Crimp pin electrical connector

Abstract

A crimp pin electrical connector includes: a housing defining an interior having a first opening and a second opening; a flange surrounding the housing; and an insert located in the interior and extending through the first opening. The insert includes at least one crimp pin, the at least one crimp pin including a crimping member and a pin, the at least one crimp pin being disposed in at least one channel included in the interior of the housing.

Description

Technical Field

[0001] The present disclosure relates generally to electrical connectors for electrical assemblies, and more particularly to crimp pin electrical connectors. Background Art

[0002] Modern aircraft use electrical machines, such as electric motors or generators for energy conversion. In the aircraft industry, it is common to find electric motors with a combination of motor and generator modes, where the motor is used in motor mode to start the aircraft engine and, depending on the mode, also used as a generator to supply electrical power to the aircraft systems. The electric machine contains electrical components, which in some cases may require a crimp pin electrical connector or a crimp socket connector to electrically or communicatively connect separate electrical components. Sometimes, these connections can leak fluid at the connector, which can contaminate local electrical components or leak fluid out of a sealed container. For crimp pin electrical connectors and crimp socket connectors, the leakage flow path extends from the wire insulation end near the crimp barrel to an inspection hole in the crimp barrel. The wire insulation end and the inspection hole are located on the outside of the seal, which would otherwise control fluid leakage. Summary of the invention

[0003] In one aspect, the present disclosure relates to a crimp pin electrical connector, comprising: a shell defining an interior having a first opening and a second opening to define an axial path through the shell between the first opening and the second opening; a flange surrounding the exterior of the shell; and an insert located in the interior and comprising a first end corresponding to the first opening, a second end corresponding to the second opening, and at least one channel extending between the first end and the second end, the insert comprising: at least one crimp pin, at least one crimp pin corresponding to at least one channel, at least some of the at least one crimp pin comprising a pin and a crimping piece, wherein at least one crimp pin is located within at least one channel so that a portion of the at least one crimp pin is located on a first side of the flange, and the crimping piece is located on a second side of the flange opposite to the first side.

[0004] On the other hand, the present disclosure relates to a wall of an electrical component, comprising: a first surface, a second surface opposite to the first surface, and a hole located in the wall; a shell, the shell defining an interior, the interior having a first opening and a second opening to define an axial path through the wall between the first opening and the second opening, the shell having a flange surrounding the exterior of the shell, at least a portion of the shell extending through the hole and the flange adjacent to the first surface; and an insert, the insert being located in the interior and comprising a first end corresponding to the first opening, a second end corresponding to the second opening, and at least one channel extending between the first end and the second end, the insert comprising at least one crimping pin, the at least one crimping pin corresponding to the at least one channel, the at least one crimping pin comprising a pin and a crimping piece, wherein the at least one crimping pin is located in the at least one channel so that a portion of the pin is axially located on a first side of the flange and the crimping piece is axially located on a second side of the flange. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] A full and enabling disclosure of the present specification, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0006] Figure 1 is a perspective view of an aircraft having an avionics chassis with electrical components and a backup generator in accordance with various aspects described herein.

[0007] Figure 2 yes Figure 1 An enlarged view of the housing cover of a standby generator, including a set of crimp pin electrical connectors.

[0008] Figure 3 yes Figure 1 An enlarged, partially exploded perspective view of an avionics chassis with the cover removed for clarity and including crimp pin electrical connectors.

[0009] Figure 4 According to various aspects described herein, for use in Figure 1 A perspective view of a crimp pin electrical connector in an electrical assembly within an aircraft.

[0010] Figure 5 yes Figure 4 A cross-sectional view of a crimp pin electrical connector including extended crimp pins. DETAILED DESCRIPTION

[0011] Aspects of the present disclosure relate to an improved crimp pin electrical connector including a set of crimp pins extending through at least a portion of a first side of a housing to a second side. Avionics equipment, including electrical components and other engine components, is continually challenged with how to dissipate heat generated by the increasing heat production in an aircraft environment, which may require the use of localized liquids or fluids for heat dissipation. Fluids may accumulate near a first side or reservoir area of ​​a housing of a crimp pin electrical connector.

[0012] Although the description generally relates to an avionics chassis or a backup generator (BUG) within an aircraft, it should be understood that, for example, the crimp pin electrical connector may be applicable to numerous elements or embodiments, such as any electronic chassis, electronic components, electric motors (such as those in an aircraft engine or not in an aircraft), or any other electrical assembly that uses a crimp pin electrical connector. Therefore, the crimp pin electrical connector as described herein will also be applicable to other environments requiring sealed electrical connections, such as non-aircraft, terrestrial or other environments, as well as any other electrical environment.

