High power three phase power and signal connector

Abstract

An electrical connector includes a connector body having a connector face, three power contacts distributed across a first dimension of the connector face, and a plurality of signal contacts that overlap along the first dimension with one of the three power contacts and that are offset from the one of the power contacts along a second dimension of the connector face, wherein the first dimension is perpendicular to the second dimension. The connector also includes a latch with a longitudinal length parallel to a direction of movement of the connector, a thickness perpendicular to the length, and a protrusion extending at least one of inwardly or outwardly from the thickness of the body, the protrusion having a longitudinally-facing surface. A recess with which the latch couples is configured to receive the protrusion of the latch.

Description

HIGH POWER THREE PHASE POWER AND SIGNAL CONNECTORTECHNICAL FIELD

[0001] This disclosure generally relates to electrical connectors, including electrical connectors for transmission of high-current, multi-phase power and signals.BACKGROUND

[0002] Electrical connectors may provide protection against ingress of foreign objects, such as dust and water. Certain connectors may also be exposed to high amounts of vibration and other physical disturbances, and need to support a desired electrical transmission or data transmission without undue degradation of the electrical signal or signals carried by the conductors in the connector.BRIEF DESCRIPTION OF THE DRAWINGS

[0003] FIG. 1A is a front perspective view of an example electrical connector receptacle.

[0004] FIG. IB is a front perspective view of an example electrical connector plug.

[0005] FIG. 2A is a front view of the electrical connector receptacle of FIG. 1A.

[0006] FIG. 2B is a front view of the electrical connector plug of FIG. IB.

[0007] FIG. 3 A is a rear view of the electrical connector receptacle of FIG. 1 A.

[0008] FIG. 3B is a rear view of the electrical connector plug of FIG. IB.

[0009] FIG. 4A is a top view of the electrical connector receptacle of FIG. 1 A.

[0010] FIG. 4B is a top view of the electrical connector plug of FIG. IB.

[0011] FIG. 5 is an exploded view of a rear support assembly that may find use with a connector of the present disclosure.

[0012] FIG. 6 is a partially exploded rear view of a portion of the electrical connector plug of FIG. IB.

[0013] FIGS. 7A, 7B, 7C, and 7D are rear views of the electrical connector receptacle of FIG. 1A in various states, with each state corresponding to a respective set of electrical cable sizes used with the receptacle.

[0014] FIGS. 8 A and 8B are perspective views of a portion of the electrical connector receptacle of FIG. 1A, showing the latching catch of the receptacle in greater detail.

[0015] FIG. 9A is a side view of an end portion of an example latch of the plug of FIG. IB in greater detail.

[0016] FIG. 9B is a side view of the example latch of FIG. 9A in an example latching catch of the connection of FIG. 1 A.DETAILED DESCRIPTION

[0017] A novel electrical connector according to the present disclosure may provide more secure connection between a plug and a receptacle and an overall more secure electrical connection through numerous novel features. First, the connector may include standard- required spacing between electrically-conductive elements for high-power applications while minimizing the size of the connector face and body. Second, the connector may provide numerous features for strain relief of cables extending out of the connector, such as smooth, flat longitudinal surfaces defining apertures for the passage of cables and individual grommets within the connector body for each cable, and adjustable-size apertures. Such adjustable-size apertures and individual grommets may also simplify the assembly and manufacturing processes where the connector body is to be used with a variety of cable sizes and cable size combinations. Third, the connector may include a latch and latch interface that is free of intersecting edges or sharp surfaces, thereby reducing the likelihood of latch failure during field use, where high amounts of vibration or other disturbances may be present.

[0018] The instant disclosure includes a pair of connectors — a plug and a receptacle — that may find use together for creating an electrical connection. That is, the plug may mate with and connect to the receptacle to create an electrical connection between wires and cables in the plug and wires and cables in the receptacle.

[0019] Referring now to the drawings, wherein like numerals refer to the same or similar features in the various views, FIGS. 1A, 2A, 3A, and 4A illustrate an electrical connector receptacle 100, and FIGS. 2A, 2B, 2C, and 2D illustrate an electrical connector plug 200. The plug 200 may mate with the receptacle 100 to provide a power and signal connection between two sets of electrical and signal cables that are coupled to the connectors 100, 200. The receptacle 100 and plug 200 both include many of the novel features of this disclosure, and will be discussed below in tandem for many aspects. In joint discussions, the term “connector” will be used to refer interchangeably to both the receptacle 100 and the plug 200.

