Linear electrical connector with helically distributed terminals

Abstract

An electrical pin connector comprising a socket and a plug configured for mating connection, the plug and the socket each comprising a tapered backshell having a surface disposed about a central axis and a plurality of pin sockets helically disposed in a parallel curve about the central axis on the tapered backshell surface for terminating a conductor.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. non-provisional patent application No. 16 / 783,927, filed on February 6, 2020, entitled “LINEAR ELECTRICAL CONNECTOR WITHHELICALLY DISTRIBUTED TERMINATIONS,” the entire contents of which are incorporated herein by reference.

[0003] Statement regarding federally sponsored research or development

[0004] not applicable.

[0005] Name of the joint research agreement or the parties involved

[0006] not applicable.

[0007] By referencing the materials submitted on the CD-ROM

[0008] not applicable.

[0009] sequence list

[0010] not applicable. Technical Field

[0011] This invention generally relates to electrical conduits, cables, and connectors, and more specifically to multi-contact electrical connector assemblies for interconnecting cabling systems, and even more specifically to electrical connectors having plug and socket contact terminals configured with termination pins spirally distributed on tapered surfaces in the plug and socket elements. The connectors of this invention are suitable for highly confined spaces, such as aircraft electrical connector panels, where large numbers of cables converge for organization and sorting via harnesses and other cable management devices, and for connection to navigation, communication, and electronic systems. Background Technology

[0012] Vehicle and aircraft systems are often located far from power and signal sources, and conductors and cables frequently pass through structural boundaries, bulkheads, panels, chassis, and walls that separate the vehicle / aircraft's main structure (wings) from the fuselage, cargo areas from the cabin, the cabin from tail components, the power plant from the wings or cockpit, and the fuselage from landing gear, etc. Cables will be used for these purposes until wireless local signal transmission for high-speed data transfer is completely reliable and secure. Wiring for cabin systems, environmental control and lighting, avionics, flight control, auxiliary power units and engine-driven alternators and backup power supplies, AC inverters, control systems, servo motors, electro-hydraulic motors and actuators, lights, etc., is typically bundled and organized in harness assemblies and is not often contained in conduits (due to weight limitations). Components and their conductors occupy considerable space, especially at bends, joints, and barrier walls. Space constraints and the need to protect structural integrity, as well as ensure internal air pressure and climate, minimize barrier penetration, thus dedicating the space to electrical connectors and harness assemblies.

[0013] In the worst-case scenario, cable bundles may be impossible to install within an aircraft because the diameter of the terminating connector is too large to pass through the opening. The diameter of a standard multi-contact connector is a function of the number and size of the contacts. Therefore, wiring and "mating" problems often arise when connectors have a large number of contacts for large conductor bundles (which require larger contacts). Consequently, there is a persistent motivation to reduce the space and weight consumed by multi-contact electrical connectors for electrical components, particularly mating mounts and panel systems in aircraft. These motivations regarding weight and space are extremely important in the development of electric aircraft.

[0014] Current solutions to connector weight and space constraints include various pin geometries that reduce area and manufacturing techniques that increase pin density in axially connected electrical plugs. However, there are inherent limitations to wire distribution density. Most notably, the number of wire termination pins occupying a given circular cross-section in the plug is limited before electrical contact occurs between conductors. Minimal spacing is required to ensure proper insulation. The most critical issue in design considerations is how to produce wire terminations (pins) with the smallest exposed diameter. Summary of the Invention

[0015] In its most basic aspect, the present invention is a pin-type electrical connector configured to distribute the end contact diameters helically / radially along a central axis. This connector solves the problems of pin overcrowding (density) and pin limitations per connector area present in conventional circular cross-section connectors. Therefore, it also solves the problem of increasing the connector cross-sectional area corresponding to an increase in the number of pins.

[0016] In the electrical plugs and sockets of this invention, each of the convex and concave connectors distributes electrical pin terminals in a parallel-bent spiral arrangement along the surface of the cylindrical back shell, rather than a circular or square face. (As used herein, "parallel-bent" refers to bends spaced apart by a fixed normal and a constant offset distance.) By redistributing the pins along the tapered surface of the connector end, an increased number of pins can be inserted into the connector, regardless of pin diameter, without increasing the overall cross-sectional diameter of the connector. Furthermore, the conductors are oriented along the connector's axis and molded into the connector itself, thereby eliminating the need for internal contacts. This reduces the effective diameter of the connector, thereby increasing the potential contact density.

[0017] More specifically, the design and method of contact distribution requires pin diameters distributed along three dimensions (r, θ, z, using cylindrical coordinate notation) instead of two dimensions (r, θ). Although there is a finite area of ​​conductor density in conventional (r, θ) distributed contacts, conductor density can be significantly increased by arranging contacts along the z-axis. This invention only achieves this feature.