[0013] Although "a group" of various elements will be described, it should be understood that "a group" can include any number of corresponding elements, including only one element. In addition, all directional references (e.g., radial, axial, upper, lower, upward, downward, left, right, transverse, front, rear, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise) are only used for identification purposes to help readers understand the present disclosure, and do not generate restrictions, especially restrictions on their position, orientation or use. Unless otherwise stated, connection references (e.g., attachment, connection, connection and engagement) should be interpreted broadly and may include intermediate members between element sets and relative movement between elements. Therefore, connection references do not necessarily infer that two elements are directly connected and are in a fixed relationship with each other. The exemplary drawings are only for illustrative purposes, and the dimensions, positions, orders and relative sizes reflected in the attached drawings may vary.

[0014] Figure 1An aircraft 10 including a gas turbine engine 12 is schematically shown, specifically, two gas turbine engines 12 are arranged on respective sides of the aircraft 10. Each gas turbine engine 12 may be a turbofan engine commonly used in modern commercial aviation, or may be various other known gas turbine engines, such as a turboprop engine or a turboshaft engine. Each gas turbine engine 12 may include a BUG 14. As shown, the aircraft 10 may include two BUGs 20, one for each gas turbine engine 12. Each BUG 20 may generally be defined as an electric motor, so that it may be configured to provide or receive power to various avionics components or systems of the aircraft 10. For example, the BUG 20 may provide mechanical power to an accessory gearbox (AGB) (not shown) for driving at least a portion of the gas turbine engine 12. Although the BUG 20 is shown and described, it should be understood that the BUG 20 may be any electric motor, including but not limited to an electric motor or a starter / generator.

[0015] The aircraft 10 may also include an onboard avionics chassis 30 (shown in phantom) for housing avionics, electronic equipment, electrical components, or avionics components for use in the operation of the aircraft 10. The avionics chassis 30 houses a variety of avionics components and protects them from contaminants, electromagnetic interference (EMI), radio frequency interference (RFI), vibration, etc. Although shown in a commercial airliner, the avionics chassis 30 can be used in any type of aircraft and any vehicle that requires similar protection. The avionics chassis 30 can be located anywhere within the aircraft, not just in the nose as shown. In addition, aspects of the present disclosure are not limited to aircraft aspects and can be included in other mobile and stationary configurations. Non-limiting example mobile configurations may include ground-based, water-based, or attached air-based vehicles. In addition, aspects of the present disclosure are not limited to aspects of avionics chassis, but rather any part of an aircraft where electrical connections are made or where crimp pin electrical connectors are utilized. Additionally, the electrical connections may be those made in an oil wetted cavity, such as within a motor or generator on an engine (eg, BUG 20), where it is necessary to seal the wetted cavity and allow for electrical connections.

[0016] Figure 2 Shows Figure 1The housing cover 22 or wall of the BUG 20. The housing cover 22 can be defined as a portion of the BUG 20 that separates the first and second portions of the BUG 20. The first portion of the BUG 20 can be defined as an area including one or more components (such as but not limited to circuit boards, leads or other electronic components) located within the wet portion of the BUG 20. As used herein, the term "wet" may refer to any component of an aircraft that is susceptible to being exposed to or exposed to a fluid (such as but not limited to a coolant, lubricant, water, gas, oil, or any combination thereof). The first portion of the BUG 20 can be defined as a wet area 24. The second area of ​​the BUG 20 can be defined as a portion of the BUG 20 that is not intended to be in direct contact with the fluid. The fluid to which a portion of the BUG 20 may be exposed includes but is not limited to a coolant, lubricant, water, oil, gas, or any combination thereof. The second area can be defined as an environmental area 26. The environmental area 26 can be further defined as a location or portion of the BUG 20 that is exposed to environmental conditions surrounding the outer portion of the BUG 20. For example, the environmental area 26 can be ambient air.

[0017] A set of electrical pin contacts, specifically a set of crimp pin electrical connectors 40, may extend through the housing cover 22 of the BUG 20. The set of crimp pin electrical connectors 40 may be configured to establish electrical connections between a set of electronic components within the BUG 20 (specifically the wet area 24 of the BUG 20) and a set of external electronic components (e.g., but not limited to, a control system, a health monitoring system, a sensor, generator operation, a full authority digital engine control (FADEC), etc.). A set of holes extending from a first surface corresponding to the wet area 24 through the housing cover 22 to a second surface corresponding to the environmental area 26 may be provided at various locations on the housing cover 22 to receive corresponding crimp pin electrical connectors 40. As shown, three holes may be provided to receive a total of three crimp pin electrical connectors 40. The set of holes may be configured to surround at least a portion of the crimp pin electrical connector 40.

