Miniaturized and light direct insertion type waterproof connector

Abstract

The invention discloses a miniaturized and light direct insertion type waterproof connector which comprises a plug and a square plate socket. The plug comprises a housing, a coupling nut, a spring, a steel ball, a stop ring, a snap spring, a crimping jack assembly and a bonding jack insulator assembly. The connecting nut and the shell are limited through the steel ball, the spring can be compressed by pressing the connecting nut, limiting of the steel ball is relieved, and rapid butt joint and locking of the plug and the socket are achieved. An F-shaped stop groove is formed in the shell and matched with the stop ring, and the spring can be prevented from resetting during pre-installation. The housing is provided with a three-key position, and the three-key position is matched with the three-key groove of the socket to prevent misplug. Through an innovative locking and mistake proofing structure and in combination with compact hole position arrangement, miniaturization and light weight of the connector are realized on the premise of ensuring an IP67 waterproof grade and reliable connection, and compared with a traditional J599 series connector, more contact bodies can be accommodated under the same shell size.

Description

Technical Field

[0001] This invention relates to the field of electrical connector technology, and specifically to a miniaturized, lightweight, direct-insertion waterproof connector. Background Technology

[0002] In modern industry, commercial aviation, aerospace, and marine fields, reliable connections between electrical equipment are crucial. Electrical connectors, as key interfaces for signal and power transmission within a system, directly impact the stability and reliability of the entire system. With technological advancements and the increasing integration and modularization of equipment, there is a pressing need for connectors that are miniaturized, lightweight, high-density, quick-connect / disconnect, and highly environmentally adaptable (e.g., waterproof and dustproof).

[0003] Traditional waterproof connectors, such as the widely used J599 series, while technologically mature and highly reliable, often result in a large size and weight due to their structural design. This makes them unsuitable for the space- and weight-sensitive needs of modern drones, portable devices, underwater equipment, and other low-altitude economic and high-end equipment sectors. Furthermore, the connection methods of traditional connectors are cumbersome and inefficient in confined spaces or situations requiring frequent plugging and unplugging.

[0004] To address the aforementioned issues, some through-hole connectors have emerged in the prior art, aiming to simplify operation. However, these solutions often suffer from the following shortcomings: Insufficient locking reliability: Simple snap-fit ​​or spring-loaded locking structures are prone to loosening under vibration and impact conditions, and cannot meet the requirements of high reliability scenarios.

[0005] Lack of error prevention and pre-installation functions: The product does not have an effective anti-misinsertion (error prevention) mechanism, or lacks the function of pre-fixing the connecting parts before docking, making it difficult to install in confined spaces with poor visibility or inconvenient operation.

[0006] Miniaturization versus high density: In the pursuit of miniaturization, the number of contacts (pins / sockets) is often sacrificed, resulting in reduced transmission capacity, or insufficient electrical insulation performance and mechanical strength at the same density.

[0007] Insufficient integration of waterproof sealing: The waterproof design may only target a single interface, lacking a comprehensive, multi-layered sealing solution from the front mating surface and side mounting surface to the rear cable outlet.

[0008] Therefore, there is an urgent need for an innovative connector design that can achieve miniaturization and lightweight design while comprehensively solving technical challenges such as fast and reliable locking, effective prevention of mis-mating, easy pre-installation, high-density contact, and comprehensive waterproof sealing. Summary of the Invention

[0009] The purpose of this invention is to overcome the shortcomings of the prior art and provide a miniaturized, lightweight, direct-insertion waterproof connector that is compact in structure, lightweight, fast and reliable in locking, has error prevention and pre-installation functions, high contact density and meets high standard waterproof requirements.

[0010] To achieve the above objectives, the present invention adopts the following technical solution: This invention provides a miniaturized, lightweight, direct-plug waterproof connector, which consists of a mating plug and a square socket.

