One-way toolless assembly insulator

Abstract

An insulation accessory, comprises an insulation sleeve portion comprising two or more flexible fixations on an outside surface of the insulation sleeve portion; a mating interface portion comprising two or more rigid fixations extending radially from an outside surface of the mating interface portion; and two or more latching hooks extending inward from an inside surface of the insulation sleeve portion, wherein the rigid fixations and extended edges of the flexible fixations are arranged to push against surfaces of a hard base around a cutout to maintain the insulation accessory inside the cutout, and extrusions of the flexible fixations are arranged to provide concentric flotation of the insulation accessory inside the cutout.

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. Connectors on hard bases such as a busbar, an enclosure, or a printed circuit board (PCB) may be subject to shock, vibration, and misalignment during mating and use. This may reduce the longevity of the connectors and the number of mating cycles.SUMMARY

[0002] The present invention generally relates to a floating insulation accessory for electrical connectors that allows toolless assembly of contacts at a busbar, an enclosure, or a PCB.

[0003] The invention provides an insulation accessory including an insulation sleeve portion comprising two or more flexible fixations on an outside surface of the insulation sleeve portion; a mating interface portion comprising two or more rigid fixations extending radially from an outside surface of the mating interface portion; and two or more latching hooks extending inward from an inside surface of the insulation sleeve portion. The rigid fixations and extended edges of the flexible fixations are arranged to push against surfaces of a hard base around a cutout to maintain the insulation accessory inside the cutout. Extrusions of the flexible fixations are arranged to provide concentric flotation of the insulation accessory inside the cutout.

[0004] The invention further provides a connector including a pin contact or a socket contact and an insulation accessory. The insulation accessory includes an insulation sleeve portion comprising two or more flexible fixations on an outside surface of the insulation sleeve portion; a mating interface portion comprising two or more rigid fixations extending radially from an outside surface of the mating interface portion; and two or more latching hooks extending inward from an inside surface of the insulation sleeve portion. The rigid fixations and extended edges of the flexible fixations are arranged to push against surfaces of a hard base around a cutout to maintain the insulation accessory inside the cutout. Extrusions of the flexible fixations are arranged to provide concentric flotation of the insulation accessory inside the cutout.

[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. 1A and 1B illustrate two perspective views of a floating insulation accessory; FIG. 2 illustrates a bottom view of a mating interface of the floating insulation accessory; FIG. 3 illustrates a cross-sectional view of the floating insulation accessory with the insulation sleeve and the mating interface coupled together; FIG. 4A and 4B illustrate external and internal perspective views of a socket (receptacle) contact for the floating insulation accessory; FIG. 5A and 5B illustrate an assembly procedure of a floating insulation accessory; FIG. 6A through 6C illustrate multiple single-contact connectors on an enclosure formed by floating insulation accessories and corresponding contacts; FIG. 7 illustrates a mating procedure for a pin floating insulation accessory with a socket contact; and FIG. 8 illustrates multiple pin floating insulation accessories coupled with corresponding socket contacts. 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 a floating insulation accessory for electrical connectors that allows toolless assembly of contacts at a busbar, an enclosure, or a PCB, and methods of assembling such connectors.

[0009] FIG. 1A and 1B illustrate two perspective views of a floating insulation accessory, arranged in accordance with at least some embodiments described herein.

[0010] Diagram 100A shows an insulation sleeve 102 and a mating interface 104 portions of a floating insulation accessory. The insulation sleeve 102 includes a plurality of flexible fixations (or snap hooks) 106, whereas the mating interface 104 includes a plurality of rigid fixations (or flanges) 108. When the insulation accessory is inserted into a cutout, the rigid fixations 108 and the flexible fixations 106 push against opposing surfaces of the cutout (e.g., a circular hole in an enclosure wall or a busbar) and provide mechanical support for the insulation accessory to remain affixed to the hard base (enclosure wall, busbar, PCB, etc.) while floating concentrically inside the cutout. Thus, the insulation accessory reduces effects of shock, vibration, and misalignment, and provides resistance against those.

[0011] Diagram 100B shows, in addition to the rigid fixations 108 and the flexible fixations 106 on the mating interface 104 and the insulation sleeve 102, respectively, corbels 112 providing support to the rigid fixations 108 and extrusions 110 at ends of the flexible fixations 106 to allow concentric flotation of the insulation accessory in a cutout.