[0018] Figure 3 According to one aspect of the present disclosure, Figure 1The avionics chassis 30 of the embodiment of the present invention is shown in FIG. 1 , wherein the front cover 50 is removed. The avionics chassis 30 includes a chassis housing 52 that defines an interior 54 and an exterior 56 of the avionics chassis 30. The avionics chassis 30 may include a chassis frame 58 having a top cover 60, a bottom wall 62, a rear wall 64, and opposing side walls 66, 68, collectively referred to as a set of walls. The chassis frame 58 may further include the aforementioned front cover 50, which may be selectively removed, provide access to the interior 54 of the avionics chassis 30 when removed, and partially restrict access to the interior 54 when coupled or installed with the chassis frame 58. The side walls 66, 68 may include an inner surface 70 and an outer surface 72. As shown, a set of heat dissipation elements (e.g., fins 73) may protrude from the outer surface 72 of the side walls 66, 68. Although heat sink fins 73 are shown, the side walls 66 , 68 may utilize a plurality of heat sink elements or configurations to remove or dissipate at least a portion of the heat generated by or within the avionics chassis 30 , or the heat stored by the avionics chassis 30 .

[0019] Avionics chassis may also include electrical pin contacts, particularly Figure 2 6 and 7. As shown, the crimp pin electrical connector 40 may extend from a first surface as an inner surface 70 through the side wall 66 to a second surface as an outer surface 72. A hole extending from the first surface to the second surface may be included in the side wall 66 and configured to surround at least a portion of the crimp pin electrical connector 40. It is contemplated that the first surface and the second surface may be any opposing surfaces of a particular wall of the set of walls of the avionics chassis 30. Although shown as a single crimp pin electrical connector 40, it should be understood that the crimp pin electrical connector 40 may be one of a set of crimp pin electrical connectors 40. The set of crimp pin electrical connectors 40 may be placed on any wall in the set of walls.

[0020] Each crimp pin electrical connector 40 may be operably coupled to one or more electrical components of the aircraft 10. The avionics chassis 30 may be configured to house a set of electronic components used in the operation of the aircraft 10. For example, the interior 54 of the avionics chassis 30 may house a set of processors, a computer, a tablet computer, an electronic flight bag (EFB), etc. Thus, the avionics chassis 30 may be configured to house, support, or include a set of electronic components within the interior 54.

[0021] Figure 4 Shows Figure 2 and Figure 3 A crimp pin electrical connector 40 for inclusion in Figure 1As used herein, it should be understood that an electrical component may refer to any suitable electrical component of the aircraft 10 that is configured to utilize or otherwise receive the crimp pin electrical connector 40. Therefore, it will be understood that the crimp pin electrical connector 40 may extend through any suitable wall of the electrical component as described herein. Non-limiting examples of walls of the electrical component through which the crimp pin electrical connector 40 may extend may include, but are not limited to, the housing cover 22 of the BUG 20 and the side wall 66 of the avionics chassis 30.

[0022] The crimp pin electrical connector 40 may include a housing 42 having a first opening 44 and a second opening 46 that define a longitudinal axis 76 extending between the first opening 44 and the second opening 46. Thus, the first opening 44 and the second opening 46 may define an axial path through the housing 42. The housing 42 may be any suitable crimp pin connector body or wire connector, such as any commercial off-the-shelf or custom connector. A flange 48 or mounting flange may be included as part of the housing 42. The flange 48 may abut a first surface of the side wall 66 or any other wall in the set of walls that faces the inner surface 70 of the avionics chassis 30, or any side of the housing cover 22 of the BUG 20, such that the flange 48 may be fastened to the wall or housing cover 22 using a set of fastener apertures 78 disposed in the flange 48. Although the flange 48 is specifically described as a 4-bolt mounting flange, it should be understood that the flange 48 may be any type of mounting for the crimp pin electrical connector 40. Specifically, the crimp pin electrical connector 40 can be constructed to include a housing 42, which is any environmentally resistant circular electrical connector having any type of flange, which is constructed to be mounted to an outer wall or surface by any suitable mounting method (such as but not limited to a locking nut, a welding bracket, etc.).

[0023] A nut 80 and a cap 82 are provided at the first opening 44, including a set of inlets 84 for receiving a set of wires connected to at least a portion of the crimp pin electrical connector 40 (specifically, a set of crimp contacts as described herein). For example, the nut 80 can be made of steel, while other materials, such as non-conductive materials, such as plastic, are also contemplated. The cap 82 can be made of a dielectric material because it is close to the set of wires that can extend through the set of inlets 84. For example, the cap 82 can be made of polyamide-imide, etc.

