or pellet 20, preferably formed of springy or resilient metal wool, i.e., filaments of a metal having good electrical conducting propm erties, such as copper, beryllium-copper, or like material. The diameter of the conductor pellet 20 can be made slightly greater than the depth of chamber 16, and hence the distance between the aligned terminal ends 14 of the terminal block leads 12. Thus, when the terminal blocks 9 and 10 are joined together and fastened, the resilient pellets are compressed between the terminals urging the pellet material into tight electrical contact bcween each pair of terminal ends 1 4.

It will also be seen that by flattening the pellets 20 between the terminals, the pellets will correspondingly expand in width and become firmly wedged within the con fines of their respective apertures 19. Thus it is readily apparent that an electrical union is formed between the aligned terminal block leads, the nature of which is not subject to weakening, deforming or rupturing under prolonged or even indefinite periods of severe vibration, shock or G-loads.

To insure proper alignment of the apertures 19 in plate 17, an indexing notch 22 is provided in one edge of plate H 17; a corresponding protuberance or pin (not shown) being provided in the edge of one or both cavities. Each aperture may be coded, i.e., marked with identification means, as is well known in the art.

All that is necessary to hermetically seal the interior chamber 16 against moisture and chemical intrusion is to provide aligned continuous seats or grooves 23 in the faying surfaces 13, or terminal block interfaces, between the terminal blocks 9 and 10, and intermediate the chamber 16 and the block exterior. An elastic O-ring 24 is provided, seated in the grooves 23 in the well known manner.

The terminal blocks 9 and 10 may be fastened together in any convenient manner, one preferred manner being shown wherein a central bolt bore 27 is drilled through the terminal block bodies 11 and a bolt 28 inserted therethrough, a nut 29 being threaded 0n the bolt end extending through the opposite side substantially as shown. T 0 strengthen the assembly washers 31 are provided at each end of bolt 28. To seal the bolt bore 27 circumferential grooves 32 are provided in the terminal block body 11 around the head 33 of bolt 28 and around the threaded end 34 thereof; an O-ring 35 being seated in each groove 32 as shown.

Where it is necessary to pressurize the internal chamber 16, space (not shown) may easily be provided within plate 17 for a small rupturable capsule of C0 The foregoing example of the pressure connector of my invention will satisfy most requirements. However, where space is a primary problem, the dimensions around the combined terminal blocks may be substantially reduced by designing the faying surfaces of the terminal block bodies in the form of inclined planes substantially as shown in FIGURE 4. In all other respects, the internal organization and arrangement of the terminal block leads, chamber, insulating plate, pellet connectors, O-ring grooves and seals remain substantially the same as in the embodiment descirbed above with reference to FIG- URES 1-3.

If desired, the bodies forming the terminal blocks may be confined within shells or receptacles made of insulating material; these forms being well known to those skilled in the art.

Obviously the pressure connector of my invention is susceptible of numerous other forms and embodiments and I do not regard it as necessary to exhaustively describe and show all or a part of the modified embodiments that will occur to those skilled in the art; such forms and modifications being deemed to fall within the spirit and scope of my invention, the gist of which is set forth in the following claims.

I claim:

1. In an electrical connector, the combination compris- (a) a pair of substantially identical terminal blocks cast of dielectric material, each of said blocks having one side surface adapted to be joined with the corresponding side surface of the other,

(b) a plurality of lead wires embedded in parallel relationship in each of said blocks, each of said lead wires having one end thereof extending from one end of its block which end is adjacent to said joining surface thereof, each of said lead wires being bent at an angle in said block to position the opposite end thereof at the surface of said side defining the joining surface with said other block, said joining sides of said blocks extending in a plane that is coextensive with the direction of the ends of said lead 'wires extending from said end of said block,

(c) means defining an airtight shallow chamber of uniform depth between said joining surfaces of said terminal blocks, the ends of each of said lead wires terminating in said chamber and aligned for interconnection therein,

((1) a compressible ball of electrically conductive wool positioned in said chamber and compressed therein between said aligned ends of said lead wires,

(e) a relatively thin fiat plate of insulating material in said chamber, said plate having apertures therethrough located and arranged in alignment with said ends of said lead wires to position and retain said compressible conductive balls between said aligned ends of said lead wires,

(f) a seal extending around said chamber between said joining surfaces of said terminal blocks,

(g) aligned bores extending transversely through each of said terminal blocks, and

(h) a fastening bolt extending through said aligned bore to fasten said blocks together.

2. The electrical connector combination in claim 1 in which said terminal block surfaces adapted to join in overlapping relationship are inclined planes.

References Cited UNITED STATES PATENTS 266,681 10/1882 Eaton 33992 XR 1,743,888 1/ 1930 Hamister 33994 XR 2,400,647 5/1946 Kohring 339221 2,486,195 10/1949 Munsey 33961 2,902,628 9/1959 Leno 33917 XR 3,158,419 11/1964 Meyer et a1. 33918 3,235,832 2/1966 Buchanan et a1. 339220 XR 3,126,520 4/1967 Herman 339-18 MARVIN A. CHAMPION, Primary Examiner.

PATRICK A. CLIFFORD, Assistant Examiner.

US. Cl. X.R. 3.39-92

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