Connector terminal and method of assembling the same

Abstract

A connector terminal having a unit-mountable connector that includes a connector body having an adapter engaging end and a unit engaging end and a mounting member between the adapter engaging end and the unit engaging end for mounting the connector body to a unit. An insert extends through the connector body and has an inner bore extending between a cable connecting end and a unit connecting end and a connector body connecting portion between the ends. One or more dual-sided contacts are received in the insert. One end of the dual-sided contact is a cable termination end configured to be terminated to a conductor of a cable and an opposite end of the dual-sided contact is a unit termination end configured to be terminated to a conductor of a unit. The unit-mountable connector is adapted to cooperate with a cable sealing adapter. The cable sealing adapter is devoid of contacts.

Description

[0001] This application is a divisional application of the invention patent application filed on October 31, 2017, with application number 201780078094.6 and entitled "Connector Terminal and Method for Assembling the Connector Terminal".

[0002] Related applications

[0003] This application claims priority to U.S. Patent Application No. 15 / 350,509, filed November 14, 2016, entitled Connector Terminal and Method of Assembling the Same, the subject matter of which is incorporated herein by reference. Technical Field

[0004] This invention relates to connector terminals, such as outdoor sealing gland terminals, and methods for assembling such connector terminals. Background Technology

[0005] Integrating electrical connectors into product designs or units is often complex and expensive, especially for outdoor applications requiring environmental sealing and ruggedness. The cables for these connectors are typically pre-terminated to the connector components rather than being field-installable. This is particularly cumbersome and costly when dealing with long, heavy cables—which are large and expensive to transport to the field.

[0006] Therefore, there is a need for a connector terminal that can be easily integrated into a unit and allows for field installation of cables at a reduced cost, while also providing robustness and environmental sealing for outdoor applications. Summary of the Invention

[0007] Therefore, the present invention can provide a unit-mountable connector comprising a connector body having an adapter engagement end and a unit engagement end opposite to the adapter engagement end, and a mounting member located between the adapter engagement end and the unit engagement end for mounting the connector body to a unit. An insert extends through the connector body. The insert has an inner hole extending between a cable connection end and a unit connection end opposite to the cable connection end. A connector body connection portion is located between the cable connection end and the unit connection end. At least one double-sided contact is received in the inner hole of the insert. One end of the double-sided contact is a cable termination end configured to terminate to at least one conductor of a cable, and the opposite end of the double-sided contact is a unit termination end configured to terminate to at least one conductor of a unit. In a preferred embodiment, the cable termination end and the unit termination end are different types of termination portions. In a preferred embodiment, the double-sided contact is a one-piece component.

[0008] The present invention may also provide a connector terminal including a unit-mountable connector, the unit-mountable connector including a connector body having an adapter engagement end and a unit engagement end opposite to the adapter engagement end, and a mounting member located between the adapter engagement end and the unit engagement end for mounting the connector body to a unit. An insert extends through the connector body. The insert has an inner hole extending between a cable connection end and a unit connection end opposite to the cable connection end. A connector body connection portion is located between the cable connection end and the unit connection end. At least one double-sided contact is received in the inner hole of the insert. A cable sealing adapter is capable of mating with the unit-mountable connector. The cable sealing adapter includes a housing having a mating end and a cable retaining end opposite to the mating end, the mating end being configured to engage the adapter engagement end of the connector body and receive the cable connection end of the insert. The cable retaining end is configured to terminate a cable. The cable sealing adapter has no contact elements. One end of the dual-sided contact of the unit-mountable connector is a cable termination end configured to terminate at least one conductor of a cable supported by a cable sealing adapter, and the opposite ends of the dual-sided contact are unit termination ends configured to terminate at least one conductor of the unit. In a preferred embodiment, the connector terminals are power terminals, and the cable is a power cable. In a preferred embodiment, the dual-sided contact is a one-piece component.