[0020] The connector 100, 200 may include a body 102, 202 defining an interior in which a plurality of electrical contacts 104, 204 (including contacts 104d, 204d and 104p, 204p discussed below) are disposed. The body 102, 202 may include a front portion 106, 206 at which the electrical contacts 104, 204 are accessible to a mating connector and a rear portion108, 208 through which electrical wires and cables may be inserted into the interior for electrical coupling with the contacts 104, 204.

[0021] The connector 100, 200 may include three electrical contacts 104p, 204p for transmission of power and a plurality of electrical contacts 104d, 204d for transmission of data. Eight data electrical contacts 104d, 204d are included in the illustrated embodiment of the connectors 100, 200. Each connector 100, 200 further includes, at the rear portion 108, 208, three power cable apertures IlOp, 210p and a data cable aperture HOd, 210d (see FIGS. 3A, 3B) (which, collectively with the power cable apertures IlOp, 210p, may be referred to herein as the cable apertures 110, 210). Cables may be inserted into the cable apertures 110, 210, routed into the interior of body 102, 202, and the electrical wires of those cables may be electrically coupled to the electrical contacts 104, 204. The three power contacts IlOp may be identical to one another in size, shape, and material. Similarly, the three power contacts 210p may be identical to one another in size, shape, and material.

[0022] The power contacts 104p, 204p may be arranged in the connector 100, 200 so as to comply with standardized minimum spacing between power contacts 104p, 204p while also minimizing the overall size of the connector 100, 200. For example, as shown in FIGS. 1A, IB, 2A, and 2B, the three power contacts 104p, 204p may be distributed across a dimension (e.g., the width WR, Wp) of the connector 100, 200. In some embodiments, the three power contacts 104p, 204p may be disposed at three different positions across the width WR, Wp, of the face of the connector as shown. The three power contacts 104p, 204p may also be distributed across another dimension (e.g., the height HR, HP) of the face of the connector 100, 200. The width WR, Wp may be perpendicular to the height H , Hp. In some embodiments, two of the three power contacts 104p, 204p may be disposed at a first position along the height HR, Hp, and the third of the three power contacts 104p, 204p may be disposed at a second position along the height HR, Hp, as shown. The power contacts 104p on the receptacle 100 may be positioned so as to connect to corresponding power contacts 204p on the plug 200. As a result of the layout of the power contacts 104p, 204p each power contact 104p, 204p may be at least 0.7 inches from each other power contact 104p, 204p (measuring from the center of the width of each contact 104p, 204p), while the overall size of the connector face remains small, with the height not exceeding 1.5 inches and the width not exceeding 2.25 inches.

[0023] The data contacts 104d may arranged on the receptacle 100 so as to send and receive data signals to and from corresponding contacts 204d on the plug 200. In some embodiments, such as the illustrated embodiment, eight (8) data contacts 104d, 204d may beprovided. In other embodiments, more of fewer than eight data contacts 104d, 204d may be provided. Each data contact 104d, 204d may be coupled to a respective signal wire, and two or more signal wires may be bundled or otherwise provided in a cable through the body 102, 202 of the connector 100, 200, in some embodiments.

[0024] The contacts 104d, 104p may be laid out on the face of the connector 100, 200 so as to comply with required spacing (e.g., required by one or more standards bodies or certification bodies) between high-power lines as well as to maintain appropriate spacing between the data lines and power lines so that the data signals are not unduly corrupted by proximate high power transmission. For example, in some embodiments, one of the power contacts 104p, 204p may be offset along height H relative to the other two power contacts 104p, 204p, and the data contacts 104d, 204d may be disposed in a group that is at the same position across the width WR, WP as the offset power contact 104d, 204d and the same position along the height HR, Hp as the other two power contacts 104d. Accordingly, two of the power contacts 1 lOp may overlap along the height HR, and two of the power contacts 21 Op may overlap along the height Hp.

