Insulation accessory for electrical connectors

Abstract

A contact assembly to be fitted in a connector body comprises a front sleeve configured to mate with a corresponding front sleeve of a mating contact, a metal contact contained partially within the front sleeve and coupled to a wire; and a back sleeve holding the metal contact mechanically and coupled with the front sleeve in a partially overlapping manner. The metal contact is a socket or a pin. The front sleeve and the back sleeve are made from a dielectric material.

Description

BACKGROUND

[0001] Connector systems provide electrical interconnection between different devices allowing exchange of data, control information, power, and other electrical signals. Depending on implementation, size, shape, pin numbers, and other characteristics of the connectors may vary. Some connector systems are for special environments such as hazardous environments, and may therefore include special sealing properties. Others may be shielded against electromagnetic interference. Pin numbers and sizes may also differ depending on the implementation such as expected current levels, number of signals to be exchanged, etc. Electrical connectors are specified according to their performance (i.e., operating voltage or maximum current) or shape / layout. Clearance and creepage distances defined by a connector's geometric layout determine the connector's operating voltage and maximum current ratings.SUMMARY

[0002] The present disclosure generally describes an insulation accessory for electrical connectors to increase clearance and creepage distances while maintaining a connector shell size and configuration.

[0003] According to an embodiment, a contact assembly to be fitted in a connector body includes a front sleeve configured to mate with a corresponding front sleeve of a mating contact; a metal contact contained partially within the front sleeve and coupled to a wire; and a back sleeve holding the metal contact mechanically and coupled with the front sleeve in a partially overlapping manner. The metal contact is a socket or a pin, and the front sleeve and the back sleeve are made from a dielectric material. The front sleeve and the back sleeve may couple mechanically through one of a screw-on and a clip-on coupling mechanism.

[0004] According to another embodiment, a connector includes a conductive shell; an insulator body located inside the conductive shell and comprising one or more contact chambers; and one or more contact assemblies arranged in the one or more contact chambers. Each contact assembly includes a front sleeve configured to mate with a corresponding front sleeve of a mating contact; a metal contact contained partially within the front sleeve and coupled to a wire; and a back sleeve holding the metal contact mechanically and coupled with the front sleeve in a partially overlapping manner. The metal contact is a socket or a pin, and the front sleeve and the back sleeve are made from a dielectric material.

[0005] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The foregoing and other features of this disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are, therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings, in which: FIG. 1 illustrates the structure of a conventional multi-contact connector; FIG. 2 illustrates side cross-section views of pin and socket insulator accessories individually and with components for contact assembly; FIG. 3A through 3C illustrate perspective and side views of a socket plug connector and a corresponding pin receptacle connector with and without the contact assemblies incorporating an example insulator accessory in coupled and uncoupled configurations; FIG. 4A illustrates an assembly drawing of a pin contact assembly and a socket contact assembly including an example insulator accessory in a screw-on configuration; FIG. 4B illustrates an assembly drawing of a pin contact assembly and a socket contact assembly including an example insulator accessory in a clip-on configuration; FIG. 4C illustrates an assembly drawing of a pin contact assembly and a socket contact assembly including an example insulator accessory in a clip-on configuration with a clip for integration; FIG. 5 illustrates cross-sectional views of a connector with insulator accessory contact assemblies in mated and unmated configurations; and FIG. 6A and 6B illustrate assembly processes for screw-on and clip-on configurations of a contact assembly with insulator accessory. DETAILED DESCRIPTION

[0007] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. The aspects of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.

[0008] This disclosure is generally drawn, inter alia, to an insulation accessory for electrical connectors to increase clearance and creepage distances, thereby an operating voltage and maximum current rating of a connector, while maintaining a connector shell size and configuration.

[0009] FIG. 1 illustrates the structure of a conventional multi-contact connector.

[0010] Diagram 100 shows the shell 102 of a conventional connector, pin contacts 106, and a common insulator 104 that houses the pin contacts (or socket contacts in a corresponding matching connector). As mentioned herein, electrical connectors are specified according to their performance (i.e., operating voltage or maximum current) or shape / layout. Clearance and creepage distances defined by a connector's geometric layout determine the connector's operating voltage and maximum current ratings. For example, direct and indirect (clearance and creepage) distances provided by the common insulator 104 between the shell 102 and individual pins or between individual pins define operating voltage and maximum current limitations. Thus, to increase operating voltage and maximum current parameters of a connector, the common insulator, and thereby the connector size, may have to be increased resulting in additional cost and size-related challenges (e.g., users may not have spacing for larger size connectors in their implementations).