[0009] The present invention also provides a method for assembling connector terminals to a unit, the connector terminals including a unit mountable connector and a cable sealing adapter, the method comprising the steps of: terminating at least one conductor of the unit to a unit connection end of a double-sided contact of the unit mountable connector; mounting a connector body of the unit mountable connector to the unit; mounting a connector cable by terminating at least one conductor of a connector cable to a cable connection end opposite to the unit connection end of the double-sided contact of the unit mountable connector; and assembling a cable sealing adapter onto the connector cable after mounting the connector cable, and engaging one end of the cable sealing adapter with the connector body of the unit mountable connector such that the cable connection end of the unit mountable connector is received in the cable sealing adapter. Attached Figure Description

[0010] A more complete understanding of the invention and its many accompanying advantages will become more readily apparent when considered in the following detailed description taken in conjunction with the accompanying drawings:

[0011] Figure 1 A perspective view of a connector terminal according to an exemplary embodiment of the present invention is shown;

[0012] Figure 2 yes Figure 1 The exploded perspective view of the connector terminals shown illustrates a unit that can be fitted with a connector that mates with a cable sealing adapter.

[0013] Figure 3 yes Figure 2 An exploded perspective view of the unit shown, which can be fitted with a connector;

[0014] Figure 4 yes Figure 2 An exploded perspective view of the cable sealing adapter shown;

[0015] Figure 5 yes Figure 1 The cross-sectional view of the connector terminal assembly shown illustrates the connector terminals mounted to the unit; and

[0016] Figure 6 This is an exploded perspective view of a unit mountable connector according to an alternative embodiment of the present invention. Detailed Implementation

[0017] Reference Figures 1 to 6 This invention relates to a connector terminal 10, such as a power terminal, and a method for assembling the connector terminal, particularly assembling the connector terminal onto a unit such as a telecommunications radio unit. The connector terminal of the invention is designed to be field-installable, allowing for the termination of cables, such as power cables, in the field without the need for pre-terminated cable assemblies or harnesses. This is particularly advantageous when dealing with large, long, and heavy cables that are expensive to transport to the field. The invention eliminates the workspace and electrical connections required for terminating cables outside the unit enclosure, thereby allowing for smaller size and increased connector robustness. The design also allows for conductor termination using standard tools instead of specific tools. While the connector terminal of the invention is preferably used in power applications, the connector terminal 10 can also be used in other applications, such as signalers.

[0018] Connector terminal 10 includes a unit-mountable connector 100 that mates with cable sealing adapter 200. The unit-mountable connector 100 is configured to be mounted to the enclosure or panel 12 of the unit. Figure 5 ). Cable sealed adapter 200 terminated and environmentally sealed cable C ( Figure 5 When the unit mountable connector 100 and the cable sealing adapter 200 are mated, an electrical and mechanical connection is provided between the unit and the cable C.

[0019] As in Figure 3As observed, the unit-mountable connector 100 typically includes a connector body 102, an insert 104 received within the connector body 102, and one or more bilateral contacts 106 received within the insert 104. The connector body 102 may include an adapter engagement end 110 connected to the cable sealing adapter 200, an opposite unit-mountable end 112 connected to the unit connection end, and a mounting member 114 located between the adapter engagement end 110 and the unit-mountable end 112. Except for the mounting member 114, the connector body 102 may be generally cylindrical in shape. The adapter engagement end 110 preferably includes external threads 116 for engaging the cable sealing adapter 200. Although threads are preferred, the adapter engagement end 110 may include any known attachment type, such as a bayonet engagement.

[0020] Mounting member 114 is preferably an outwardly extending flange, such as in Figure 1 and Figure 2 The mounting member 114 may be provided with one or more mounting holes 118 for receiving fasteners to mount the connector body 102 to the panel or enclosure 12 of the unit. The mounting member 114 may be of any shape, such as generally rectangular, as long as it is provided with one or more mounting holes 118. The mounting member 114 includes a mounting surface 120 facing the unit mountable end 112 for abutting the panel or enclosure 12 of the unit when the unit mountable connector 100 is mounted on the mounting surface 120. In a preferred embodiment, the mounting surface 120 of the mounting member 114 includes an annular groove 122 that receives a sealing member 124, such as an O-ring or washer.