[0011] The plug includes a housing, a connecting nut, a spring, a steel ball, a retaining ring, a snap ring, a crimping socket assembly, and an adhesive socket insulator assembly. The connecting nut forms a circumferential and axial limiting fit with the housing via at least one of the steel balls. Pressing the connecting nut compresses the spring axially, allowing the steel ball to move radially and releasing its restriction on the relative movement between the connecting nut and the housing.

[0012] The square-shaped socket includes a square-shaped housing, crimping pins, adhesive pin insulator assemblies, and necessary seals. The inner side of the mating end of the square-shaped housing has a ball groove that mates with the steel balls on the plug.

[0013] During the plug-socket mating process, first press the connecting nut on the plug. The spring is compressed, and the steel ball is released from its limiting position. After inserting the plug into the socket, the steel ball on the plug, driven by the spring's restoring force, engages with the steel ball groove on the socket's square housing. Simultaneously, the connecting nut, under the action of the spring, resets and presses the steel ball firmly into the steel ball groove, thus achieving quick and reliable single-press locking and unlocking. This locking mechanism has few parts and a compact structure, effectively reducing the axial length and overall volume of the connector.

[0014] In a preferred embodiment of the present invention, an F-shaped retaining groove is provided on the outer peripheral wall of the plug housing, and the retaining ring is fixed inside the housing and slides in engagement with the F-shaped retaining groove. When the connecting nut is pressed down, rotating it by a certain angle (e.g., 90°) causes the protruding part of the retaining ring to slide into the transverse part of the F-shaped retaining groove and be locked, thereby physically preventing the compressed spring from rebounding and keeping the connecting nut in the pressed state. This pre-installation fixing function allows the operator to fix the connecting nut before fully inserting the plug into the socket, and then perform precise alignment, greatly facilitating installation operations in complex environments.

[0015] In a preferred embodiment of the present invention, three convex keys (three-key positions) asymmetrically distributed along the circumference are provided on the outer cylindrical surface of the mating end of the plug housing. Correspondingly, three perfectly matching keyways are provided on the inner cylindrical surface of the interface of the square housing. This three-key anti-misfit insertion structure provides a unique mating angle, forcing correct circumferential alignment, effectively preventing pin bending, device short circuits, or signal corruption caused by misinsertion, thus improving the safety and reliability of the system. Compared with common single-key or double-key designs, the three-key structure provides higher anti-misfit coding capacity and reliability for the same diameter.

[0016] In a preferred embodiment of the present invention, a retaining ring groove is provided on the plug housing, and the retaining ring is installed in the groove. The retaining ring and the spring work together to limit the axial displacement of the connecting nut in the locked state, providing a firm axial limit for the connector, ensuring that no axial loosening occurs between the plug and the socket under dynamic loads such as vibration and impact, and guaranteeing continuous and stable electrical contact.

[0017] As a preferred embodiment of the present invention, the tail of the plug employs a double-sealing design. First, a sealing groove is provided at the tail, within which a first sealing ring, preferably an O-ring, made of an elastic material such as nitrile rubber, is installed, forming a first elastic seal. Second, a potting cavity is provided between the cable lead-out end and the housing, and this cavity is filled with potting compound such as epoxy resin, forming a second cured seal. This combined sealing method effectively prevents moisture, humidity, dust, etc., from entering the connector from the tail, meeting IP67 or even higher protection requirements.

[0018] In a preferred embodiment of the present invention, the square-shaped socket is fastened to the device panel or housing with screws through mounting holes on its square housing. A second sealing ring, which is an O-ring, is provided between the square housing and the device mounting surface to achieve a static seal at the interface between the socket and the device, preventing external media from seeping into the device through the installation gap, thereby achieving waterproofing between the socket and the device.

[0019] As a preferred embodiment of the present invention, the plug and / or the square socket are designed with standard mounting threads at the tail end, which can be flexibly matched with tail accessories of different structures according to the user's cable type and usage environment, thereby enhancing the product's versatility and environmental adaptability.