[0011] FIG. 2 illustrates side cross-section views of pin and socket insulator accessories individually and with components for contact assembly.

[0012] Diagram 200 shows a conventional socket contact 202 and pin contact 204. A corresponding socket sleeve assembly 206 and a pin sleeve assembly 208 according to examples are also shown. Diagram 200 further shows assembly drawings of a socket contact assembly according to examples with its individual components, socket contact front sleeve 212, socket 220, back sleeve 216, and single wire seal 218; and a pin contact assembly according to examples with its individual components, pin contact front sleeve 214, pin 222, back sleeve 216, and single wire seal 218. In some examples, the back sleeve 216 may also include an O-ring seal for environmental sealing.

[0013] A standardized connector may have a conductive shell (e.g., aluminum housing) and an insulator (e.g., rubber insulating body). The contacts may be mounted by pressing them into the insulator from behind. The insulating body may have an undercut in which the contact is fixed. Government or industry standards may define different contact sizes, shell sizes and / or contact layouts. As mentioned herein, the connector's operating voltage and maximum current parameters are defined by the clearance and creepage distances determined by the connector's shell, body, contact sizes and layout. Thus, increasing operating voltage and maximum current values may be challenging, if not impossible, while maintaining the connector size.

[0014] An insulator accessory according to examples may provide pin and socket contact assemblies that may be incorporated into a connector fitting into same size contact chambers (common insulator) and increase clearance and creepage distances while maintaining connector size and layout. Bigger metal contacts (pin / socket) may be replaced by smaller contacts with a front sleeve and a back sleeve forming the contact assembly. Shape and size of the insulator accessory contact assembly (with the sleeves) may be similar or same as the contacts to fit into an existing contact chamber in a connector. A "labyrinth" mating configuration of the front and back sleeves (overlap) may provide larger clearance / creepage distances, thus increasing the connector's operating voltage and maximum current limitations while maintaining a connector size. In some examples, material for the plastic sleeve(s) may be selected for higher dielectric constant compared to typically rubber material used in contacts.

[0015] FIG. 3A through 3C illustrate perspective and side views of a socket plug connector and a corresponding pin receptacle connector with and without the contact assemblies incorporating an example insulator accessory in coupled and uncoupled configurations.

[0016] Diagram 300A shows a pair of example socket plug (302) and pin receptacle (304) connectors with contact layouts (306 and 308, respectively) according to VG95234 (German military standard) or MIL-STD-5015 (US military standard) 32-1 arrangement. Diagram 300A also shows the same connectors (312 and 314) with pin and socket contacts replaced by insulator accessory contact assemblies (316, 318) utilizing sleeve arrangement. In the illustrated examples, the pin receptacle 304 is arranged to be affixed to an enclosure while the socket plug 302 is arranged to be affixed to a loose cable. Diagram 300B shows a perspective view of the pin receptable 304 and the socket plug 302 in coupled (mated) configuration.

[0017] Diagram 300C shows side views of a receptacle connector 322 and a plug connector 324. The receptacle connector 322 and the plug connector 324 may be pin or socket type, and in the shown example, they are both arranged to be affixed to loose cables. Diagram 300C shows the receptacle connector 322 and the plug connector 324 in coupled and uncoupled configurations. The coupling is through a bayonet style coupling mechanism.

[0018] In the illustrated example connectors, the standard specified 50 VAC to 75 VAC operating voltage range may be increased up to 1000 VAC range without changing connector size or layout configuration. The example connectors and contacts shown herein are for illustration purposes, and do not pose a limit on embodiments. A sleeve-based insulation accessory contact assembly may be utilized in any practical connector configuration, size, and type. For example, sleeve-based insulation accessory contact assemblies may be used in round, square, rectangular, triangular, or any other shape connectors. In addition to size and layout variations, connectors housing such contact assemblies may be coupled through bayonet, latch, lever, push-pull, screw, snap-in, or similar mechanisms, and be made of any suitable connector shell and body materials.

[0019] FIG. 4A illustrates an assembly drawing of a pin contact assembly and a socket contact assembly including an example insulator accessory in a screw-on configuration, arranged in accordance with at least some embodiments described herein.

[0020] Diagram 400A shows assembled and unassembled versions of a socket contact assembly 402 with sleeve-based insulator accessory. The socket contact assembly 402 may include a socket contact front sleeve 404, socket 406, back sleeve 408, and single wire seal 410. The single wire seal 410 may be used to secure a wire into the back sleeve 408 (thereby the socket contact assembly 402), while the back sleeve 408 may be coupled with the socket contact front sleeve 404 through a threaded mechanism ("screw-on" configuration).