[0024] Figure 5 Shows from Figure 4 View of VV captured Figure 44 is a cross-sectional view of a crimp pin electrical connector 40, showing a housing 100 of a housing 42. The housing 100 of the housing 42 may include an interior 102. The interior 102 may include: an interface seal 104; a dielectric insert 106; a gasket 108 including at least one set of sealing barriers 110. The interior 102 may be divided into a first side 112 and a second side 114. Figure 2 and Figure 3 In the example shown, the first side 112 may be in the direction of the outer surface 72 of the avionics chassis 30 or the environmental area 26 of the BUG 20. The second side 114 may be in the direction of the inner surface 70 of the avionics chassis 30 or the wet area 24 of the BUG 20. Thus, at least a portion of the second side 114 may be defined as an area of ​​the crimp pin electrical connector 40 where gas, liquid, or other substances may accumulate. It is further contemplated that the second side 114 may be defined as a wet side or a reservoir side of the crimp pin electrical connector 40, while the first side 112 may be defined as an environmental side of the crimp pin electrical connector 40.

[0025] The flange 48 can completely surround the exterior of the housing 100 and at least partially form a portion of the reservoir. The flange 48 can be positioned and fixed so that it forms a seal between the first side 112 and the second side 114 of the crimp pin electrical connector 40 so that liquid does not leak from one side to the other. For example, with respect to the BUG 20, the flange 48 forms a seal on the housing cover 22 so that oil, lubricant, or other fluid cannot be transferred from the wet area 24 to the ambient area 26 through the set of holes formed in the housing cover 22.

[0026] The interface seal 104 can be on the first side 112 of the crimp pin electrical connector and is configured to contact at least a portion of the crimp pin electrical connector 40, specifically, the set of crimp contacts as described herein. The interface seal 104 can be compressed between the dielectric insert 106 and the dielectric insert 106 of an external connector (not shown). The external connector can be defined as a connector that can be electrically connected to a portion of the crimp pin electrical connector 40 through the second opening 46. The interface seal 104 can be located between the dielectric insert 106 and the second opening 46 of the housing 100. It is contemplated that the interface seal 104 can be mated or bonded to the dielectric insert 106. The interface seal 104 can be formed of any suitable sealing material (for example, but not limited to, fluorosilicone, etc.).

[0027] The dielectric insert 106 can be disposed between the interface seal 104 and the gasket 108. As shown, the dielectric insert 106 can span between the first side 112 and the second side 114 of the crimp pin electrical connector. The dielectric insert 106 can define an area of ​​the interior 102 of the crimp pin electrical connector 40. However, it is contemplated that the dielectric insert 106 can span between the interface seal 104 and the gasket 108 along any portion of the interior 102. The dielectric insert 106 can include any suitable rigid dielectric material, such as, but not limited to, a glass-filled dielectric material. It will be further understood that in some cases, the interface seal 104 can be omitted so that the dielectric insert remains within the interior 102, against the housing 100 toward the second opening 46.

[0028] The back shell gasket 83 can be connected to the housing 100. The gasket 108 can be positioned between the back shell gasket 83 and the dielectric insert 106 on the second side 114 (also referred to as the wet side or sump side) of the flange 48. The interface between the back shell gasket 83 and the gasket 108 can be defined by a lower wall 116. The back shell gasket 83 can also include or abut against a collar 86 surrounding at least a portion of the back shell gasket 83. The nut 80 can be coupled to or otherwise placed on a portion of the collar 86. The nut 80 can then be threaded onto a portion of the housing 100 (specifically, onto a set of housing threads 119) so that the cap 82 is compressively held against a portion of the collar 86. In this way, the collar 86 and the cap 82 can compressively hold the back shell gasket 83 against the gasket 108 via the threads of the nut 80.

[0029] It should be understood that the back shell gasket 83 can be included in the gasket 108 so that they are integrally formed. Alternatively, the gasket 108 and the back shell gasket 83 can be formed as two separate parts. Both the gasket 108 and the back shell gasket 83 can be made of a compressible sealing material (such as a fluorocarbon or fluorosilicone), while any suitable dielectric compressible material is contemplated, such as rubber, silicone, carbon or other materials that are resistant to leakage and corrosion.