[0018] This invention also maximizes the cross-sectional density of the conductor by integrating insulation into the connector and distributing the conductor connections along a helical array around the cylinder. Currently, the limiting factors in reducing the diameter of conductor connectors are the pin and conductor diameters: However, the diameter of the pins and wires limits the distribution density (per Or the conductor cross-section). Two strategies address this limitation: (1) removing the conductor insulation through the connector to reduce the conductor-center conductor distribution in a manner that maximizes conductor insulation separation and increases conductor throughput relative to the connector's axial cross-section; and (2) a helical distribution of conductor terminal leads with respect to a tapered geometry, which improves the distribution of conductor terminal leads in a typical circular cross-section by increasing the additional distribution dimension along the central axis. This is relative to the diameter dimension. This increases the potential pin density without requiring major modifications to the terminal pins (although improved pin design can be part of design optimization).

[0019] Therefore, as will be understood upon viewing the accompanying drawings and the detailed description below, the construction of the electrical connector allows it to accommodate increasing numbers of conductors without having to expand the cross-sectional area of ​​the connector (both male and female) housing. When cables or conductors are added, they are terminated at points on the cylindrical surfaces of each male and female connector element.

[0020] The foregoing summary outlines the more important features of the invention, thereby enhancing the understanding of the following detailed description and the invention's contribution to the art. Additional features of the invention will be described in the detailed description of preferred embodiments, which form the subject matter of the appended claims. Attached Figure Description

[0021] The invention will be better understood when considered in the following detailed description, and objectives other than those described above will become apparent. This description refers to the accompanying drawings, in which:

[0022] Figure 1 This is a top perspective view of an assembled linear connector, showing the mechanical and electrical connections between the plug and socket.

[0023] Figure 2 This is the same view of the plug being removed from the socket;

[0024] Figure 3A This is an exploded top perspective view of the plug element (convex connector), showing the assembled socket element (concave connector);

[0025] Figure 3B This is an exploded top perspective view of the concave connector of the non-spiral connector of the present invention, showing that there is no convex connector in this view.

[0026] Figure 4A This is an outer view of the convex connector;

[0027] Figure 4B This is its frontal, inner end view;

[0028] Figure 5A This is an outer view of the concave connector;

[0029] Figure 5B This is its inner end view;

[0030] Figure 6A This is a cross-sectional side view of the joined convex and concave connectors, showing details of the nested concave connector sleeve and back shell ring;

[0031] Figure 6B This is a cross-sectional side view of the connected convex and concave connectors, showing details of the nested convex concentric sleeves and back shell rings;

[0032] Figure 7 It is a detailed perspective view showing the surface shape of a convex or concave concentric sleeve;

[0033] Figure 8A This is a side view of the outermost concave connector sleeve and the concave back shell ring;

[0034] Figure 8B This is an end view of its front view, which also shows two nested internal connector sleeves;

[0035] Figure 9A This is a side view of the concave connector sleeve and the concave back shell ring.

[0036] Figure 9B This is an end view of its front view, showing the outermost connector sleeve removed and the innermost nested connector sleeve in place;

[0037] Figure 10A This is a side view of the innermost concave connector sleeve and concave back shell ring;

[0038] Figure 10B This is an end view of its front view, showing the removed middle and outermost concave connector sleeves;

[0039] Figure 11 This is a cross-sectional side view (not to scale) showing the structure of the spiral back shell connection of the concentric rings of the plug element's back shell, characterized by a flexible PCB electrically connected to the spiral back shell.

[0040] Figure 12 This is a cross-sectional side view showing a typical feedthrough configuration of a conventional insulated wire terminated in a socket in the back housing;

[0041] Figure 13 It is its inner end view; and

[0042] Figure 14 This is a detailed top perspective view of the contact between the pins of the convex and concave components and the conductive epoxy channels of the connector housing and concentric rings. Detailed Implementation

[0043] Reference will now be made in detail to specific embodiments or features, examples of which are shown in the accompanying drawings. Generally, corresponding reference numerals are used throughout the drawings to denote the same or corresponding parts. Similarly, whenever possible, the same reference numerals are used in all drawings to denote the same or similar parts.

[0044] First refer to Figure 1A through 14, wherein the same reference numerals denote the same parts in the various views, illustrate an embodiment of a novel and improved electrical connector, generally designated 10 herein. In one embodiment, the device includes a first connector-mateable connector half 100 and a second connector-mateable connector half 200, which are complementary pairs comprising a convex connector half (plug) and a concave connector half (receptacle), respectively. As will be immediately understood, in one embodiment, the convex connector half 100 and the concave connector half 200 may be cylindrical in their overall external geometry (and thus, the cross-section as viewed at the ends is circular), although the external cross-sectional geometry is not essential and is therefore non-limiting. However, for the space-saving objective of the invention, the internal geometry must be cylindrical.

[0045] Both the convex connector half and the concave connector half are generally hollow tubular shells that can receive wires or cables. Thus, the convex connector half 100 first includes an inner convex shell 102 and first to fourth convex concentric sleeves 104, 106, 108, and 110, the diameters of which continuously decrease, and are axially inserted into the open end of a directly larger diameter concentric sleeve with tight tolerance clearance. The largest convex concentric sleeve 104 is sequentially inserted into the convex shell 102.