[0021] Diagram 400A also shows assembled and unassembled versions of a pin contact assembly 422 with sleeve-based insulator accessory. The pin contact assembly 422 may include a pin contact front sleeve 424, pin 426, back sleeve 428, and single wire seal 430. As in the socket contact assembly, the single wire seal 430 may be used to secure a wire into the back sleeve 428 (thereby the pin contact assembly 422), while the back sleeve 428 may be coupled with the pin contact front sleeve 424 through a threaded mechanism ("screw-on" configuration).

[0022] In some examples, the back sleeves 408 and 428 for the socket and pin contact assemblies, as well as the single wire seals 410 and 430 may be the same components. Thus, pin and socket contact assemblies may be formed using two distinct components (front sleeves and pin / socket) and two common components reducing overall cost and complexity of the contact assemblies (thereby the connectors), making it easier to manufacture them, and increasing reliability through reduced part-count.

[0023] FIG. 4B illustrates an assembly drawing of a pin contact assembly and a socket contact assembly including an example insulator accessory in a clip-on configuration, arranged in accordance with at least some embodiments described herein.

[0024] Diagram 400B shows assembled and unassembled versions of a socket contact assembly 432 with sleeve-based insulator accessory. The socket contact assembly 432 may include a socket contact front sleeve 434, back sleeve 436, and socket 438. The back sleeve 436 may be coupled with the socket contact front sleeve 434 through a clip-on type locking mechanism ("clip-on" configuration).

[0025] Diagram 400B also shows assembled and unassembled versions of a pin contact assembly 442 with sleeve-based insulator accessory. The pin contact assembly 442 may include a pin contact front sleeve 444, back sleeve 446, and pin 448. As with the socket contact assembly, the back sleeve 446 may be coupled with the pin contact front sleeve 444 through a clip-on type locking mechanism ("clip-on" configuration).

[0026] In some examples, the back sleeves 436 and 446 for the socket and pin contact assemblies may be the same component. Thus, pin and socket contact assemblies may be formed using two distinct components (front sleeves and pin / socket) and a common component (back sleeve) reducing overall cost and complexity of the contact assemblies (thereby the connectors), making it easier to manufacture them, and increasing reliability through reduced part-count.

[0027] FIG. 4C illustrates an assembly drawing of a pin contact assembly and a socket contact assembly including an example insulator accessory in a clip-on configuration with a clip for integration, arranged in accordance with at least some embodiments described herein.

[0028] Diagram 400C shows assembled and unassembled versions of a pin contact assembly 452 with sleeve-based insulator accessory. The pin contact assembly 452 may include a pin contact sleeve 454, pin 458, and a clip 456. The pin 458 may be inserted into the pin contact sleeve 454 and held in place through the clip 456 ("clip-on" configuration using a clip). The clip 456 may be metal, plastic, or similar suitable material.

[0029] Diagram 400C also shows assembled and unassembled versions of a socket contact assembly 462 with sleeve-based insulator accessory. The socket contact assembly 462 may include a socket contact sleeve 464, socket 468, and a clip 466. The socket 468 may be inserted into the socket contact sleeve 464 and held in place through the clip 466 ("clip-on" configuration using a clip). The clip 466 may be metal, plastic, or similar suitable material.

[0030] The screw-on type and the clip-on type socket and pin contact assemblies utilizing sleeve-based insulation accessories may be manufactured through machining or injection molding. The screw-on type may be easier for machining due to the rotatory symmetry (turning). However, injection molding may also be used for manufacturing higher quantities. The clip-on type may be easier to manufacture using injection molding compared to machining.

[0031] FIG. 5 illustrates cross-sectional views of a connector with insulator accessory contact assemblies in mated and unmated configurations, arranged in accordance with at least some embodiments described herein.

[0032] Diagram 500 shows cross-sectional view of a pair of mated connectors 510 with sleeve-based contact assemblies and unmated connectors 520, 530. As shown in the mated connectors 510, a conductive connector shell 512 contains an insulator connector body 516 and within contact spaces the contact assemblies 518 and contacts 514 (pin / socket). As discussed herein, the labyrinth overlap configuration of the contact assemblies (front and back sleeves) increase clearance and creepage distances allowing higher operating voltage and maximum current parameters for the connectors. Despite the increased clearance and creepage distances, the contact assemblies according to examples fit into exiting contact chambers within the connectors allowing connector size and layout to remain the same (e.g., a standardized size and layout). The pair of receptacle / plug connectors' mating does not change either.

[0033] FIG. 6A and 6B illustrate assembly processes for screw-on and clip-on configurations of a contact assembly with insulator accessory, arranged in accordance with at least some embodiments described herein.