[0021] Figure 6An alternative design for the connector body 102' for the unit-mountable connector 100 is shown. Except that the connector body 102' is threaded onto the unit instead of bolted, it is similar to the connector body 102 of the described embodiment. Like the connector body 102 of the described embodiment, the connector body 102' includes an adapter engagement end 110 with external threads for engaging the cable sealing adapter 200. Unlike the connector body 102 of the described embodiment, the unit engagement end 102' of the connector body 102' also includes external threads 600 for threaded engagement with the panel or enclosure 12 of the unit. The connector body 102' includes a mounting member 114', which is an outwardly extending flange similar to the mounting member 114 of the described embodiment. The mounting member 114' preferably includes a plurality of gripping surfaces 602 for facilitating rotation and applying torque to the connector body 102' when the connector body 102' is threaded onto the panel or enclosure 12 of the unit.

[0022] Insert 104 is received in and extends through connector body 102. Insert 104 typically includes a cable connection end 130, a corresponding unit connection end 132, and a connector body connection portion 134 located between the cable connection end 130 and the unit connection end. Cable connection end 130 extends through and beyond adapter engagement end 110 of connector body 102, unit connection end 132 extends through and beyond unit connection end 112 of connector body 102, and connector body connection portion 134 is received within connector body 102. An inner bore 136 of insert 104 extends between these ends and supports bilateral contacts 106. Figure 2 and Figure 3 As observed, the cable connection end 130 of the insert 104 includes one or more holes 138 located outside the connector body 102, thereby allowing access to the dual-sided contacts 106. The end face 140 of the cable connection end 130 may include one or more openings 142 that also provide access to the dual-sided contacts 106. Figure 2 ).

[0023] The inner bore 136 of the insert 104 is preferably generally cylindrical and may include one or more partitions 144 to divide the inner bore 136 into multiple compartments, wherein each compartment supports a separate double-sided contact 106, as in Figure 5 This was observed in [the context].

[0024] Each double-sided contact 106 includes opposing termination ends, one end being a cable termination end 150 and the other end being a unit termination end 152. Each double-sided contact 106 is preferably one-piece or integrally formed. The cable termination end 150 is configured to electrically and mechanically connect to and terminate the conductor of the cable C, and the unit termination end 152 is configured to electrically and mechanically connect to and terminate the conductor of the unit. In a preferred embodiment, the cable termination end 150 and the unit termination end 152 are different types of termination mechanisms. For example, the cable termination end 150 may be a clamping termination where the end 150 is clamped to the conductor of the cable C via a spring clamp or clamping fastener such as a screw 160, and the unit termination end 152 may be a crimp termination where the end 152 is crimped to the conductor of the unit. Alternatively, the cable termination end 150 and the unit termination end 152 may be the same type of termination mechanism. When a clamping fastener such as a screw 160 is used at the cable termination end 150, the screw 160 can be easily inserted from the external through hole 138 of the unit mountable connector 100 into the inner hole 136 of the insert and through the corresponding hole 158 of the double-sided contact 106. Figure 5 ), so as to clamp the cable termination end 150 of the double-sided contact 106 onto the conductor of the cable C.