[0046] At the outer end 124 of the convex connector half is a wire retainer 126, which has an open outer end 128 with an inclined inner edge 130. The convex shell 102 extends inward from the inner end 132 of the wire retainer 126.

[0047] Therefore, as described above, each concentric sleeve includes inner ends 104a, 106a, 108a, 110a and outer ends 104b, 106b, 108b, 110b. In assembly, each concentric sleeve is inserted into the next larger diameter sleeve with tight tolerances, such that the outer cylindrical surface of each sleeve slidably approaches and engages the inner surface of the next larger concentric sleeve. During insertion and assembly, in the nested structure, the corresponding inner ends 104a, 106a, 108a, 110a of the concentric sleeves extend to and align with the inner terminal 102a of the cylindrical portion of the convex shell 102, wherein the sleeves converge inwardly uniformly to form a hemispherical inner convex end 122c. When assembled in this way, the outer ends of the concentric sleeves are coplanar with each other and coplanar with the outer terminal 102b of the convex shell 102 (see...). Figure 6B ).

[0048] The next convex connector half includes multiple nested convex back shells 132, 134, 136, 138, and 140, which are the same number as the concentric sleeves. Each convex back shell includes inner ends 132a, 134a, 136a, 138a, and 140a, and outer ends 132b, 134b, 136b, 138b, and 140b, cylindrical portions 132c, 134c, 136c, 138c, and 140c, and tapered portions 132d, 134d, 136d, 138d, and 140d. The outermost back shell 132, and only the outermost back shell, is not inserted into any other back shell, including a closed end 132e, and provides a surface with multiple helical (coiled) bent, offset (parallel) pin socket (hole) rows, into which conductors are inserted and terminated.

[0049] During assembly, each conical back shell is inserted into the next larger diameter back shell with tight tolerances, such that the outer surfaces of the conical and cylindrical portions of each convex back shell slidably approach and engage the inner surface of the next larger back shell. When assembled and in a nested configuration, the inner ends of the convex back shells are planar aligned with each other, and the outer ends are also aligned with each other (see again). Figure 6B ).

[0050] It should be noted that each concentric sleeve between the convex shell 102 and the smallest concentric sleeve 110 includes a plurality of axially oriented parallel rows 150 with pin holes 152. In one embodiment, as shown, each concentric sleeve includes 6 rows of 12 holes. During assembly, the helical bent rows of nested concentric sleeves are stacked and aligned such that the aligned holes create a continuous through-hole or pin socket through the convex shell 102 up to the innermost concentric sleeve 110.

[0051] Conductive pins 154 are inserted into channels (pin sockets) and extend from surface 102d of the convex housing 102. The conductive pins 154 are configured to secure concentric sleeves within their nested structure and provide a conductive path from the surface of the convex housing to a conductive filament 155 in a channel disposed on one of the inner concentric sleeves. The pins may include pressable contacts for mating with complementary concave connector halves.

[0052] Therefore, it will also be noted that each concentric sleeve includes a plurality of filament channels 156 disposed around the surface of the concentric sleeve, each channel including a transverse portion 156a extending from the pin socket to a longitudinal portion 156b, the longitudinal portion 156b extending to an outer end. Although in Figure 8A-10BThe structural features associated with the concentric sleeve of the concave connector half 200 are shown in detail, but compared to the convex connector, each row of pin sockets in the concentric sleeve 104 with the largest diameter includes four filament channels. With the inner pin socket (closest to the inner end 104a) as the first pin socket (first pin socket in the illustrated embodiment) and the outer pin socket as the last pin socket (twelfth pin socket in the illustrated embodiment), the concentric sleeve 104 includes filament channels extending from the first, fourth, seventh, and tenth pin sockets in each row. It should be noted that for each consecutive filament channel, the lateral portion is shortened, thereby separating the longitudinal portion of the filament channel with a non-conductive sleeve material.

[0053] The concentric sleeve 106 also includes four filament channels for each of the parallel row pin sockets, each filament channel extending from the second pin socket, the fifth pin socket, the eighth pin socket, and the eleventh pin socket, respectively.

[0054] The concentric sleeve 108 includes three filament channels for each of the parallel row pin sockets, each filament channel extending from the third, sixth, and ninth pin sockets. However, as those skilled in the art will understand, this is merely an exemplary pattern distribution; the hole and filament channel distribution can take many possible configurations, and while they do not have to be a regular sequence, using a regular sequence greatly enhances device logic and fabrication.

[0055] Finally, for this set of concentric sleeves, concentric sleeve 110 includes a single filament channel for each row of pin sockets.

[0056] Similar to concentric sleeves, each tapered portion 132d, 134d, 136d, 138d, and 140d of the nested back shells 132, 134, 136, 138d, and 140d includes multiple rows 160 of spaced-apart pin sockets 162, the number of which is the same as the number of holes in the concentric sleeve. Instead of being axially or longitudinally oriented, these rows are slightly counter-tapered when viewed from the outer end, requiring a continuous tapered side facing the cylindrical portion when viewed upwards from the tapered end. Each row terminates at the junction of the tapered and cylindrical portions (i.e., the position where the tapered portion abruptly transitions into the cylindrical portion).