[0034] The assembly process of "screw-on" type contact assembly shown in diagram 600A may begin with crimping of a wire to the contact (pin or socket), which may be performed in advance. Thus, a production line for such contact assemblies may receive pre-crimped contacts. Next, the back sleeve may be pulled over the pre-crimped contact until a slotted portion of the internal surface of the back sleeve snaps into a contact groove and secures the contact inside the back sleeve. Finally, the front sleeve may be screwed onto the back sleeve through their matching threaded surfaces completing the contact assembly. A pressure created by the screw-on mechanism on the back sleeve may further secure the locking of the contact inside the back sleeve by pushing the slotted portion (latch) of the back sleeve into the contact groove.

[0035] The assembly process of "clip-on" type contact assembly shown in diagram 600B may begin with crimping of a wire to the contact (pin or socket), which may be performed in advance. Thus, a production line for such contact assemblies may receive pre-crimped contacts. Next, the back sleeve may be pulled over the pre-crimped contact until a slotted portion of the internal surface of the back sleeve snaps into a contact groove and secures the contact inside the back sleeve. Finally, the front sleeve may be clipped (or snapped) onto the back sleeve through the extrusions with hooks of the front and back sleeves extending over each other and matching recess surfaces completing the contact assembly. A pressure created by the clip-on mechanism on the back sleeve may further secure the locking of the contact inside the back sleeve by pushing the slotted portion (latch) of the back sleeve into the contact groove. While the screw-on version may be assembled orientated with the latching hooks in the right groove, the clip-on version may be assembled by pushing in axial direction until latch hooks snap into recess.

[0036] The present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as illustrations of various aspects. Many modifications and variations can be made without departing from its spirit and scope. Functionally equivalent methods and apparatuses within the scope of the disclosure, in addition to those enumerated herein, are possible from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0037] The herein described subject matter sometimes illustrates different components contained within, or connected with, different other components. Such depicted architectures are merely examples, and in fact, many other architectures may be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively "associated" such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality may be seen as "associated with" each other such that the desired functionality is achieved, irrespective of architectures or intermediate components. Likewise, any two components so associated may also be viewed as being "operably connected", or "operably coupled", to each other to achieve the desired functionality, and any two components capable of being so associated may also be viewed as being "operably couplable", to each other to achieve the desired functionality. Specific examples of operably couplable include but are not limited to physically connectable and / or physically interacting components and / or wirelessly interactable and / or wirelessly interacting components and / or logically interacting and / or logically interactable components.

[0038] With respect to the use of substantially any plural and / or singular terms herein, those having skill in the art can translate from the plural to the singular and / or from the singular to the plural as is appropriate to the context and / or application. The various singular / plural permutations may be expressly set forth herein for sake of clarity.

[0039] In general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation, no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and / or "an" should be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, means at least two recitations, or two or more recitations).

[0040] Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general, such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and / or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

[0041] For any and all purposes, such as in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as "up to," "at least," "greater than," "less than," and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, a range includes each individual member. Thus, for example, a group having 1-3 cells refers to groups having 1, 2, or 3 cells. Similarly, a group having 1-5 cells refers to groups having 1, 2, 3, 4, or 5 cells, and so forth.

Examples

Embodiment Construction

[0007]In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. The aspects of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.

[0008]This disclosure is generally drawn, inter alia, to an insulation accessory for electrical connectors to increase clearance and creepage distances, thereby an operating voltage and maximum current rating of a connector, while maintaining...

BACKGROUND

[0001] Connector systems provide electrical interconnection between different devices allowing exchange of data, control information, power, and other electrical signals. Depending on implementation, size, shape, pin numbers, and other characteristics of the connectors may vary. Some connector systems are for special environments such as hazardous environments, and may therefore include special sealing properties. Others may be shielded against electromagnetic interference. Pin numbers and sizes may also differ depending on the implementation such as expected current levels, number of signals to be exchanged, etc. Electrical connectors are specified according to their performance (i.e., operating voltage or maximum current) or shape / layout. Clearance and creepage distances defined by a connector's geometric layout determine the connector's operating voltage and maximum current ratings.SUMMARY

[0002] The present disclosure generally describes an insulation accessory for electrical connectors to increase clearance and creepage distances while maintaining a connector shell size and configuration.