[0025] The connector 100, 200 may include a first body portion 112, 212 and a second body portion 114, 214 that may clamp together to form the connector body 102, 202. Rear portions 112a, 114a of the first and second body portions 112, 114 are shown in FIG. 5. As will be discussed below, the rear portions 112a, 114a of the first body portion 112 and second body portion 114 may include various features for defining cable apertures 110 and for sealing the connector to prevent entry of foreign bodies into the interior of the connector 100. Identical features may be provided on the plug 200.

[0026] Referring to FIG. 5, the connector 100 may include, at the rear portion 108, a multi-part clamp assembly including a lower clamping portion 114a, an upper clamping portion 112a, a data cable clamping insert 116 (which may also be referred to herein as a clamp insert), and a data cable clamp 118. The upper clamping portion 112a and lower clamping portion 114a may collectively define three power cable apertures IlOp that are positioned on the rear portion 108 in a similar configuration to the positioning of the power contacts 104p on the front portion 106 of the connector 100. That is, the three power cable apertures IlOp, 210p may be disposed at three different positions across the width W, as shown. The power cable apertures IlOp may also be distributed across the height H of the face of the connector 100. In some embodiments, two of the three power cable apertures IlOp, 210p may be disposed at a first position Hl (see FIGS. 3A, 3B) along the height HR, Hpand the third of the three power cable apertures 1 lOp, 210p may be disposed at a second position H2 (see FIGS. 3A, 3B) along the height HR, Hp, as shown.

[0027] The first body portion 112, 212 and second body portion 114, 214 may meet along a longitudinal seam 120, 220 (see FIGS. 1A, IB), and may include various features for reducing intrusion of foreign bodies through the seam 120, 220. For example, the first body portion 112 may include inner sidewalls 122 (see FIG. 5) that abut corresponding sidewalls 124 on the second body portion 114. The inner sidewalls 122 of the first body portion 112 may be of sufficient height so that the inner sidewalls 122 prevent foreign body intrusion in both a collapsed configuration of the connector 100 (corresponding to a smaller cable size, see FIGS. 7 A and 7B) and an expanded configuration of the connector 100 (corresponding to a larger cable size, see FIGS. 7C and 7D). The collapsed and expanded configurations are described further below.

[0028] With continued reference to FIG. 5, the first body portion 112 may define a passageway, such as a channel 126, in which the data cable insert 116 and data cable clamp 118 may be disposed once assembled. When coupled together, the first body portion 112, data cable insert 116, and data cable clamp 118 may collectively define the data cable aperture 1 lOd through which a data cable may extend for further extension through the interior of the connector 100 for electrical coupling to the data contacts 104d.

[0029] The data cable insert 116 may have two configurations for assembly. In a first configuration, the data cable aperture 1 lOd may be a first diameter. In a second configuration, the data cable aperture 1 lOd may be a second diameter. The first configuration may differ from the second configuration by a rotational position or orientation of the data cable insert 116. For example, the first configuration may correspond to a first concave side 128 of the data cable insert facing the data cable clamp, as shown in FIG. 5. The second configuration may correspond to a second concave side 130 of the data cable insert facing the data cable clamp. The second concave side 130 may be opposite the first concave side 128, in some embodiments. Both the first and second concave sides 128, 130 may include a generally arcuate sidewall 132 and one or more bridge members 134, 136 spanning the sidewall. The bridge member 134 of the first concave side 128 may be larger in height than the bridge member 136 of the second concave side 130, thereby resulting in a larger opening for a data cable when the data cable aperture 1 lOd is formed by the second concave side 130. The bridge member 134 of the first concave side 128 may be may be at the same longitudinal position as the bridge member 136 of the second concave side 130 and may be of equivalent longitudinal thickness. In assembly, the data cable insert 116 may be placed in a desiredposition in the upper clamping portion passageway 126, the data cable clamp 118 may be placed over the data cable insert 116, and the data cable clamp 118 may be coupled to the upper clamping portion 112a with one or more fasteners through fastener apertures 133.

[0030] Referring to FIGS. 1A-5, the connector 100, 200 may include finger grips 134, 234 on both lateral sides of the connector 100, 200. The finger grips 134, 234 may be disposed on the rear portion 108, 208 of the connector 100, 200 and may face forward. That is, the connector 100, 200 may include a plurality of finger grip protrusions 136, 236 disposed on a distal-facing surface 138, 238 of the first and second body portions 112, 114, 212, 214 of the connector 100, 200. The distal-facing surface 138, 238 may be generally arcuate, e.g., concave.