[0057] Furthermore, all inserted back covers include filament channels 164, which, like those on the concentric sleeves, include transverse and longitudinal portions, the latter at substantially parallel angles to the adjacent rows of holes. The longitudinal filament channels are angled to form continuous parallel rows on the cylindrical portions, terminating at the inner end of the back cover at the cylindrical portions. Similarly, as with the concentric sleeves, the filament channels extend from regularly spaced pin sockets on each row of pin sockets on the tapered portions. The largest insert back cover 134 includes filament channels in each row 160 of pin sockets 162 extending from the first, fourth, seventh, and tenth pin sockets (counted from the outer ends of these rows); the next largest insert back cover 136 includes filament channels in each row of pin sockets extending from the second, fifth, eighth, and eleventh pin sockets; the next largest insert back cover 138 includes filament channels in each row of pin sockets extending from the third, sixth, and ninth pin sockets; and the smallest insert back cover 140 includes filament channels only in the 12th pin socket of each row of pin sockets.

[0058] As previously described, when assembled into a nested structure, the inner ends of the convex back shells are aligned with each other, and the outer ends are also aligned with each other. The pin sockets of each “layer” of the back shells are also aligned with each other and extend downward from the outermost back shell 132 to the innermost back shell 140.

[0059] The structural aspects of the filament channels on the convex plug element (i.e., the back shell and concentric sleeve) are described in more detail below in conjunction with the description of the concave connector element 200. Now, and generally speaking, each channel is an uninterrupted, elongated recess cut or formed in the surface of the concentric sleeve and continuing on the adjacent back shell. It begins and originates from the pin hole of the concentric sleeve, extends from one of the concentric sleeves, and terminates in the socket hole in the adjacent convex back shell. The conductive filament is connected to the pin in the pin hole of the concentric sleeve and extends the length of the channel from the pin hole, first laterally along the transverse portion of the channel on the concentric sleeve, then longitudinally (axially) into and along the channel, across the adjacent edges of the concentric sleeve and the back shell of the corresponding size, and continues on the cylindrical and tapered portions of the back shell until it turns at the transverse portion on the back shell and terminates at the pin socket on the back shell.

[0060] See now Figure 3B , Figure 3BThis is an exploded perspective view of only the concave connector half 200, showing that the components generally reflect the structure and operating parts of the convex connector half, where dimensional differences are immediately apparent. Specifically, the concave connector half 200 first includes an inner concave receptacle shell 202 and first to third concave connector shell rings 204, 206, and 208, from the innermost to the outermost, respectively. In this case, the connector shell rings are also concentric, but their diameters continuously increase, with the next smallest connector shell ring axially inserted into the open end of a directly larger diameter connector shell ring with a tight gap. The largest concentric concave connector ring 208 is inserted into the concave outer connector shell 210 covering the nested assembly. The concave receptacle shell 202 includes an inner flange 202a, which, when assembled, abuts all the inner ends 204a-210a of the concentric connector shell rings and the outer connector shell.

[0061] Each concave connector housing ring and outer connector housing includes inner ends 204a, 206a, 208a, 210a and outer ends 204b, 206b, 208b, and 210b. During assembly, each concave connector housing ring is inserted with tight tolerances into the next larger diameter connector housing ring, such that the outer cylindrical surface of each connector housing ring slidably approaches and engages the inner surface of the next larger connector housing ring. During assembly, the inner ends of the connector housing rings are coplanar and aligned abut against the annular flange 202a on the innermost connector housing ring 202. The outer ends are aligned with each other and with the outer end 102b of the concave socket housing (see...). Figure 6A ).

[0062] The outer end 202b of the concave socket housing 202 is closed by a cap 202c including a central concave recess 202d. The inner convex housing 102 is inserted into the socket housing such that the end 102c engages with the cap 202c.

[0063] A retaining plug 212 with a convex element is connected to a cap 202c to provide a mounting structure for a concave back cover, as described below.

[0064] The next concave connector half includes multiple nested concave back shells 232, 234, 236, 238, arranged from largest to smallest, and in the same number as the concentric connector rings. Each concave back shell includes inner ends 232a, 234a, 236a, 238a and outer ends 232b, 234b, 236b and 238b, cylindrical portions 232c, 234c, 236c and 238c, and tapered portions 232d, 234d, 236d and 238d. The outermost concave back shell 232 includes a closed end 232e and provides a surface with rows of pin sockets (holes) into which conductors are inserted and terminated.

[0065] At its outer end 210b, the concave outer connector housing 210 is connected to the inner end 232a of the outermost concave back housing 232 and extends inward from the inner end, the outermost concave back housing being a concave wire retainer 226.

[0066] The outer end 224 of the concave connector half includes an axially oriented concave wire retainer 226 with an open outer end 228. The wire retainer surrounds and is mounted on most of the tapered portion 232d of the outermost concave back shell 232, such that the inner end 226a of the wire retainer 226 approaches the wire 232f at the transition from the tapered portion 232d to the cylindrical portion 232c of the back shell 232.