[0025] As in Figure 4 As observed, the cable sealing adapter 200 typically includes: a housing 202; a primary sealing member 204 for sealing the cable C, such as a wide cable sealing gasket; an auxiliary sealing member 206, such as an O-ring or washer, received in the housing 202; and a clamping nut 208. The cable sealing adapter 200 may also include a cable gasket compression member 210, a cable shielding ring 212, and a cable reducer 214. The housing 202 may be generally cylindrical, having a mating end 220 configured to engage an adapter engagement end 110 of the connector body 102 and receive a cable connection end 130 of the insert 104. In a preferred embodiment, the internal thread 230 of the mating end 220 engages the external thread 116 of the connector body 102. Conversely, the mating end 220 is a cable retaining end 222 configured to terminate the cable C. The cable retaining end 222 may include an external thread 224 that engages a corresponding thread 226 of the clamping nut 208. Figure 5 This allows the clamping nut 208 to be pushed onto the housing 202 to compress the main sealing member 204 and the cable washer compressor 210 to terminate the pre-fabricated end of the cable C. The nut 208 can be pushed onto the housing 202 using any known attachment method other than threaded connection, such as bayonet attachment.

[0026] The connector terminals 10 can be assembled by first electrically and mechanically connecting the unit engagement ends 112 of the unit mountable connector 100 to the panel or enclosure 12 of the unit. For this purpose, one or more conductors of the unit are terminated, for example, by clamping the unit engagement ends 152 of each double-sided contact 106 of the unit mountable connector 100. This step preferably occurs inside the unit. The unit engagement ends 112 of the connector body 102 are sized to receive in an opening in the panel or enclosure of the unit and extend through the opening in the panel or enclosure of the unit, as in... Figure 5 This is observed in the image. Then, the connector body 102 of the unit-mountable connector 100 can be mounted to the unit. Fasteners such as bolts can extend through mounting holes 118 in the mounting flange 114 and into the unit's panel or enclosure 12 to complete the mounting of the unit-mountable connector 100. Alternatively, the connector body can be mounted via threads 600 (…). Figure 6 It is installed to the panel or enclosure 12 of the unit by means of a threaded connection. When installed, the mounting surface 120 of the mounting member 114, together with the sealing member 124, is adjacent to or nearly adjacent to the panel or enclosure 12 of the unit.

[0027] Once the unit mountable connector 100 is mounted on the unit, the cable C can be terminated to the unit mountable connector 100 by terminating each conductor of the cable C at the cable connection end 150 of each double-sided contact 106 of the unit mountable connector 100, for example, by clamping it to the cable connection end 150 of each double-sided contact 106 of the unit mountable connector 100 via screws or spring clips. Since the unit mountable connector 100 includes double-sided contacts 106 for termination, the cable sealing adapter 200 does not require corresponding contacts. Therefore, the cable sealing adapter 200 has no contacts. The cable C mounting step preferably occurs outside the unit.

[0028] The cable sealing adapter 200 can then be assembled onto the cable C and mated to the cable engagement end 110 of the unit mountable connector 100. A clamping nut 208 is pushed into the housing 202 of the cable sealing adapter 200 to terminate and seal the pre-fabricated end of the cable C. The mating end 220 connects to the cable engagement portion 110 of the connector body 102 of the unit mountable connector 100, such that the cable connection end 130 of the insert 104 of the unit mountable connector 100 is received in the mating end 220 to secure the cable sealing adapter 200 to the unit mountable connector 100.

[0029] While specific embodiments have been chosen to illustrate the invention, those skilled in the art will understand that various changes and modifications can be made to the invention without departing from the scope of the invention as defined by the appended claims. For example, although the connector terminals of the present invention are preferably used for outdoor applications with suitable environmental sealing, the connector terminals can also be used for indoor applications with or without environmental sealing.