[0003] According to an embodiment, a contact assembly to be fitted in a connector body includes a front sleeve configured to mate with a corresponding front sleeve of a mating contact; a metal contact contained partially within the front sleeve and coupled to a wire; and a back sleeve holding the metal contact mechanically and coupled with the front sleeve in a partially overlapping manner. The metal contact is a socket or a pin, and the front sleeve and the back sleeve are made from a dielectric material. The front sleeve and the back sleeve may couple mechanically through one of a screw-on and a clip-on coupling mechanism.

[0004] According to another embodiment, a connector includes a conductive shell; an insulator body located inside the conductive shell and comprising one or more contact chambers; and one or more contact assemblies arranged in the one or more contact chambers. Each contact assembly includes a front sleeve configured to mate with a corresponding front sleeve of a mating contact; a metal contact contained partially within the front sleeve and coupled to a wire; and a back sleeve holding the metal contact mechanically and coupled with the front sleeve in a partially overlapping manner. The metal contact is a socket or a pin, and the front sleeve and the back sleeve are made from a dielectric material.

[0005] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The foregoing and other features of this disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are, therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings, in which: FIG. 1 illustrates the structure of a conventional multi-contact connector; FIG. 2 illustrates side cross-section views of pin and socket insulator accessories individually and with components for contact assembly; FIG. 3A through 3C illustrate perspective and side views of a socket plug connector and a corresponding pin receptacle connector with and without the contact assemblies incorporating an example insulator accessory in coupled and uncoupled configurations; FIG. 4A illustrates an assembly drawing of a pin contact assembly and a socket contact assembly including an example insulator accessory in a screw-on configuration; FIG. 4B illustrates an assembly drawing of a pin contact assembly and a socket contact assembly including an example insulator accessory in a clip-on configuration; FIG. 4C illustrates an assembly drawing of a pin contact assembly and a socket contact assembly including an example insulator accessory in a clip-on configuration with a clip for integration; FIG. 5 illustrates cross-sectional views of a connector with insulator accessory contact assemblies in mated and unmated configurations; and FIG. 6A and 6B illustrate assembly processes for screw-on and clip-on configurations of a contact assembly with insulator accessory. DETAILED DESCRIPTION

[0007] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. The aspects of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.

[0008] This disclosure is generally drawn, inter alia, to an insulation accessory for electrical connectors to increase clearance and creepage distances, thereby an operating voltage and maximum current rating of a connector, while maintaining a connector shell size and configuration.

[0009] FIG. 1 illustrates the structure of a conventional multi-contact connector.

[0010] Diagram 100 shows the shell 102 of a conventional connector, pin contacts 106, and a common insulator 104 that houses the pin contacts (or socket contacts in a corresponding matching connector). As mentioned herein, electrical connectors are specified according to their performance (i.e., operating voltage or maximum current) or shape / layout. Clearance and creepage distances defined by a connector's geometric layout determine the connector's operating voltage and maximum current ratings. For example, direct and indirect (clearance and creepage) distances provided by the common insulator 104 between the shell 102 and individual pins or between individual pins define operating voltage and maximum current limitations. Thus, to increase operating voltage and maximum current parameters of a connector, the common insulator, and thereby the connector size, may have to be increased resulting in additional cost and size-related challenges (e.g., users may not have spacing for larger size connectors in their implementations).

[0011] FIG. 2 illustrates side cross-section views of pin and socket insulator accessories individually and with components for contact assembly.

[0012] Diagram 200 shows a conventional socket contact 202 and pin contact 204. A corresponding socket sleeve assembly 206 and a pin sleeve assembly 208 according to examples are also shown. Diagram 200 further shows assembly drawings of a socket contact assembly according to examples with its individual components, socket contact front sleeve 212, socket 220, back sleeve 216, and single wire seal 218; and a pin contact assembly according to examples with its individual components, pin contact front sleeve 214, pin 222, back sleeve 216, and single wire seal 218. In some examples, the back sleeve 216 may also include an O-ring seal for environmental sealing.

[0013] A standardized connector may have a conductive shell (e.g., aluminum housing) and an insulator (e.g., rubber insulating body). The contacts may be mounted by pressing them into the insulator from behind. The insulating body may have an undercut in which the contact is fixed. Government or industry standards may define different contact sizes, shell sizes and / or contact layouts. As mentioned herein, the connector's operating voltage and maximum current parameters are defined by the clearance and creepage distances determined by the connector's shell, body, contact sizes and layout. Thus, increasing operating voltage and maximum current values may be challenging, if not impossible, while maintaining the connector size.