[0030] The set of sealing barriers 110 can be disposed within the gasket 108 to provide a seal inside the crimp pin electrical connector 40. Specifically, the set of sealing barriers 110 can provide a primary seal through a set of channels 122 and can be located on the reservoir side or second side 114 of the flange 48. The set of sealing barriers 110 can include any suitable sealing material, such as but not limited to fluorosilicone or other sealing materials. The set of sealing barriers 110 can further divide the crimp pin electrical connector into a first side 118 or reservoir side of the sealing barrier 110 and a second side 120 of the sealing barrier 110. However, it will be further understood that the set of sealing barriers 110 can be defined as a portion of the gasket 108. Therefore, the set of sealing barriers 110 can be integral with the gasket 108 and made of the same material as the gasket 108. The set of sealing barriers 110 can be further defined as a portion within the gasket 108 that compressively seals a portion of the crimp pin electrical connector 40 (specifically the set of crimp contacts as described herein) to form a barrier to prevent fluid from transferring between the first side 118 and the second side 120 of the sealing barrier 110.

[0031] Each channel 122 in the set of channels 122 may extend from the first opening 44 to the second opening 46 of the housing 42. The set of channels 122 may extend from the first opening 44 to the second opening 46 of the housing 42. Figure 4 ) and are formed at least within the interface seal 104, the dielectric insert 106, and the gasket 108. The set of sealing barriers 110 can inscribe at least a portion of the set of channels 122. Although illustrated as a constant cross-sectional area, it should be understood that the set of channels 122 can have a cross-sectional area that varies along the longitudinal axis 76. For example, the set of channels 122 can have a smaller cross-sectional area or contact retention features, such as protrusions or ribs, in the dielectric insert 106.

[0032] A set of inserts or electrical inserts may be provided, passing through the inlet 84 and into the passage 122. Each insert in the set of inserts may include a lead 134, an electrical insulator 124, and a crimp contact (specifically a crimp pin 128) in the set of crimp contacts. Each insert may be defined by a first end 130 corresponding to the first opening 44 and a second end 132 corresponding to the second opening 46. As shown, there are two inserts, so that two leads 134, two electrical insulators 124, and two crimp pins 128 are included in the crimp pin electrical connector and are configured to fit through at least a portion of the set of passages 122. It should be understood that the number of inserts may correspond to the number of passages 122. Therefore, the total number of crimp pins 128 may correspond to the total number of passages 122. At least a portion of each insert may extend into the housing 100 or the interior 102 at the second end 132 and pass through the cap 82, the collar 86, and the nut 80 near the first opening 44. It is contemplated that there may be any number of one or more inserts, and thus any number of one or more leads 134 , electrical insulators 124 , or crimp pins 128 passing through corresponding passages 122 .

[0033] The set of electrical insulators 124 may be located entirely on the second side 114 of the flange 48. Specifically, each of the set of electrical insulators may be provided on the first side 118 of the sealing barrier 110. Each electrical insulator 124 of the set of electrical insulators 124 may include a lead 134 or an electrical lead having an insulating cover 136 extending around at least a portion of the periphery of the lead 134. The set of electrical insulators 124 may extend through at least a portion of a corresponding one of the set of entries 84, the cap 82, to a terminal point within the backshell gasket 83. The set of leads 134 may terminate within a portion of the set of crimp pins 128 located within a portion of the gasket 108.

[0034] At least some of the set of crimp pins 128 may include a pin 138 and a crimp 140. The crimp pin 128 may be configured such that the pin 138 is the only portion of the crimp pin 128 that extends into the first side 112 of the flange 48. Thus, the pin 138 may extend within the set of channels 122 through at least a portion of the gasket 108, the dielectric insert 106, the interface seal 104, and ultimately into a portion of the housing 100. The pin 138 may extend from the first side 112 of the flange 48 to at least a portion of the second side 114 of the flange 48, or to at least a portion of the first side 118 of the sealing barrier 110. The pin 138 may also include a retaining shoulder 148 defined as a portion of the pin 138 that extends from an outer surface of the pin 138 into the channel 122. The retaining shoulder 148 may be configured to fit within a portion of the channel 122 or the dielectric insert 106 to provide a locking or retaining method for the crimp pin 128. Additionally, the passage 122 within the dielectric insert 106 may have a variable cross-sectional area that includes metal contact retention tines or other various contact retention features for retaining at least a portion of the crimp pin 128 , specifically the pin 138 .

[0035] The crimp 140 is completely located within the second side 114 of the flange 48. Specifically, the crimp 140 is completely located within the first side 118 of the sealing barrier 110. Therefore, the crimp 140 can extend along at least a portion of the crimp pin 128 on the first side 118 of the sealing barrier 110. The crimp 140 can be configured to deform at least a portion of a barrel 142 that is completely located on the second side 114 of the flange 48 or completely located on the first side 118 of the sealing barrier 110. Specifically, the barrel 142 or the crimp 140 can be at least partially located within the gasket 108 and the backshell gasket 83. In particular, it is contemplated that at least a portion of the crimp 140 can be received within a portion of the corresponding channel 122 extending through the gasket 108. The barrel 142 can be configured such that it can surround at least a portion of the lead 134.