[0031] The connectors 100, 200 may include features for securely coupling the receptacle 100 to the plug 200. For example, the receptacle 100 may include one or more receiving formations 140 and the plug 200 may include one or more corresponding latches 240 for coupling with the receiving formations.

[0032] Referring to FIGS. IB, 4B, 9A, and 9B, each latch 240 may include a body 242 having a longitudinal length (in direction L, see FIG. 4B) parallel to a direction of movement of the plug 200 to mate the plug 200 with the receptacle 100 and a thickness (in direction T, see FIG. 4B) perpendicular to the length. The latch 240 may further include a protrusion 244 extending at least one of inwardly (as shown) or outwardly from the thickness of the body 242. The latch body 242 may define an aperture 246 see FIG. IB), and the protrusion 244 may be adjacent to the aperture 246, in some embodiments. In some embodiments, the protrusion may be formed by cutting, stamping, or otherwise removing material from the body 242 of the latch 240, with the removed material forming the protrusion 244 and the space vacated by the removed material forming the aperture 246. As a result, the protrusion 244 may have substantially the same width as the aperture 246, and the protrusion 244 may be monolithic with the body 242. The latch 240 may have a hooked end 248, in some embodiments.

[0033] FIGS. 8A and 8B illustrate the receiving formation 140 in greater detail. Each receiving formation 140 on the receptacle 100 may include a recess 142 configured to receive the protrusion 244 of the latch 240, such that coupling the latch protrusion 244 with the recess 142 secures the receptacle 100 to the plug 200. The recess 142 may be adjacent to two longitudinal support arms 144 coupled directly to a longitudinally -facing surface 146 of the recess. The surface 146 may contact the protrusion 244 and, through that contact, may resistlongitudinal movement of the latch 240 and uncoupling of the latch 244 from the receiving formation 140.

[0034] In some embodiments, the latch 240 may be provided on the plug 200 and the recess 140 may be provided on the receptacle, as illustrated. In other embodiments, the latch 240 may be provided on the receptacle 100, and the recess 140 may be provided on the plug 200.

[0035] The rear portion 108, 208 of the receptacle 100, 200 may include several features for sealing the connector 100, 200 interior against foreign body intrusion, for providing strain relief to cables extending through the apertures 104, 204 at the rear of the connector 100, 200 and for ease of assembly. The rear portion 108, 208 of the connector 100, 200 may include, as noted above, a first body portion 112, 212 and a second body portion 114, 214 that collectively define power cable apertures 1 lOp, 210p and a data cable insert 116 and data cable clamp 118 that, along with the body portions 112, 114, additionally define a data cable aperture 1 lOd, 210d. The apertures 110, 210 may be sized and shaped so as to provide smooth, flat surfaces to minimize strain on inserted cables from bending and other torque. In addition, the connector 200 may include four grommets 250a, 250b, 250c, 250d. Each grommet 250 may be placed about a respective cable (e.g., each of three power cable grommets 250b, 250c, 250d may be placed about a respective power cable, and a data cable grommet 250a may be placed about the data cable). Each cable, and each cable aperture 210, may have a separate, individual grommet, made of a separate piece of material from the other grommets. Although the grommets 250 are shown with reference to the plug 200, the receptacle 100 may include similar individual grommets for each cable and each cable aperture 110. As a result, at assembly, different grommet sizes may be selected for different cables, so that different combinations of cable sizes may be used with the connector 100, 200 given a modular set of grommets. In contrast, in known connectors, a single grommet body is provided for all cables, such that each different cable size combination requires a unique grommet body. Accordingly, individual grommets as in the present disclosure enables simplified modular assembly.

[0036] In a first aspect of the present disclosure, an electrical connector is provided that includes a connector body having a connector face, three power contacts distributed across a first dimension of the connector face, and a plurality of signal contacts that overlap along the first dimension with one of the three power contacts and that are offset from the one of the power contacts along a second dimension of the connector face, wherein the first dimension is perpendicular to the second dimension.

[0037] In an embodiment of the first aspect, the one of the three power contacts is offset in the second dimension with respect to the other two of the three power contacts.