[0020] As a preferred embodiment of the present invention, the plug housing is preferably made of high-strength aluminum alloy material through precision machining. Aluminum alloy has excellent specific strength, which can significantly reduce the overall weight of the connector while ensuring the structural strength and rigidity of the housing, thus achieving a lightweight connector.

[0021] In a preferred embodiment of the present invention, the sockets in the crimping socket assembly are arranged in a compact circumferential array within the adhesive socket insulator assembly, and the crimping pins are arranged in a corresponding compact circumferential array within the adhesive pin insulator assembly. By refining the design of the dielectric strength, creepage distance, and clearance of the insulator, and optimizing the layout of the contacts, the maximum contact density is achieved within a limited space.

[0022] As a preferred embodiment of the present invention, the compact circumferential array arrangement allows the connector to accommodate more contacts than the maximum number of contacts for the standard product at the same housing mounting interface size as defined in the J599 series standard, provided that the housing mounting interface size is conformed to the J599 series standard.

[0023] Beneficial effects: Compared with the prior art, the beneficial effects of the present invention are as follows: This invention employs a press-type steel ball spring locking mechanism, enabling quick connection with a simple press, insert, and release action, providing both ease of operation and secure locking. The F-type stop groove and stop ring work together to temporarily lock the connecting nut before docking, freeing up both hands for precise alignment and reducing installation difficulty. A three-key asymmetric anti-misalignment structure ensures a unique correct docking angle, effectively preventing damage or malfunctions caused by incorrect insertion. The compact hole arrangement design allows for more contacts within the same interface size as the standard J599 series, enabling high-density wiring. A multi-layered protection system, including a docking interface sealing ring, a tail O-ring and potting compound, and a mounting surface sealing ring, meets IP67 waterproof requirements. The use of lightweight materials such as an aluminum alloy shell significantly reduces weight while maintaining strength, making it suitable for weight-sensitive applications such as aerospace.

[0024] The connector of this invention integrates the advantages of convenient operation, user-friendly installation, reliable error prevention, high density, full sealing, and lightweight, making it suitable for a variety of harsh environments. Attached Figure Description

[0025] Figure 1 This is a cross-sectional schematic diagram of the plug structure provided in an embodiment of the present invention; Figure 2 for Figure 1 A three-dimensional structural diagram of the plug shown; Figure 3 This is a cross-sectional schematic diagram of the square socket structure provided in an embodiment of the present invention; Figure 4 for Figure 3 The diagram shows the three-dimensional appearance structure of the square socket.

[0026] In the diagram: 11-Housing, 12-Connecting nut, 13-Steel ball, 14-Bonded socket insulator assembly, 15-Crimped socket assembly, 16-First sealing ring, 17-Spring, 18-Stop ring, 19-Snap ring, 21-Square housing, 22-Crimped pin, 23-Bonded pin insulator assembly, 24-Second sealing ring. Detailed Implementation

[0027] The embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0028] The following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. This application can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. It should be noted that, in the absence of conflict, the following embodiments and features in the embodiments can be combined with each other. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0029] It should be noted that, unless otherwise defined, the technical or scientific terms used in this invention should have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar words used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Words such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects.

[0030] Please see Figures 1 to 4 This invention provides a miniaturized, lightweight, direct-plug waterproof connector, which consists of two main structures: a detachable plug and a square socket. Together, they form a complete electrical connection system that allows for quick plugging and unplugging and provides high reliability and sealing.

[0031] Plug structure: like Figure 1 and Figure 2 As shown, the plug mainly includes a housing 11, a connecting nut 12, a spring 17, a steel ball 13, a retaining ring 18, a snap ring 19, a crimping socket assembly 15, an adhesive socket insulator assembly 14, and a first sealing ring 16.