[0036] The barrel 142 may also include an inspection hole 144 that may extend through one or both walls of the crimp pin 128 at the barrel 142. The inspection hole 144 may be formed as a circular hole or any other hole, such as but not limited to a slot or slit. The inspection hole 144 may be located entirely on the second side 114 of the flange 48, specifically on the first side 118 of the sealing barrier 110. It will be further understood that each barrel 142 may include a set of inspection holes 144. Thus, any number of one or more inspection holes 144 may be included on the barrel 142.

[0037] The crimp 140 can be further defined as a portion of the crimp pin 128 that can compressively hold at least a portion of the lead 134. The crimp 140 can reduce the local cross-sectional area of ​​the barrel 142 so that the barrel 142 presses upward against the lead 134 and compressively holds the lead 134. Therefore, the crimp can operably connect the crimp pin 128 to the electrical insulator 124. It is contemplated that the crimp 140 can also be located around another portion of the electrical insulator 124 (e.g., the insulating cover 136). Additionally or alternatively, it is contemplated that the crimp 140 is one of a group of crimps 140 located at various suitable locations along the crimp pin 128. For example, there can be a first crimp 140 positioned around the lead 134 as shown and a second crimp 140 positioned around a portion of the insulating cover 136.

[0038] Compared with conventional crimp pin electrical contacts, the crimp pin electrical connector or crimp contact described herein provides an improved environmental seal. For example, in terms of BUGs during operation, internal pressure and fluid can be applied to the crimp pin electrical connector. In conventional crimp pin electrical connectors, liquids, gases or other substances can leak along a portion of the stranded wire of the lead exposed to the fluid and leak within the insulating cover surrounding the lead. There can be space between the end of the contact and the insulating cover of the lead so that the fluid can leak into the contact or part of the crimp pin electrical connector. In addition, the barrel open end and inspection hole in the conventional crimp pin electrical connector can provide a fluid leakage path. Since the terminal, crimping piece, inspection hole and any other leakage path described herein of the insulating cover in the conventional crimp pin electrical connector are located on the second side of the sealing barrier, any leaking fluid will flow out around the pin of the crimp pin and enter the area of ​​the crimp pin electrical connector on the first side of the flange or environment. The crimp pin electrical connector is extended as described herein so that leakage caused by a pressure vent across the connector is eliminated by establishing the termination of the crimp, inspection hole, and insulating covering of the crimp pin electrical connector on the second side of the flange (specifically the first side of the sealing barrier). Pressure and fluid (such as pressure and fluid generated from BUG operation) can be completely maintained within the first side of the sealing barrier on the second side of the flange. Therefore, by eliminating the leakage path that is not addressed by standard contacts or crimp pin electrical contacts in the crimp pin electrical connector, internal pressure and fluid remain sealed within the pressure vessel. In addition, despite the absence of a pressure vent across the connector, any fluid wicked along the stranded wire leads feeding into the connector will be confined to the reservoir where the fluid is already expected.

[0039] Further benefits of the crimp pin electrical connector as described herein include increased stability of the crimp pin. The increased stability is due in part to the extended design of the crimp pin compared to conventional crimp pins. For example, conventional crimp pin designs may only partially extend onto the second side of the flange and terminate completely within the second side of the sealing barrier. When compared to the crimp pin of the present disclosure, the leads crimped to the crimp pin are relatively unsupported through the sealing barrier. If the insert or crimp pin electrical connector is subject to an external load, this will produce side loading, and fluid will bypass the seal between the leads and the sealing barrier. In addition, if no leads are connected to the crimp pin of a conventional crimp pin electrical connector, the sealing barrier will not engage and fluid will leak around the conventional crimp pin to the external environment. The crimp pin as described herein extends completely through the second side of the flange, the channel on the first side of the sealing barrier, through the gasket and into the back shell gasket. Therefore, compared to conventional crimp pin designs, the gasket and the additional back shell gasket can act as a constraint to better stabilize the crimp pin. The increased stability of the extended crimp pins as described herein ensures that the extended crimp pins remain engaged with the sealing barrier through side loading of the leads, inserts, or crimp pin electrical connectors.

[0040] It is further contemplated that the crimp pin electrical connectors described herein may allow for improved installation and removal of crimp pins compared to conventional electrical connectors, particularly sealed electrical connectors. For example, a sealed electrical connector may require soldering between the crimp pins and the leads. This can add another layer of difficulty to manufacturing when connecting the sealed connector to the assembly, as soldering may require a skilled and certified operator. However, the crimp pin electrical connector as described herein is configured so that it can be repeatedly installed and removed from the crimp pin electrical connector without soldering. Therefore, the extended crimp pins can be installed and removed from the crimp pin electrical connector using the same tools and in the same manner as conventional crimp pins.