[0038] In an embodiment of the first aspect, the one of the three power contacts is disposed between the other two of the three power contacts in the first dimension.

[0039] In an embodiment of the first aspect, the three power contacts are identical to one another in size, shape, and material.

[0040] In an embodiment of the first aspect, the connector body has a rear portion opposite the connector face, wherein the rear portion defines a plurality of cable apertures, wherein each of the cable apertures has a size that is adjustable during assembly of the connector.

[0041] In an embodiment of the first aspect, the connector body defines a recess configured to receive a protrusion of a latch of a second connector, wherein coupling the latch protrusion with the recess secures the connector body to second connector.

[0042] In a second aspect of the present disclosure, an electrical connector pair is provided that includes a plug having a plug body, a receptacle configured to mate with the plug and having a receptacle body, and a latch, disposed on one of the receptacle body or the plug body. The latch body has a longitudinal length parallel to a direction of movement of the one of the plug or receptacle to mate the plug with the receptacle and a thickness perpendicular to the length. The latch further includes a protrusion extending at least one of inwardly or outwardly from the thickness of the body, the protrusion having a longitudinally-facing surface. The other of the receptacle body or the plug body defines a recess configured to receive the protrusion of the latch, wherein coupling the latch protrusion with the recess secures the receptacle body to the plug body.

[0043] In an embodiment of the second aspect, the latch body defines an aperture, the protrusion adjacent to and having the same width as the aperture.

[0044] In an embodiment of the second aspect, the protrusion is monolithic with the latch body.

[0045] In an embodiment of the second aspect, the recess is partially defined by a longitudinally-facing surface configured to interface with the longitudinally-facing surface of the protrusion. In a further embodiment of the second aspect, the other of the receptacle body or the plug body comprises two longitudinal support arms coupled directly to the longitudinally-facing surface.

[0046] In an embodiment of the second aspect, the latch comprises a hooked end, wherein a tip of the hook is adjacent to the protrusion.

[0047] In a third aspect of the present disclosure, an electrical connector is provided that includes a first body portion, a second body portion, wherein the first and second body portions are configured to clamp together and collectively define one or more power cable apertures, and a clamp insert, configured to be secured to the first body portion or the second body portion in two or more positions to at least partially define a signal cable aperture, wherein, when the clamp insert is in a first position of the two or more positions, the signal cable aperture has a first size, and when the clamp insert is in a second position of the two or more positions, the signal cable aperture has a second size, and the first size is different from the second size.

[0048] In an embodiment of the third aspect, the first body portion or the second body portion defines a receiving formation, the first position comprises a first orientation of the clamp insert in the receiving formation, and the second position comprises a second orientation of the clamp insert in the receiving formation. In a further embodiment of the third aspect, the first orientation is different from the second orientation by a 180-degree rotation of the clamp insert.

[0049] In an embodiment of the third aspect, the connector further includes a signal cable clamp, configured to be coupled to the first body portion or the second body portion to define, collectively with the clamp insert, the signal cable aperture.

[0050] In an embodiment of the third aspect, the first and second body portions, when clamped together, collectively define two or more power cable apertures, the electrical connector further including a first grommet, disposed inward of a first power cable aperture of the two or more power cable apertures and configured to be disposed about a first power cable disposed in the first power cable aperture, and a second grommet, separate from the first grommet, disposed inward of a second power cable aperture of the two or more power cable apertures and configured to be disposed about a second power cable disposed in the second power cable aperture.

[0051] In an embodiment of the third aspect, the one or more power cable apertures are defined in a first end of the first and second body portions, the first end facing in a proximal direction, and the connector further comprises a set of finger grip protrusions, disposed on a distal-facing surface of the first and second body portions. In a further embodiment of the third aspect, the distal-facing surface is concave.

[0052] In an embodiment of the third aspect, the one or more power cable apertures are adjustable in size.

[0053] While this disclosure has described certain embodiments, it will be understood that the claims are not intended to be limited to these embodiments except as explicitly recited in the claims. On the contrary, the instant disclosure is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the disclosure. Furthermore, in the detailed description of the present disclosure, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. However, it will be obvious to one of ordinary skill in the art that systems and methods consistent with this disclosure may be practiced without these specific details. In other instances, well known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure various aspects of the present disclosure.