[0032] The connecting nut 12 is fitted onto the outside of the housing 11, and its inner wall has an annular groove. A steel ball 13 is positioned between the hemispherical recess on the outer wall of the housing 11 and the annular groove on the inner wall of the connecting nut 12. Under the preload of the spring 17, a portion of the steel ball 13 engages with the groove of the connecting nut 12, thereby restricting the axial movement of the connecting nut 12 relative to the housing 11 and forming an initial limiting state. This limiting structure ensures the stability of the connecting nut's position in the non-operating state, preventing accidental slippage or detachment.

[0033] Pressing the connecting nut 12 compresses the spring 17 and allows the steel ball 13 to move radially to release the locking mechanism. Specifically, when the connecting nut 12 is pressed towards the socket, the spring 17 is compressed, the contact position between the groove on the inner wall of the connecting nut 12 and the steel ball 13 changes, and the steel ball 13 retracts radially towards the center of the housing, thereby releasing the axial constraint on the connecting nut 12. This is the key action to achieve quick insertion and removal; a simple press releases the mechanical lock, preparing for insertion or removal.

[0034] The housing 11 is an aluminum alloy housing, for example, precision machined from 7075 high-strength aluminum alloy, with anodized surface treatment to improve corrosion resistance. Using an aluminum alloy housing significantly reduces the overall weight of the connector while ensuring structural strength and rigidity, which is key to achieving the goal of "lightweight design".

[0035] The outer peripheral wall of the housing 11 is provided with an F-shaped retaining groove, which consists of an axial groove and a circumferential (transverse) groove communicating with it, and is shaped like the letter "F". The retaining ring 18 is fixed inside the housing 11 and slides in engagement with the F-shaped retaining groove. The retaining ring 18 is an elastic retaining ring with an inner protrusion, which is embedded in the F-shaped retaining groove. The F-shaped retaining groove and the retaining ring form a unique mechanical logic structure, providing a physical basis for realizing the pre-installation function.

[0036] When the connecting nut 12 is pressed and then rotated, the retaining ring 18 can engage with the transverse portion of the F-shaped retaining groove, thereby locking the connecting nut 12 in the position compressing the spring 17. During operation, first press the connecting nut 12, then rotate it approximately 90 degrees. The inner protrusion of the retaining ring 18 slides from the axial portion of the F-shaped groove into the transverse portion and is locked in place, physically preventing the connecting nut 12 from springing back under spring force. This pre-installation positioning function is highly practical, allowing users to pre-fix the connecting nut in the unlocked state in confined spaces or when visibility is poor, freeing their hands to accurately align the plug and socket, greatly improving installation convenience and efficiency.

[0037] In this embodiment of the invention, the outer wall of the mating end of the housing 11 is provided with three asymmetrically distributed protruding keys. The width and / or circumferential spacing of these three protruding keys are designed to be different from each other. This asymmetrical distribution ensures uniqueness in the circumferential direction.

[0038] The housing 11 has an annular retaining ring groove, and the retaining ring 19 is installed in the retaining ring groove to axially limit the connecting nut 12. Specifically, the retaining ring 19 is a standard hole elastic retaining ring, which restricts the final movement position of the connecting nut 12 towards the end of the plug. The retaining ring and the spring work together to provide a firm axial limit for the connecting nut in the locked state, ensuring that the connection will not loosen in the vibrating and impact environment, and ensuring the long-term stability of the electrical contact.

[0039] The plug's tail end is also provided with a sealing groove and a potting cavity. Specifically, a first sealing ring 16 is installed in the sealing groove; exemplarily, the first sealing ring is an O-ring made of elastic materials such as nitrile rubber. A potting cavity is provided between the cable lead-out end and the housing 11, and the potting cavity is filled with potting compound. The O-ring is installed in the groove before the tail thread, forming a first elastic seal. After the cable is assembled, epoxy resin potting compound is used to fill all gaps between the cable and the housing, forming a second cured seal. This dual tail sealing design, combining an O-ring elastic seal and a potting compound cured seal, effectively prevents moisture, humidity, and dust from entering the connector from the tail end, meeting IP67 or even higher protection requirements.