[0041] In addition to the configurations shown in the above figures, the present disclosure also contemplates many other possible configurations. Within the scope not yet described, the different features and structures of each aspect can be used in combination with other features and structures as needed. A feature that cannot be described in all aspects does not mean that it is interpreted as not being available, but is for the sake of brevity of description. Therefore, various features of different aspects can be mixed and matched as needed to form new aspects, whether or not the new aspects are explicitly described. The combination or arrangement of the features described herein is covered by the present disclosure.

[0042] This written description uses examples to disclose aspects of the invention, including the best mode, and also to enable any person skilled in the art to practice aspects of the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

[0043] Further aspects of the invention are provided by the subject matter of the following clauses:

[0044] A crimp pin electrical connector comprises: a shell defining an interior, the interior having a first opening and a second opening to define an axial path through the shell between the first opening and the second opening; a flange, the flange surrounding the exterior of the shell; and an insert, the insert being located in the interior and comprising a first end corresponding to the first opening, a second end corresponding to the second opening, and at least one channel extending between the first end and the second end, the insert comprising: at least one crimp pin, the at least one crimp pin corresponding to the at least one channel, at least some of the at least one crimp pin comprising a pin and a crimping piece, wherein the at least one crimp pin is located in the at least one channel so that a portion of the at least one crimp pin is located on a first side of the flange, and the crimping piece is located on a second side of the flange opposite to the first side.

[0045] A crimp pin electrical connector according to any preceding clause, wherein the flange is located between the first opening and the second opening.

[0046] A crimp pin electrical connector according to any preceding clause, wherein the insert further comprises an electrical insulator and leads.

[0047] A crimp pin electrical connector according to any of the preceding clauses, wherein the at least one crimp pin is included in a group of crimp pins and the at least one channel is included in a group of channels, wherein the total number of crimp pins included in the group of crimp pins corresponds to the total number of channels included in the group of channels.

[0048] A crimp pin electrical connector according to any preceding clause, wherein said at least one crimp pin has a barrel located on said second side of said flange.

[0049] A crimp pin electrical connector according to any preceding clause, wherein the barrel includes an inspection hole located on the second side of the flange.

[0050] A crimp pin electrical connector according to any preceding clause, wherein the barrel comprises a slot or a slit.

[0051] A crimp pin electrical connector according to any preceding clause, wherein the at least one passage extends through the gasket and at least a portion of the crimp is received within a portion of the at least one passage extending through the gasket.

[0052] A crimp pin electrical connector according to any preceding clause, further comprising a sealing barrier defining a first side and a second side of the sealing barrier.

[0053] A crimp pin electrical connector according to any preceding clause, wherein the crimp is located entirely on the first side of the sealing barrier.

[0054] A wall of an electrical component, comprising: a first surface, a second surface opposite to the first surface, and a hole located in the wall; a shell, the shell defining an interior, the interior having a first opening and a second opening to define an axial path through the wall between the first opening and the second opening, the shell having a flange surrounding the exterior of the shell, at least a portion of the shell extending through the hole and the flange adjacent to the first surface; and an insert, the insert being located in the interior and comprising a first end corresponding to the first opening, a second end corresponding to the second opening, and at least one channel extending between the first end and the second end, the insert comprising at least one crimping pin, the at least one crimping pin corresponding to the at least one channel, the at least one crimping pin comprising a pin and a crimping piece, wherein the at least one crimping pin is located in the at least one channel so that a portion of the pin is axially located on a first side of the flange and the crimping piece is axially located on a second side of the flange.

[0055] A wall as claimed in any preceding clause wherein the wall is a housing cover of a standby generator.

[0056] A wall as claimed in any preceding clause, wherein the flange is located between the first opening and the second opening.

[0057] A wall as claimed in any preceding clause, wherein the insert further comprises an electrical insulator and leads.

[0058] A wall according to any preceding clause, wherein the at least one crimp pin is included in a group of crimp pins and the at least one channel is included in a group of channels, wherein the total number of crimp pins included in the group of crimp pins corresponds to the total number of channels included in the group of channels.

[0059] A wall as in any preceding clause, wherein the at least one crimp pin has a barrel located on the second side.

[0060] A wall as claimed in any preceding clause wherein the barrel includes an inspection aperture at the second side.

[0061] A wall as claimed in any preceding clause wherein the barrel comprises a slot or slit.

[0062] A wall as in any preceding clause, further comprising a gasket comprising a sealing barrier defining a first side and a second side.