[0067] During assembly, each conical concave back shell is inserted into the next larger diameter concave back shell with tight tolerances, such that the outer surfaces of the conical and cylindrical portions of each concave back shell slidably approach and engage the inner surface of the next larger concave back shell. When assembled and in a nested structure, the inner ends of the concave back shells between the socket shell 202 and the outer concave connector shell 210 are planar aligned with each other, and the outer ends of all connector shells 202b-210b are also aligned with each other (see again). Figure 6A ).

[0068] Similar to the convex connector half, each concentric sleeve between the concave receptacle housing 202 and the smallest concentric connector rings 204, 206, 208 and the outer concave housing 210 includes a plurality of axially oriented parallel rows 250 of pin holes 252. In the illustrated embodiment, each concentric connector ring includes 6 rows of 12 holes. During assembly, the nested rows of concentric sleeves are aligned such that the aligned holes create a continuous through-hole or pin socket from the outermost concentric connector housing 208 to the concave receptacle housing 202.

[0069] Inserted into the channel (pin socket) and extending from the surface 202c of the concave socket housing 202 are rows of conductive pins 254. The conductive pins 254 are inserted into pin holes in the concave socket housing 202 and are configured to pass through pin holes in the concave concentric connector rings and secure the concentric connector rings in their nested configuration, thereby providing a conductive path from the cylindrical inner side 202d of the concave socket housing to a conductive filament in a filament channel provided on one of the inner concentric connector rings.

[0070] Each concentric connector ring includes a plurality of filament channels 256 disposed around the surface of the concentric sleeve, each filament channel including a transverse portion 256a extending from the pin socket to a longitudinal portion 256b, the longitudinal portion 256b extending to an inner end.

[0071] Now for reference Figure 7 The details of the filament channel features of the convex concentric sleeve and the concave concentric connector ring are shown. Figure 7The configuration shown is that of the concave concentric connector ring 204, but this view also shows the structural features of the filament channels more generally, including the structures visible in all the convex concentric sleeves 104-110 and the concave connector rings 204-208. Here it can be seen that each row of pin sockets 150 / 250 in the concentric sleeves and concentric connector rings includes multiple filament channels 156 / 256. Each filament channel includes a transverse segment 156a / 256a and a longitudinal segment 156b / 256b, and a conductive filament 155 / 255 is provided in each channel. The conductive epoxy resin disposed in the filament channels to fix the conductive filaments and ensure the continuity of the entire channel is not shown in this view. Figure 8A , 9A As shown in 10A.

[0072] Similar to a concave concentric connector ring, each tapered portion 232d, 234d, 236d, and 238d of the nested concave back covers 232, 234, 236, and 238 includes multiple rows 260 of spaced-apart pin sockets 262, the number of which is the same as the number of holes in the concave concentric connector ring. When viewed from the outer end, the rows on the back cover are slightly counterclockwise tilted, which requires that the continuous tapered sides face the cylindrical portion when viewed from the tapered end upwards (see...). Figure 5A Each row terminates at the junction of the conical and cylindrical sections (i.e., the conical section abruptly tilts and transitions to the cylindrical section).

[0073] Furthermore, all inserted concave back shells include filament channels 264, which, like the filament channels provided on the concentric connecting rings, include a transverse section 264a and a longitudinal section 264b, the longitudinal section 264b being inclined substantially parallel to the holes in the adjacent row. The filament channels are angled longitudinally to the cylindrical portion along the tapered surface, wherein they continue in parallel rows on the cylindrical portion and terminate at the inner end of the concave back shell.

[0074] See now Figure 8A-10B The diagram illustrates the structure and geometry of the filament channels disposed within the concave back shell and the concave concentric connector ring. Each end view (8B, 9B, and 10B) shows the layers of the concentric sleeve or concentric connector ring, with the conductive epoxy and filaments removed from the filament channels to provide greater clarity of the channels. As previously described, the structure and operating characteristics of the concave concentric connector ring are substantially the same as those of the convex concentric sleeve; therefore, these views provide details of how electrical continuity is achieved on the convex concentric sleeve coupled to the convex back shell and on the concave back shell coupled to the concave concentric connector ring.

[0075] Next, let's look at... Figure 8AFurthermore, the inner pin socket (the socket closest to the inner end 208a) is again designated as the first socket, and the outer pin socket as the last socket. The concave concentric connector ring 208 includes a filament channel 256, which comprises a transverse segment 256a and a longitudinal segment 256b extending from the fourth pin socket, seventh pin socket, and tenth pin socket on each row 272, 274, and 276, respectively. The first pin socket 270 leads to the different filament channels 257 only through the transverse portion. It will be noted again that for each consecutive filament channel, the transverse segment is shortened, and thus the longitudinal portion 256b of the filament channel is separated by a non-conductive sleeve material 268.

[0076] Next, let's look at... Figure 9A The concave concentric connector ring 206 also includes four filament channels for each row of pin sockets, each filament channel extending from the second pin socket 286, the fifth pin socket 288, the eighth pin socket 290, and the eleventh pin socket 292, respectively. Corresponding to and adjacent to the concave concentric connector ring 206, the concave back shell 236 includes filament channels located in each row of pin sockets extending from the second concave back shell pin socket 294, the fifth concave back shell pin socket 294, the eighth concave back shell pin socket 294, and the eleventh concave back shell pin socket 200, respectively.