[0012] An insulation accessory as described herein may not only provide outstanding performance / resistance against shock, vibration, and misalignment during mating caused by the floating principle of each contact or connector, but also ensures longevity and capability of high number of mating cycles. Single contact connectors formed by the insulation accessory and contacts within may be installed on hard bases (enclosure walls, busbars, PCBs) in high numbers and dense configurations. Example implementations may include, but are not limited to, swappable batteries which are connected directly when they are placed into small or large vehicles, charging ports for similar vehicles and unmanned aerial vehicles (UAVs), etc. By selecting a thickness and length of the insulation accessory, along with dielectric properties of its material, high voltage or current applications may also be implemented, in addition to low voltage power or signal applications.

[0013] FIG. 2 illustrates a bottom view of a mating interface of the floating insulation accessory, arranged in accordance with at least some embodiments described herein.

[0014] Diagram 200 shows the integrated components of the floating insulation accessory from a bottom perspective and includes mating interface 204 rigid fixations 208 (flanges), corbels 212 to support the rigid fixations, flexible fixations 206 and extrusions 210 at the ends of the flexible fixations 206. The diagram also shows hooks 216 to affix a contact inside the floating insulation accessory.

[0015] As mentioned herein, the rigid fixations 208 extending radially from a body of the insulation accessory and the flexible fixations 206 push against opposing surfaces of a cutout, into which the floating insulation accessory is inserted and provide mechanical support for the insulation accessory to remain affixed to the hard base while floating concentrically inside the cutout. All relative movements, forces, shocks and vibrations may be covered by the contact between the insulation accessory and the hard base and may not affect the electrical connection.

[0016] A floating insulation accessory according to examples may house pin and socket contact assemblies at a hard base. While providing shock, vibration, misalignment resistance for the electrical connection and dense, multiple connection configurations, the insulation accessory may also allow increase of clearance and creepage distances for high power / voltage applications through selection of dimensions and material.

[0017] FIG. 3 illustrates a cross-sectional view of the floating insulation accessory with the insulation sleeve and the mating interface coupled together, arranged in accordance with at least some embodiments described herein.

[0018] Diagram 300 shows insulation sleeve and mating interface portions (302, 304) of the floating insulation accessory along with rigid fixations 308, flexible fixations 306 and latching hooks 322 to affix a contact inside the insulation accessory. rigid fixations 308 and extended edges 324 of the flexible fixations 306 may push a hard base wall around a cutout affixing the floating insulation accessory along a z-dimension, while the extrusions 310 of the flexible fixations 306 may provide a spring function and allow concentric flotation along x- and y-dimensions inside the cutout.

[0019] An insulation accessory according to examples may be inserted into a cutout with the insulation sleeve 302 first. The flexible fixations 306 may be pushed (bent) toward the body of the accessory to fit inside the cutout and released once the accessory is in place. A number, shape, and size of the rigid and flexible fixations may be selected depending on application, cutout size, material, etc. For example, 2-6 fixations may be used in practical implementations. The latching hooks 322 may extend radially inward and mate with a corresponding groove on an outside surface of a contact (pin or socket) holding the contact in place inside the insulation accessory.

[0020] FIG. 4A and 4B illustrate external and internal perspective views of a socket (receptacle) contact for the floating insulation accessory, arranged in accordance with at least some embodiments described herein.

[0021] Diagrams 400A and 400B show outside and inside views of a socket contact with a body 402, a socket hole 406 to receive a pin, a wrench shape 404, surface area 408, and groove 410. The surface area 408 may be a metric thread with which the socket contact may be screwed into a busbar using the wrench shape 404. The body of the socket contact may be conductive (e.g., metal). In some cases, an additional insulation cover may be used. The contact, therefore, includes groove 410 for an O-ring.

[0022] FIG. 5A and 5B illustrate an assembly procedure of a floating insulation accessory, arranged in accordance with at least some embodiments described herein.

[0023] Diagram 500A shows a floating insulation accessory 502, a contact 504 coupled to a wire 510, and a sheet metal 506 (e.g., representing a wall of an enclosure) with cutouts 508. In some examples, the contact 504 (pin or socket) may be coupled (e.g., crimping, soldering, etc.) with the wire 510 and then pushed into the floating insulation accessory 502. Once the contact 504 is pushed all the way in, the latching hooks on the inside surface of the floating insulation accessory 502 may snap into the groove on the outside surface of the contact 504 affixing the contact inside the insulation accessory.

[0024] As shown in diagram 500B, the floating insulation accessory 502 coupled with the contact 504 may then be pushed into the cutout. As the insulation accessory is pushed in, the flexible fixations may bend inward and be released once the insulation accessory is fully inside the cutout affixing the insulation accessory floatingly in the cutout. The assembly motions are along a z-dimension relative to a surface of the sheet metal 506, while the floating of the insulation accessory is concentrically inside the cutout along x- and y-dimensions. Due to the spring force of the flexible fixations 306 the insulator stays concentric in the cutout 508 when free of load.