[0063] A wall as claimed in any preceding clause, wherein the crimp is located entirely on the first side of the sealing barrier.

Claims

1. A crimp pin electrical connector, characterized in that: include: a housing defining an interior having a first opening and a second opening to define an axial path through the housing between the first opening and the second opening; a flange surrounding an exterior of the housing; an insert located in the interior and comprising a first end corresponding to the first opening, a second end corresponding to the second opening, and at least one channel extending between the first end and the second end, the insert comprising: at least one crimp pin, the at least one crimp pin corresponding to the at least one channel, at least some of the at least one crimp pin comprising a pin and a crimp; and a sealing barrier forming a portion of the passageway and compressively sealing at least a portion of the at least one crimp pin, the sealing barrier having a first side and a second side, wherein the sealing barrier is configured to restrict egress of a fluid within the crimp pin electrical connector from the first side to the second side; wherein the at least one crimping needle is located in the at least one channel such that a portion of the at least one crimping needle is located on a first side of the flange, and the crimping member is located on a second side of the flange opposite to the first side; wherein the at least one passage extends through the gasket and at least a portion of the crimp is received within a portion of the at least one passage extending through the gasket; wherein the crimping member is completely located on the first side of the sealing barrier; wherein the crimping member is at least partially located within a rear shell gasket, the rear shell gasket and the gasket having an interface; and Wherein, the insert includes a lead, the at least one crimping pin has a barrel, the barrel is located on the second side of the flange and is at least partially located within the gasket and the back shell gasket, and the barrel is configured so that it can surround at least a portion of the lead.

2. The crimp pin electrical connector according to claim 1, characterized in that: in, The flange is located between the first opening and the second opening.

3. The crimp pin electrical connector according to claim 1, characterized in that: in, The insert further includes an electrical insulator.

4. The crimp pin electrical connector according to claim 1, characterized in that: in, The at least one crimp pin is included in a group of crimp pins and the at least one channel is included in a group of channels, wherein a total number of crimp pins included in the group of crimp pins corresponds to a total number of channels included in the group of channels.

5. The crimp pin electrical connector according to claim 1, characterized in that: in, The barrel includes an inspection hole located on the second side of the flange.

6. The crimp pin electrical connector according to claim 5, characterized in that: in, The barrel includes a slot or slit.

7. A wall of an electrical component, separating a first region containing a fluid from a second region, characterized in that: The wall comprises: a first surface, a second surface opposite the first surface, and an aperture in the wall; a housing defining an interior having a first opening and a second opening to define an axial path through the wall between the first opening and the second opening, the housing having a flange surrounding an exterior of the housing, at least a portion of the housing extending through the aperture and the flange abutting the first surface; an insert located in the interior and comprising a first end corresponding to the first opening, a second end corresponding to the second opening, and at least one channel extending between the first end and the second end, the insert comprising: at least one crimping pin, the at least one crimping pin corresponding to the at least one channel, the at least one crimping pin comprising a pin and a crimping member; and a sealing barrier forming a portion of the passageway and compressively sealing at least a portion of the at least one crimp pin, the sealing barrier having a first side and a second side, wherein the sealing barrier is configured to restrict egress of the fluid from the first side to the second side; wherein the at least one crimping needle is located within the at least one channel such that a portion of the needle is axially located on a first side of the flange and the crimping member is axially located on a second side of the flange; wherein the at least one passage extends through the gasket and at least a portion of the crimp is received within a portion of the at least one passage extending through the gasket; wherein the crimping member is completely located on the first side of the sealing barrier; wherein the crimping member is at least partially located within a rear shell gasket, the rear shell gasket and the gasket having an interface; and Wherein, the insert includes a lead, the at least one crimping pin has a barrel, the barrel is located on the second side of the flange and is at least partially located within the gasket and the back shell gasket, and the barrel is configured so that it can surround at least a portion of the lead.

8. The wall according to claim 7, characterized in that in, The wall is the housing cover of the backup generator.

9. The wall according to claim 7, characterized in that in, The flange is located between the first opening and the second opening.

10. The wall according to claim 7, characterized in that in, The insert further includes an electrical insulator.

11. A wall according to any one of claims 7 to 10, characterized in that in, The at least one crimp pin is included in a group of crimp pins and the at least one channel is included in a group of channels, wherein a total number of crimp pins included in the group of crimp pins corresponds to a total number of channels included in the group of channels.

12. The wall according to claim 7, characterized in that in, The barrel includes an inspection aperture located on the second side.

13. The wall according to claim 12, characterized in that in, The barrel includes a slot or slit.

14. A wall according to any one of claims 7 to 10, characterized in that Further included is a gasket, the sealing barrier being disposed within the gasket.

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