Claims

1. A connector terminal comprising: a unit-mountable connector comprising: a connector body having an adapter-engaging end portion and a unit-engaging end portion opposite the adapter-engaging end portion, and a mounting member between the adapter-engaging end portion and the unit-engaging end portion for mounting the connector body to a unit, an insert extending completely through the connector body, the insert having an inner bore extending between a cable connection end portion and a unit connection end portion opposite the cable connection end portion, and a connector body connection portion between the cable connection end portion and the unit connection end portion, and at least one dual-sided contact received in the inner bore of the insert; and a cable seal adapter mateable with the unit-mountable connector, the cable seal adapter comprising a housing having a mating end portion configured to engage the adapter-engaging end portion of the connector body and to receive the cable connection end portion of the insert, and a cable securing end portion opposite the mating end portion configured to terminate a cable, the cable seal adapter being devoid of any contacts, the cable seal adapter configured to receive an end portion of the cable; wherein the dual-sided contact of the unit-mountable connector is one-piece, wherein one end portion of the dual-sided contact is a cable termination end portion configured to terminate to at least one conductor of the cable supported by the cable seal adapter, and an opposite end portion is a unit termination end portion configured to terminate at least one conductor of the unit, wherein the cable termination end portion of the dual-sided contact is different from the unit termination end portion, and wherein the cable termination end portion is a crimp termination end portion, and the unit termination end portion is a compression termination end portion.

2. The connector terminal according to claim 1, wherein At least one sealing member is disposed within the housing between the cable connection end portion of the insert and an inner surface of the housing.

3. The connector terminal according to claim 2, wherein Another sealing member is supported by the mounting member at a mounting surface of the mounting member facing the unit-engaging end portion of the connector body.

4. The connector terminal according to any one of claims 1 to 3, wherein The cable securing end portion of the housing is configured to receive a nut member adapted to compress the cable.

5. The connector terminal according to claim 4, wherein A cable seal member is received in the nut member.

6. The connector terminal according to claim 1, wherein The cable connection end portion of the insert includes at least one aperture receiving a crimp fastener, and the crimp fastener engages the crimp termination end portion of the dual-sided contact.

7. The connector terminal according to claim 1, wherein The mounting member is an outwardly extending flange.

8. The connector terminal according to claim 1, wherein The inner bore of the insert receives another dual-sided contact having one end portion that is a cable termination end portion configured to terminate to at least one conductor of the cable, and an opposite end portion that is a unit termination end portion configured to terminate a unit.

9. The connector terminal according to claim 1, wherein The adapter-engaging end of the connector body includes external threads for engaging corresponding threads of an adapter; and the unit-engaging end of the connector body is sized to extend through an opening in a unit.

10. A method of assembling a connector terminal to a unit, the connector terminal including a unit-mountable connector and a cable-sealing adapter, the method comprising the steps of: terminating at least one conductor of the unit to a unit-terminating end of a double-sided contact of the unit-mountable connector; mounting a connector body of the unit-mountable connector to the unit; installing a cable by terminating at least one conductor of the cable to a cable-terminating end of the double-sided contact of the unit-mountable connector opposite the unit-terminating end of the double-sided contact; and assembling the cable-sealing adapter on the cable after the step of installing the cable and mating an end of the cable-sealing adapter with the connector body of the unit-mountable connector such that a cable-connection end of the unit-mountable connector is received in the cable-sealing adapter.

11. The method of claim 10, wherein, The step of terminating the at least one conductor of the unit to the unit-terminating end of the double-sided contact includes crimping the unit-terminating end.

12. The method of claim 11, wherein, The step of terminating the at least one conductor of the cable includes clamping the cable-terminating end of the double-sided contact.

13. The method of any one of claims 10-12, wherein, The double-sided contact is one-piece and the cable-sealing adapter is devoid of any contacts.

14. The method of any of claims 10-12, further comprising the step of extending a unit-engaging end of the connector body through an aperture of the unit.

15. The method of any of claims 10-12, further comprising the step of abutting a mounting member of the connector body against the unit.

16. The method of claim 15, further comprising the step of fastening the mounting member to the unit.

17. The method of claim 15, further comprising the step of positioning a sealing member between the unit and the mounting member.

18. The method of claim 10, wherein, The step of terminating at least one conductor of the unit occurs inside the unit and the step of installing the cable occurs outside the unit.

19. The method of claim 18, further comprising the step of threadably engaging an end of the cable-sealing adapter with the connector body of the unit-mountable connector.

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