[0014] An insulator accessory according to examples may provide pin and socket contact assemblies that may be incorporated into a connector fitting into same size contact chambers (common insulator) and increase clearance and creepage distances while maintaining connector size and layout. Bigger metal contacts (pin / socket) may be replaced by smaller contacts with a front sleeve and a back sleeve forming the contact assembly. Shape and size of the insulator accessory contact assembly (with the sleeves) may be similar or same as the contacts to fit into an existing contact chamber in a connector. A "labyrinth" mating configuration of the front and back sleeves (overlap) may provide larger clearance / creepage distances, thus increasing the connector's operating voltage and maximum current limitations while maintaining a connector size. In some examples, material for the plastic sleeve(s) may be selected for higher dielectric constant compared to typically rubber material used in contacts.

[0015] FIG. 3A through 3C illustrate perspective and side views of a socket plug connector and a corresponding pin receptacle connector with and without the contact assemblies incorporating an example insulator accessory in coupled and uncoupled configurations.

[0016] Diagram 300A shows a pair of example socket plug (302) and pin receptacle (304) connectors with contact layouts (306 and 308, respectively) according to VG95234 (German military standard) or MIL-STD-5015 (US military standard) 32-1 arrangement. Diagram 300A also shows the same connectors (312 and 314) with pin and socket contacts replaced by insulator accessory contact assemblies (316, 318) utilizing sleeve arrangement. In the illustrated examples, the pin receptacle 304 is arranged to be affixed to an enclosure while the socket plug 302 is arranged to be affixed to a loose cable. Diagram 300B shows a perspective view of the pin receptable 304 and the socket plug 302 in coupled (mated) configuration.

[0017] Diagram 300C shows side views of a receptacle connector 322 and a plug connector 324. The receptacle connector 322 and the plug connector 324 may be pin or socket type, and in the shown example, they are both arranged to be affixed to loose cables. Diagram 300C shows the receptacle connector 322 and the plug connector 324 in coupled and uncoupled configurations. The coupling is through a bayonet style coupling mechanism.

[0018] In the illustrated example connectors, the standard specified 50 VAC to 75 VAC operating voltage range may be increased up to 1000 VAC range without changing connector size or layout configuration. The example connectors and contacts shown herein are for illustration purposes, and do not pose a limit on embodiments. A sleeve-based insulation accessory contact assembly may be utilized in any practical connector configuration, size, and type. For example, sleeve-based insulation accessory contact assemblies may be used in round, square, rectangular, triangular, or any other shape connectors. In addition to size and layout variations, connectors housing such contact assemblies may be coupled through bayonet, latch, lever, push-pull, screw, snap-in, or similar mechanisms, and be made of any suitable connector shell and body materials.

[0019] FIG. 4A illustrates an assembly drawing of a pin contact assembly and a socket contact assembly including an example insulator accessory in a screw-on configuration, arranged in accordance with at least some embodiments described herein.

[0020] Diagram 400A shows assembled and unassembled versions of a socket contact assembly 402 with sleeve-based insulator accessory. The socket contact assembly 402 may include a socket contact front sleeve 404, socket 406, back sleeve 408, and single wire seal 410. The single wire seal 410 may be used to secure a wire into the back sleeve 408 (thereby the socket contact assembly 402), while the back sleeve 408 may be coupled with the socket contact front sleeve 404 through a threaded mechanism ("screw-on" configuration).

[0021] Diagram 400A also shows assembled and unassembled versions of a pin contact assembly 422 with sleeve-based insulator accessory. The pin contact assembly 422 may include a pin contact front sleeve 424, pin 426, back sleeve 428, and single wire seal 430. As in the socket contact assembly, the single wire seal 430 may be used to secure a wire into the back sleeve 428 (thereby the pin contact assembly 422), while the back sleeve 428 may be coupled with the pin contact front sleeve 424 through a threaded mechanism ("screw-on" configuration).

[0022] In some examples, the back sleeves 408 and 428 for the socket and pin contact assemblies, as well as the single wire seals 410 and 430 may be the same components. Thus, pin and socket contact assemblies may be formed using two distinct components (front sleeves and pin / socket) and two common components reducing overall cost and complexity of the contact assemblies (thereby the connectors), making it easier to manufacture them, and increasing reliability through reduced part-count.

[0023] FIG. 4B illustrates an assembly drawing of a pin contact assembly and a socket contact assembly including an example insulator accessory in a clip-on configuration, arranged in accordance with at least some embodiments described herein.

[0024] Diagram 400B shows assembled and unassembled versions of a socket contact assembly 432 with sleeve-based insulator accessory. The socket contact assembly 432 may include a socket contact front sleeve 434, back sleeve 436, and socket 438. The back sleeve 436 may be coupled with the socket contact front sleeve 434 through a clip-on type locking mechanism ("clip-on" configuration).