[0077] See now Figure 10A The concave concentric connector ring 204 also includes four filament channels for each row of pin sockets, each filament channel extending from the third pin socket 302, the sixth pin socket 304, the ninth pin socket 306, and the twelfth pin socket 308, respectively. Corresponding to and adjacent to the concave concentric connector ring 204 is a concave back shell 238, which includes filament channels in each row of concave back shell pin sockets extending from the third concave back shell pin socket 310, the sixth concave back shell pin socket 312, the ninth concave back shell pin socket 314, and the twelfth concave back shell pin socket 316.

[0078] Therefore, and importantly, while numbers and geometric patterns bring a high degree of expected understandability and predictability to the components (and thus their manufacture and use), it should be understood that any of a variety of alternative geometries can be conceived. A fundamental feature is the use of opposing tapered backshell surfaces at each end of the connector, connected by multiple layers of concentric nested sleeves and rings to provide multiple electrical connections from opposite ends along a continuous electrical path. The layers required to achieve continuity are determined by the number of pins and pin sockets on each side of the connector and the available surface area for separating and distributing the filament channels. In pure practical terms, the number of pin sockets on the concave backshell should match the number on the convex backshell, as a difference in number would only mean an unnecessary additional hole on one of the connector backshell assemblies. Similarly, the precise hole sequence of the filament channels does not need to match on the concave and convex backshells. However, for ease of use, it makes little sense to differ the number and position of the filament channel terminals on the convex and concave ends from matching each connector half. However, the fundamental aspect is that the number of sockets used on each side of a set of filament channels at each layer of the back shell is precisely matched, and more importantly, each connector half includes a specific pin located on the back shell, which is connected via filament channels to a specific corresponding pin on the mating connector half.

[0079] The connection between the convex concentric sleeve and the corresponding convex back shell, and the connection between the concave concentric connector ring and the corresponding concave back shell, must be rigid. Conductive filaments disposed in the filament channels can serve this purpose independently, although rigidity increases significantly when bonded with high-conductivity colloidal epoxy resin disposed in channels 175 / 275 (in the convex and concave connector halves, respectively). During manufacturing, the filament channels on the back shell, sleeve, and ring are filled with epoxy resin until slightly below the level flush with the component surface, approximately 0.25-0.38 inches above / outside. At this point, the filaments are embedded and then peroxidized. This mates with the previously epoxy-oxidized and assembled back shell (before bonding time), or with one "concentric part" assembled at a time. The entire connector is then cured. In such embodiments, the back shell cannot be removed. In other embodiments, the connector may be designed with a detachable back shell. This back shell and concentric ring connection is the most challenging part of manufacturing and can be optimized to minimize the number of contacts or process steps during manufacturing.

[0080] Furthermore, the connection of the connector halves must be robust and precise, with indexing to ensure that the pins on the convex housing contact the appropriate pins on the inner side of the concave socket housing. This can be achieved by any of a plurality of indexing and locking guarantee devices, not shown in the embodiments, but known in the art.

[0081] Now go to Figure 11The cross-sectional side view shows a feedthrough electrical connection configuration for a convex connector half 100, which has multiple flexible PCBs 300 terminating in pin sockets 162. The terminations are located at sockets in a multi-layer convex back shell assembly 100b connected to a corresponding multi-layer concentric sleeve assembly 100a. When flexible PCBs are used instead of conventional wires, the connector employs a manifold construction and is used in conjunction with a locking mechanism or retaining clip 352, and the wire retainer is modified or eliminated accordingly.

[0082] Figure 12 The same convex connector half-piece structure 100 is shown here for terminating conventional insulated wires 354, which terminate at pin sockets 162 in a multi-layer back shell. In such an embodiment, the use of wire retainer 126 is advantageous and therefore preferred.

[0083] Figure 13 yes Figure 11 and Figure 12 The end view elevation of the structure shows a flexible PCB or wire disposed in a pin socket and secured by a replaceable retaining mechanism 356.

[0084] Figure 14 This is a detailed top perspective view showing the contact between the pins of the convex and concave elements and the conductive epoxy channels of the connector housing and concentric rings. Here, it can be seen that the filamentary channel 256 at the first layer 360 is in electrical contact with the conductive pins 154 / 254, which hold the convex concentric sleeve and concave concentric connector housing in their nested structure and provide a conductive path from the surface of the sleeve or connector housing to the corresponding pin in the other mating connector half. The conductive epoxy at the second or other layers 370 does not contact the conductors in the first layer. The contact between the pins and the conductive epoxy at those layers where contact is desired is located at the depth of the conductive epoxy, i.e., the surface area of ​​the epoxy contacting the pins.

[0085] In various embodiments, polyethylene is an advantageous insulating material and a preferred material for manufacturing connector components. The back cover acts as an insulator, thus eliminating the need for insulated wires.