[0040] The sockets in the crimp socket assembly 15 are arranged in a compact circular array within the adhesive socket insulator assembly 14. The sockets are made of gold-plated copper alloy, and the insulator is made of high-performance PPS (polyphenylene sulfide) material. Through precise calculations and mold design, the maximum number of sockets within a limited diameter is achieved while ensuring that the specified electrical clearance and creepage distance are met between every two sockets. The compact circular array arrangement is the core technology for achieving miniaturization while maintaining high density, directly increasing the number of signal transmission channels per unit cross-sectional area.

[0041] Square socket structure: like Figure 3 and Figure 4 As shown, the square socket includes a square housing 21, crimped pins 22, and adhesive pin insulator assembly 23.

[0042] The inner side of the mating end of the square housing 21 is provided with an annular steel ball groove that mates with the steel ball 13. When the plug is inserted into place, the steel ball 13 is precisely aligned with this steel ball groove. The steel ball groove and the steel ball of the plug together form the mating surface of the locking mechanism, which can achieve reliable mechanical locking.

[0043] The inner wall of the mating end of the square housing 21 is provided with three keyways, the shape and position of which precisely match the three raised keys on the plug housing. The three keyways and the three raised keys work together to form an anti-misinsertion function. The plug can only be inserted when all three are perfectly aligned, fundamentally eliminating misinsertion caused by incorrect circumferential direction and protecting equipment safety.

[0044] The square housing 21 has mounting holes, typically four through holes located at the four corners of the square. This allows for the secure fixing of the socket to the device panel or structural components using screws. A second sealing ring 24, typically a rubber O-ring or silicone gasket, is placed between the square housing 21 and the device mounting surface. This sealing ring provides a static seal between the socket and the device housing, preventing external liquids from seeping into the device through the mounting gaps.

[0045] The crimping pins 22 are arranged in a corresponding compact circumferential array within the adhesive pin insulator assembly 23. Their arrangement is completely consistent with the sockets inside the plug, ensuring one-to-one electrical connection. Corresponding to the compact arrangement on the plug side, they together achieve high-density contact.

[0046] In this embodiment of the invention, optionally, the plug and / or the square socket have standard mounting threads at their tails for connecting tail accessories. Users can flexibly select straight or curved protective flexible conduit connectors or cable clamps, etc., according to the cable type (e.g., shielded cable, armored cable) and the usage environment. This modular tail design enhances the product's versatility and environmental adaptability.

[0047] Integration process and verification: Locking: Press the plug connecting nut 12 (or use the pre-installation function to lock it first) to retract the steel ball 13. Align the three protruding keys of the plug with the three key slots of the socket and insert it. When the plug reaches the bottom position, the steel ball 13 aligns with the ball groove. Loosen (or release) the connecting nut 12, the spring 17 returns to its original position, pushing the connecting nut 12 back into place, aligning its inner wall groove with the steel ball 13 and pressing it radially out, locking it into the ball groove of the socket, completing a quick and reliable mechanical locking. At the same time, the sealing ring at the mating interface is compressed, forming a seal.

[0048] High-Density Verification: The external mounting interface (square size, mating thread, three-button structure) of the connector provided in this embodiment of the invention is designed to be fully compatible with the No. 20 housing interface in the J 599 series standards. Under the same standard interface size constraint, thanks to the compact circumferential array arrangement, the connector of this embodiment of the invention successfully integrates 19 pairs (38 cores) of contacts. Consulting the J599 standard, it is known that the typical maximum contact configuration for a No. 20 housing is 15 pairs (30 cores). This indicates that the aforementioned compact circumferential array arrangement allows the connector of this embodiment of the invention to accommodate more contacts than the maximum number of contacts for standard products under this interface size defined in the J 599 series standards, while conforming to the same housing mounting interface size. Thus, without changing the external mounting boundary, a significant increase in the number of transmission channels is achieved, resolving the contradiction between miniaturization and high density.