[0025] Diagram 400B also shows assembled and unassembled versions of a pin contact assembly 442 with sleeve-based insulator accessory. The pin contact assembly 442 may include a pin contact front sleeve 444, back sleeve 446, and pin 448. As with the socket contact assembly, the back sleeve 446 may be coupled with the pin contact front sleeve 444 through a clip-on type locking mechanism ("clip-on" configuration).

[0026] In some examples, the back sleeves 436 and 446 for the socket and pin contact assemblies may be the same component. Thus, pin and socket contact assemblies may be formed using two distinct components (front sleeves and pin / socket) and a common component (back sleeve) reducing overall cost and complexity of the contact assemblies (thereby the connectors), making it easier to manufacture them, and increasing reliability through reduced part-count.

[0027] FIG. 4C illustrates an assembly drawing of a pin contact assembly and a socket contact assembly including an example insulator accessory in a clip-on configuration with a clip for integration, arranged in accordance with at least some embodiments described herein.

[0028] Diagram 400C shows assembled and unassembled versions of a pin contact assembly 452 with sleeve-based insulator accessory. The pin contact assembly 452 may include a pin contact sleeve 454, pin 458, and a clip 456. The pin 458 may be inserted into the pin contact sleeve 454 and held in place through the clip 456 ("clip-on" configuration using a clip). The clip 456 may be metal, plastic, or similar suitable material.

[0029] Diagram 400C also shows assembled and unassembled versions of a socket contact assembly 462 with sleeve-based insulator accessory. The socket contact assembly 462 may include a socket contact sleeve 464, socket 468, and a clip 466. The socket 468 may be inserted into the socket contact sleeve 464 and held in place through the clip 466 ("clip-on" configuration using a clip). The clip 466 may be metal, plastic, or similar suitable material.

[0030] The screw-on type and the clip-on type socket and pin contact assemblies utilizing sleeve-based insulation accessories may be manufactured through machining or injection molding. The screw-on type may be easier for machining due to the rotatory symmetry (turning). However, injection molding may also be used for manufacturing higher quantities. The clip-on type may be easier to manufacture using injection molding compared to machining.

[0031] FIG. 5 illustrates cross-sectional views of a connector with insulator accessory contact assemblies in mated and unmated configurations, arranged in accordance with at least some embodiments described herein.

[0032] Diagram 500 shows cross-sectional view of a pair of mated connectors 510 with sleeve-based contact assemblies and unmated connectors 520, 530. As shown in the mated connectors 510, a conductive connector shell 512 contains an insulator connector body 516 and within contact spaces the contact assemblies 518 and contacts 514 (pin / socket). As discussed herein, the labyrinth overlap configuration of the contact assemblies (front and back sleeves) increase clearance and creepage distances allowing higher operating voltage and maximum current parameters for the connectors. Despite the increased clearance and creepage distances, the contact assemblies according to examples fit into exiting contact chambers within the connectors allowing connector size and layout to remain the same (e.g., a standardized size and layout). The pair of receptacle / plug connectors' mating does not change either.

[0033] FIG. 6A and 6B illustrate assembly processes for screw-on and clip-on configurations of a contact assembly with insulator accessory, arranged in accordance with at least some embodiments described herein.

[0034] The assembly process of "screw-on" type contact assembly shown in diagram 600A may begin with crimping of a wire to the contact (pin or socket), which may be performed in advance. Thus, a production line for such contact assemblies may receive pre-crimped contacts. Next, the back sleeve may be pulled over the pre-crimped contact until a slotted portion of the internal surface of the back sleeve snaps into a contact groove and secures the contact inside the back sleeve. Finally, the front sleeve may be screwed onto the back sleeve through their matching threaded surfaces completing the contact assembly. A pressure created by the screw-on mechanism on the back sleeve may further secure the locking of the contact inside the back sleeve by pushing the slotted portion (latch) of the back sleeve into the contact groove.

[0035] The assembly process of "clip-on" type contact assembly shown in diagram 600B may begin with crimping of a wire to the contact (pin or socket), which may be performed in advance. Thus, a production line for such contact assemblies may receive pre-crimped contacts. Next, the back sleeve may be pulled over the pre-crimped contact until a slotted portion of the internal surface of the back sleeve snaps into a contact groove and secures the contact inside the back sleeve. Finally, the front sleeve may be clipped (or snapped) onto the back sleeve through the extrusions with hooks of the front and back sleeves extending over each other and matching recess surfaces completing the contact assembly. A pressure created by the clip-on mechanism on the back sleeve may further secure the locking of the contact inside the back sleeve by pushing the slotted portion (latch) of the back sleeve into the contact groove. While the screw-on version may be assembled orientated with the latching hooks in the right groove, the clip-on version may be assembled by pushing in axial direction until latch hooks snap into recess.