Claims

CLAIMSWhat is claimed is:

1. An electrical connector comprising: a connector body having a connector face; three power contacts distributed across a first dimension of the connector face; and a plurality of signal contacts that overlap along the first dimension with one of the three power contacts and that are offset from the one of the power contacts along a second dimension of the connector face, wherein the first dimension is perpendicular to the second dimension.

2. The electrical connector of claim 1, wherein the one of the three power contacts is offset in the second dimension with respect to the other two of the three power contacts.

3. The electrical connector of claim 1, wherein the one of the three power contacts is disposed between the other two of the three power contacts in the first dimension.

4. The electrical connector of claim 1, wherein the three power contacts are identical to one another in size, shape, and material.

5. The electrical connector of claim 1, wherein the connector body has a rear portion opposite the connector face, wherein the rear portion defines a plurality of cable apertures, wherein each of the cable apertures has a size that is adjustable during assembly of the connector.

6. The electrical connector of claim 1, wherein the connector body defines a recess configured to receive a protrusion of a latch of a second connector, wherein coupling the latch protrusion with the recess secures the connector body to second connector.

7. An electrical connector pair comprising: a plug having a plug body; a receptacle configured to mate with the plug and having a receptacle body; and a latch, disposed on one of the receptacle body or the plug body, the latch comprising: a body having:a longitudinal length parallel to a direction of movement of the one of the plug or receptacle to mate the plug with the receptacle; and a thickness perpendicular to the length; a protrusion extending at least one of inwardly or outwardly from the thickness of the body, the protrusion having a longitudinally-facing surface; wherein the other of the receptacle body or the plug body defines a recess configured to receive the protrusion of the latch, wherein coupling the latch protrusion with the recess secures the receptacle body to the plug body.

8. The electrical connector pair of claim 7, wherein the latch body defines an aperture, the protrusion adjacent to and having the same width as the aperture.

9. The electrical connector pair of claim 7, wherein the protrusion is monolithic with the latch body.

10. The electrical connector pair of claim 7, wherein the recess is partially defined by a longitudinally-facing surface configured to interface with the longitudinally-facing surface of the protrusion.

11. The electrical connector pair of claim 10, wherein: the other of the receptacle body or the plug body comprises two longitudinal support arms coupled directly to the longitudinally-facing surface.

12. The electrical connector pair of claim 7, wherein the latch comprises a hooked end, wherein a tip of the hook is adjacent to the protrusion.

13. An electrical connector comprising: a first body portion; a second body portion, wherein the first and second body portions are configured to clamp together and collectively define one or more power cable apertures; anda clamp insert, configured to be secured to the first body portion or the second body portion in two or more positions to at least partially define a signal cable aperture, wherein: when the clamp insert is in a first position of the two or more positions, the signal cable aperture has a first size; when the clamp insert is in a second position of the two or more positions, the signal cable aperture has a second size; and the first size is different from the second size.

14. The electrical connector of claim 13, wherein: the first body portion or the second body portion defines a receiving formation; the first position comprises a first orientation of the clamp insert in the receiving formation; and the second position comprises a second orientation of the clamp insert in the receiving formation.

15. The electrical connector of claim 14, the first orientation is different from the second orientation by a 180-degree rotation of the clamp insert.

16. The electrical connector of claim 13, further comprising: a signal cable clamp, configured to be coupled to the first body portion or the second body portion to define, collectively with the clamp insert, the signal cable aperture.

17. The electrical connector of claim 13, wherein the first and second body portions, when clamped together, collectively define two or more power cable apertures, the electrical connector further comprising: a first grommet, disposed inward of a first power cable aperture of the two or more power cable apertures and configured to be disposed about a first power cable disposed in the first power cable aperture; and a second grommet, separate from the first grommet, disposed inward of a second power cable aperture of the two or more power cable apertures and configured to be disposed about a second power cable disposed in the second power cable aperture.

18. The electrical connector of claim 13, wherein: the one or more power cable apertures are defined in a first end of the first and second body portions, the first end facing in a proximal direction; and the connector further comprises a set of finger grip protrusions, disposed on a distal- facing surface of the first and second body portions.

19. The electrical connector of claim 18, wherein the distal-facing surface is concave.

20. The electrical connector of claim 13, wherein the one or more power cable apertures are adjustable in size.

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