[0086] In various embodiments, the conical back shell may include exposed conductive channels, and in other embodiments, they may include overmolded solid conductors. The latter embodiment presents manufacturing challenges, making exposed conductive epoxy and exposed channels a preferred approach; however, some applications may utilize overmolded structures.

[0087] The component is designed to be permanent. However, such a feature is not essential to the basis of the invention. However, manufacturing a durable, detachable connector is costly. Therefore, in various embodiments, if not uniquely so, the construction depends primarily on the construction of the conical back shell. Once the conical back shell is fitted during assembly, it does not need to be changed, but the design can be configured to include this capability.

[0088] When the two connector halves mate, a plurality of spaced continuous electrical paths across the connectors are created by inserting the convex shell 102 of the convex connector half 100 into the concave socket shell 202 of the concave connector half 200, and by aligning, rotating and locking to establish appropriate corresponding pin connections.

[0089] As can be seen from the above, in one basic aspect, the electrical connector of the present invention comprises: (a) a convex connector half, the convex connector half comprising: (i) a plurality of cylindrical concentric sleeves, each of the cylindrical concentric sleeves having a central axis, an inner end and an outer end, and a row of spaced-apart axially aligned pin holes, the cylindrical concentric sleeves being axially aligned and nested in layers to align the pin holes in the plurality of concentric sleeves; (ii) a plurality of conductive pins, one conductive pin being inserted into each of the plurality of pin holes; (iii) a plurality of convex back shells, the plurality of convex back shells having a central axis, a tapered portion having an inner end and a cylindrical portion having an outer end, the... The convex back shells are axially aligned and nested in layers, such that the inner end of each of the conical portions abuts the corresponding outer end of one of the cylindrical concentric sleeves. Each of the conical portions has a plurality of spaced-apart helically bent pin socket rows configured to helically distribute terminating conductors along the central axis. The pin sockets in all the convex back shells are aligned with each other. (iv) A cylindrical convex shell has a central axis axially disposed above the plurality of concentric sleeves. The convex back shells and the cylindrical concentric sleeves are configured to have a plurality of spaced-apart insulating channels containing conductive material. A conductive material electrically connects each of the pin sockets in the convex back shell to one of the conductive pins in the pin holes disposed in the cylindrical concentric sleeve; and (b) a concave connector half comprising: (i) a plurality of cylindrical concentric rings, each having a central axis, an inner end and an outer end, a row of spaced-apart axially aligned pin holes, the cylindrical concentric rings being axially aligned and nested in layers to align the pin holes in the plurality of concentric rings, and a plurality of conductive pins, one of which is inserted into the plurality of pin holes. Each of the plurality of concave concentric rings includes: an innermost concave receptacle housing configured to receive the convex receptacle housing in a locking connection manner such that the pins in the concave connector half are in electrical contact with the pins in the convex connector half; and (ii) a plurality of concave back shells having a central axis; a tapered portion having an inner end adjacent to a corresponding outer end of one of the cylindrical concentric rings; and a cylindrical portion having an outer end, the tapered portion having a plurality of spaced-apart helically bent pin receptacle rows configured to helically distribute terminating conductors along the central axis;The concave back shell and the cylindrical concentric ring are configured to have a plurality of spaced-apart insulating channels containing a conductive material, such that each of the pin receivers in the concave back shell is electrically connected to one of the conductive pins in the pin holes disposed in the cylindrical concentric ring.

[0090] In a more fundamental aspect, the electrical connector of the present invention is an assembly comprising: a concave connector half having a plurality of axially nested concave back shells, the concave back shells having tapered portions disposed around a central axis; and a plurality of parallel, helically curved, row-shaped pin sockets, the pin sockets being helically distributed around the central axis; a concave coupling structure configured to receive an insertion element in a convex connector half and having a plurality of conductive pins disposed in the concave coupling structure, the concave back shells and the concave coupling structure including an integral electrical path between one of the pin sockets and one of the conductive pins in each pin socket of the concave coupling structure; and a convex connector half having a plurality of axially nested convex back shells, the convex back shells including: an outer convex back shell having a tapered portion disposed around a central axis. The device comprises: a concave portion; and a plurality of parallel, spirally curved rows of pin sockets, the rows of pin sockets being spirally distributed around the central axis; a convex connection structure having a plurality of conductive pins disposed on a surface, the plurality of conductive pins being configured to be inserted into the concave connection structure to make the conductive pins in the convex connection structure electrically contact each other; the convex back shell and the convex connection structure including an integral electrical path between each of the pin sockets and the conductive pins in the convex connection structure; wherein when the convex connector half is inserted into the concave connection structure to make the conductive pins of each connector half electrically contact each other, each of the pin sockets in the convex back shell has a continuous electrical path to only one of the pin sockets on the concave back shell.

[0091] In its most basic aspect, the invention can be seen to include a socket and a plug configured for mating connection, the plug and the socket each including a conical back shell having a surface disposed around a central axis and a plurality of pin sockets helically disposed around the central axis on the surface of the conical back shell for terminating conductors.