[0025] FIG. 6A through 6C illustrate multiple single-contact connectors on an enclosure formed by floating insulation accessories and corresponding contacts, arranged in accordance with at least some embodiments described herein.

[0026] Diagram 600A shows a solid busbar conductor 604 with an inner thread 606 for a contact and a contact 602 screwed into the inner thread 606. The diagram also shows sheet metal 612 with cutouts 614. Two floating insulation accessories 608 coupled to wires 610 are shown in position to mate with the contacts on the solid busbar conductor 604. The wires 610 are shown with lugs, but any connection type may be used on the wires including loose wires.

[0027] Diagram 600B shows a series of floating insulation accessories 622 on sheet metal 612 with wires 624 representing a dense connection configuration, where all connections are resistant to vibration, shock, and misalignment through floating insulation accessories. Diagram 600C shows another series of floating insulation accessories 634 on sheet metal 612 with wires 636 and a corresponding solid busbar 632 with matching contacts 638.

[0028] FIG. 7 illustrates a mating procedure for a pin floating insulation accessory with a socket contact, arranged in accordance with at least some embodiments described herein.

[0029] Diagram 700 shows a floating insulation accessory 702 with a pin contact 704 inside and affixed to a hard base 703 (e.g., a cutout in a sheet metal) and a corresponding socket contact 706 with its wire 708 at step 710. Step 720 and step 730 show the socket contact (and the wire) being approached to the floating insulation accessory and a tip of the socket contact being inserted into the floating insulation accessory. An outer solid lateral surface of the socket contact may engage with floating insulation accessory first. At step 740 the socket contact is fully inserted into the floating insulation accessory and the pin contact is mated in pre-engaged concentric position. This mating provides low axial force on contact spring.

[0030] FIG. 8 illustrates multiple pin floating insulation accessories coupled with corresponding socket contacts, arranged in accordance with at least some embodiments described herein.

[0031] Diagram 800 shows a series of floating insulation accessories 810 (with their respective contacts and lugged wires) affixed on a sheet metal and mated with corresponding contacts 820 on a solid busbar. Details are shown in side-view of two floating insulation accessories 806, sheet metal portion 808, wires 804, and lugs 802 on the wires 804. The assemblies are coupled with matching contacts on a solid busbar conductor 809.

[0032] 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.

[0033] 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.

[0034] 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.

[0035] 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).

[0036] 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."

Claims

1. An insulation accessory, comprising: an insulation sleeve portion (102; 302) comprising two or more flexible fixations (106; 206; 306) on an outside surface of the insulation sleeve portion (102; 302); a mating interface portion (106; 206; 306) comprising two or more rigid fixations (108; 208; 308) extending radially from an outside surface of the mating interface portion (106; 206; 306); and two or more latching hooks (322) extending inward from an inside surface of the insulation sleeve portion (102; 302), wherein the rigid fixations (108; 208; 308) and extended edges (324) of the flexible fixations (106; 206; 306) are arranged to push against surfaces of a hard base (703) around a cutout (508; 614) to maintain the insulation accessory inside the cutout (508; 614), and extrusions (110; 210; 310) of the flexible fixations (106; 206; 306) are arranged to provide concentric flotation of the insulation accessory inside the cutout (508; 614).

2. The insulation accessory of claim 1, wherein the insulation sleeve portion (102; 302) and the mating interface portion (106; 206; 306) are integrated and made from a dielectric material.

3. The insulation accessory of claim 1 or claim 2, wherein the latching hooks (322) are arranged to mate with a groove (410) on an outside surface of a pin contact (704) or a socket contact, and hold the pin contact (704) or the socket contact inside the insulation accessory.

4. The insulation accessory of any of claims 1 to 3, further comprising two or more corbels (112, 212) on the outside surface of the mating interface portion (106; 206; 306) to provide mechanical support to the rigid fixations (108; 208; 308).

5. The insulation accessory of any of claims 1 to 4, wherein the concentric flotation of the insulation accessory inside the cutout (508; 614) is to provide resistance to one or more of shock, vibration, or misalignment.

6. The insulation accessory of any of claims 1 to 5, wherein the hard base (703) is an enclosure wall, a busbar, or a printed circuit board (PCB), and the cutout (508; 614) is substantially circular.

7. The insulation accessory of any of claims 1 to 6, wherein one or more of a number, a shape, or a size of the rigid fixations (108; 208; 308) and the flexible fixations (106; 206; 306) is selected based on one or more of an application, a cutout size, or a material of the insulation accessory.

8. A connector, comprising: a pin contact (704) or a socket contact; and an insulation accessory of any of claims 1 to 7 encapsulating the pin contact (704) or the socket contact.

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