[0036] The present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as illustrations of various aspects. Many modifications and variations can be made without departing from its spirit and scope. Functionally equivalent methods and apparatuses within the scope of the disclosure, in addition to those enumerated herein, are possible from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0037] The herein described subject matter sometimes illustrates different components contained within, or connected with, different other components. Such depicted architectures are merely examples, and in fact, many other architectures may be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively "associated" such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality may be seen as "associated with" each other such that the desired functionality is achieved, irrespective of architectures or intermediate components. Likewise, any two components so associated may also be viewed as being "operably connected", or "operably coupled", to each other to achieve the desired functionality, and any two components capable of being so associated may also be viewed as being "operably couplable", to each other to achieve the desired functionality. Specific examples of operably couplable include but are not limited to physically connectable and / or physically interacting components and / or wirelessly interactable and / or wirelessly interacting components and / or logically interacting and / or logically interactable components.

[0038] With respect to the use of substantially any plural and / or singular terms herein, those having skill in the art can translate from the plural to the singular and / or from the singular to the plural as is appropriate to the context and / or application. The various singular / plural permutations may be expressly set forth herein for sake of clarity.

[0039] In general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation, no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and / or "an" should be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, means at least two recitations, or two or more recitations).

[0040] Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general, such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and / or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

[0041] For any and all purposes, such as in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as "up to," "at least," "greater than," "less than," and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, a range includes each individual member. Thus, for example, a group having 1-3 cells refers to groups having 1, 2, or 3 cells. Similarly, a group having 1-5 cells refers to groups having 1, 2, 3, 4, or 5 cells, and so forth.

Examples

Embodiment Construction

[0007]In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. The aspects of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.

[0008]This disclosure is generally drawn, inter alia, to an insulation accessory for electrical connectors to increase clearance and creepage distances, thereby an operating voltage and maximum current rating of a connector, while maintaining...

Claims

1. A contact assembly to be fitted in a connector body (516), the contact assembly (316, 318; 402, 422; 432, 442; 452, 462; 518;) comprising: a front sleeve (404, 424; 434, 444) configured to mate with a corresponding front sleeve of a mating contact; a metal contact (514) contained partially within the front sleeve and coupled to a wire; and a back sleeve (408, 428; 436, 446) holding the metal contact mechanically and coupled with the front sleeve (404, 424; 434, 444) in a partially overlapping manner, wherein the metal contact (514) is a socket (406; 438; 468) or a pin (426; 448; 458) and the front sleeve (404, 424; 434, 444) and the back sleeve (408, 428; 436, 446) are made from a dielectric material.

2. The contact assembly of claim 1, wherein the front sleeve (404, 424; 434, 444) and the back sleeve (408, 428; 436, 446) are configured to couple mechanically through one of a screw-on and a clip-on coupling mechanism.

3. The contact assembly of claim 1 or claim 2, wherein the contact (514) is secured inside the back sleeve (408, 428; 436, 446) through a slotted portion of an internal surface of the back sleeve (408, 428; 436, 446) and a contact groove.

4. The contact assembly of any of claims 1 to 3, further comprising a single wire seal (410, 430) to secure the contact pre-crimped onto the wire to the back sleeve (408, 428; 436, 446).

5. The contact assembly of any of claims 1 to 4, wherein the front sleeve (404, 424; 434, 444) has a distinct shape for a socket (406; 438; 468) and a pin (426; 448; 458), and the back sleeve (408, 428; 436, 446) has a common shape for the socket (406; 438; 468) and the pin (426; 448; 458).

6. The contact assembly of any of claims 1 to 5, further comprising an O-ring fitted between the front sleeve and the back sleeve for environmental sealing.

7. The contact assembly of any of claims 1 to 6, wherein the contact assembly (316, 318; 402, 422; 432, 442; 452, 462; 518;) is configured to fit into a contact chamber of a standardized connector.

8. A connector, comprising: a conductive shell (512); an insulator body (516) inside the conductive shell (512) and comprising one or more contact chambers; and one or more contact assemblies (316, 318; 402, 422; 432, 442; 452, 462; 518;) according to any of claims 1 to 7 arranged in the one or more contact chambers.

9. The connector of claim 8, wherein a receptacle configuration and a plug configuration of the connector (306, 308;322, 324; 520, 530) are configured to mate through one of a bayonet, a latch, a lever, a push-pull, a screw, or a snap-in coupling mechanism.

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