[0092] The foregoing disclosure is sufficient to enable those skilled in the art to practice the invention and provides the best mode of practice currently contemplated by the inventors. While a full and complete disclosure of preferred embodiments of the invention is provided herein, it is not intended to limit the invention to the precise constructions, dimensional relationships, and operations shown and described. Various modifications, alternative constructions, alterations, and equivalents will readily conceive of and may be suitably employed by those skilled in the art without departing from the true spirit and scope of the invention. Such modifications may involve alternative materials, components, structural arrangements, dimensions, shapes, forms, functions, operational features, etc.

[0093] Therefore, the above description and illustrations should not be construed as limiting the scope of the invention, which is defined by the appended claims.

Claims

1. A multi-contact electrical connector assembly, comprising a concave receptacle and a convex plug configured for mating connection, the convex plug comprising: A convex shell, the convex shell having an inner end and an outer end, Multiple concentric convex sleeves, each having an inner end and an outer end, wherein the largest convex sleeve is inserted into a convex shell such that the outer ends of the multiple concentric convex sleeves are coplanarly aligned with each other and with the outer end of the convex shell. Multiple axially oriented nested convex conical back shells, each having an inner end electrically connected to the outer end of each of the multiple concentric nested sleeves and the outer end of the convex shell, and... The socket includes: A concave socket housing, the concave socket housing having an inner end and an outer end. Multiple concentric nested concave rings, each having an inner end and an outer end, are nested inside the concave socket housing such that the outer ends are coplanarly aligned with each other and with the outer ends of the concave socket housing. The feature is that each of the plurality of nested conical back shells with convex and concave axial orientations includes an outer conical back shell having an outer conical back shell surface disposed around a central axis, and a plurality of pin sockets helically disposed on the outer conical back shell surface in a parallel bending manner around the central axis to terminate conductors, thereby providing a plurality of electrical connections for the assembly from opposite ends in a continuous electrical path.

2. The multi-contact electrical connector assembly of claim 1, wherein, The pin sockets are arranged in a spirally curved parallel row.

3. The multi-contact electrical connector assembly of claim 2, wherein, The convex plug includes axially oriented nested cylindrical sleeves, each sleeve being connected to one of a plurality of convex conical back shells, the cylindrical sleeves having a surface that coincides with and abuts the convex back shell to which they are connected, and wherein the concave socket includes axially oriented nested cylindrical connector shell rings, each sleeve being connected to one of a plurality of concave conical back shells, the cylindrical connector shell rings having a surface that coincides with and abuts the concave back shell to which they are connected.

4. The multi-contact electrical connector assembly of claim 3, wherein, The cylindrical connector sleeve and the cylindrical connector shell ring each include a plurality of pin holes, and further include conductive pins disposed in each of the plurality of pin holes.

5. The multi-contact electrical connector assembly of claim 4, wherein, The pin sockets are arranged in evenly spaced, longitudinally oriented columns.

6. The multi-contact electrical connector assembly of claim 5, wherein, Each of the pin sockets is electrically contacted with one of the conductive pins via a continuous conductive filament channel disposed on a continuous surface of a pair of concave concave back shells and concave cylindrical connector rings connected to a pair of convex concave back shells and cylindrical sleeves.

7. The multi-contact electrical connector assembly of claim 6, wherein, The filament channel includes conductive filaments.

8. The multi-contact electrical connector assembly of claim 7, wherein, The conductive filaments are fixed in the filament channels by conductive epoxy resin.

9. The multi-contact electrical connector assembly of claim 6, wherein, The number of pin sockets is equal to the number of pin holes.

10. The multi-contact electrical connector assembly of claim 6, wherein, The filamentary channel extends through the continuous and adjacent surfaces of the single-layer connected convex conical back shell and convex cylindrical sleeve, as well as the concave conical back shell and cylindrical connecting shell.

11. A pin-type electrical connector, comprising: Convex connector half piece; as well as Concave connector half; The concave connector half has multiple axially nested concave back shells, each concave back shell having a tapered portion with an outer surface arranged around a central axis, and multiple parallel helically bent rows of pin sockets spirally distributed around the central axis on the outer surface. The concave connection structure is configured to receive an insertion element in the convex connector half and has multiple conductive pins disposed in the concave connection structure. The concave back shells and the concave connection structure include an integral electrical path between each of the pin sockets in the concave connection structure and one of the conductive pins. as well as The convex connector half has multiple axially nested convex back shells. The convex connector half includes: an outer convex back shell having a tapered portion with an outer surface arranged around a central axis; and a plurality of parallel helically bent rows of pin sockets spirally distributed around the central axis on the outer surface. A convex connection structure has a plurality of conductive pins disposed on the convex connection structure and configured to insert into the concave connection structure to make electrical contact between the conductive pins in the convex connection structure and the conductive pins in the concave connection structure. The convex back shells and the convex connection structure include an integral electrical path between each of the pin sockets and one of the conductive pins in the convex connection structure. When the convex connector half is inserted into the concave connection structure to make electrical contact between the conductive pins of each connector half, each pin socket in the convex back shell has a unique continuous electrical path to the pin socket on the concave back shell.

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