[0049] In summary, the miniaturized and lightweight direct-insertion waterproof connector provided by the embodiments of the present invention achieves comprehensive performance in terms of extremely simple operation, user-friendly installation, reliable error prevention, high space utilization, comprehensive sealing, and light weight through the synergistic effect of various components. It is especially suitable for widespread application in fields with extreme requirements for performance, space, and weight, such as aerospace, marine vessels, and high-end industrial equipment.

[0050] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, various modifications and variations can be made to the embodiments of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A miniaturized, lightweight, direct-insertion waterproof connector, characterized in that, Includes plugs and square sockets; The plug includes a housing (11), a connecting nut (12), a spring (17), a steel ball (13), a retaining ring (18), a snap ring (19), a crimping socket assembly (15), and an adhesive socket insulator assembly (14); the connecting nut (12) forms an axial limit with the housing (11) through the steel ball (13), pressing the connecting nut (12) can compress the spring (17) and allow the steel ball (13) to move radially to release the limit; The square socket includes a square housing (21), a crimping pin (22), and an adhesive pin insulator assembly (23); the inner side of the mating end of the square housing (21) is provided with a steel ball groove that mates with the steel ball (13); When the plug is connected to the square socket, the steel ball (13) falls into the steel ball groove. After the connecting nut (12) is loosened, the spring (17) resets and drives the connecting nut (12) to press the steel ball (13) into the steel ball groove, thereby achieving mechanical locking.

2. The miniaturized, lightweight, direct-insertion waterproof connector according to claim 1, characterized in that, The outer peripheral wall of the housing (11) is provided with an F-shaped stop groove. The stop ring (18) is fixed inside the housing (11) and slides in cooperation with the F-shaped stop groove. When the connecting nut (12) is pressed and rotated, the stop ring (18) can be inserted into the transverse part of the F-shaped stop groove, thereby locking the connecting nut (12) in the position of compressing the spring (17).

3. The miniaturized, lightweight, direct-insertion waterproof connector according to claim 1 or 2, characterized in that, The outer wall of the mating end of the housing (11) is provided with three asymmetrically distributed protruding keys, and the inner wall of the mating end of the square housing is provided with three keyways. The protruding keys and the keyways cooperate to prevent incorrect insertion.

4. The miniaturized, lightweight, direct-insertion waterproof connector according to claim 1, characterized in that, The housing (11) is provided with a retaining ring groove, and the retaining ring (19) is installed in the retaining ring groove to axially limit the connecting nut (12).

5. The miniaturized, lightweight, direct-insertion waterproof connector according to claim 1, characterized in that, The plug has a sealing groove and a potting cavity at its tail. The sealing groove contains a first sealing ring (16), and the potting cavity is filled with potting adhesive.

6. The miniaturized, lightweight, direct-insertion waterproof connector according to claim 1, characterized in that, The square socket is fixed to the external device by screws, and a second sealing ring (24) is provided between the square housing and the device mounting surface to achieve waterproofing between the socket and the device.

7. The miniaturized, lightweight, direct-insertion waterproof connector according to claim 1, characterized in that, The plug and / or the square socket are provided with mounting threads at the tail for connecting tail accessories.

8. The miniaturized, lightweight, direct-insertion waterproof connector according to claim 1, characterized in that, The housing (11) is made of aluminum alloy.

9. The miniaturized, lightweight, direct-insertion waterproof connector according to claim 1, characterized in that, The sockets in the crimping socket assembly (15) are arranged in a compact circumferential array within the adhesive socket insulator assembly (14), and the crimping pins (22) are arranged in a corresponding compact circumferential array within the adhesive pin insulator assembly (23).

10. The miniaturized, lightweight, direct-insertion waterproof connector according to claim 9, characterized in that, The compact circumferential array arrangement allows the connector to accommodate more contacts than the maximum number of contacts for the standard product at that interface size as defined in the J599 series standards, provided that the same housing mounting interface size is conformed to the J599 series standards.

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