Floating socket connector for mounting on a busbar

Abstract

A socket connector and its method of assembly, and method of assembly with a busbar are provided. The socket connector includes a housing including a main body having a recess, and a coupling projection extending from the main body. The coupling projection has a diameter which is less than a diameter of the main body and has a coupling structure on an outer surface thereof which is configured to engage with and electrically couple with the busbar. The contact assembly is mounted within the housing and is movable relative thereto. The contact assembly receives and electrically couples with the pin. A tool is provided for engaging the socket connector with the busbar.

Description

FLOATING SOCKET CONNECTOR FOR MOUNTING ON A BUSBAR TECHNICAL FIELD

[0001] This disclosure relates to busbar mounted connectors.DESCRIPTION OF RELATED ART

[0002] Power connectors are used in equipment consuming high amounts of power and consequently utilize high current. In some instances, multiple power connectors are mounted on busbars in an array. In larger arrays of power connectors, alignment of a male pin to a female socket connector may be difficult due to a buildup of tolerances. High power systems can also generate heat and the resultant expansion of the system when carrying high current can cause relative movement between the male pin and the female socket connector.SUMMARY

[0003] A connector and its method of assembly with a busbar are provided.

[0004] In an embodiment, a socket connector for receiving a pin, which is mountable in a through hole in a busbar, is provided. The socket connector includes a contact assembly receiving housing and contact assembly mounted within the contact assembly receiving housing. The contact assembly receiving housing includes a main body defining an outer diameter, a recess within the main body, and a coupling projection extending from the main body. The coupling projection has an outer diameter which is less than the outer diameter of the main body such that the main body forms a shoulder which rests on the busbar. The recess is defined by a side wall surface and a lower wall surface. The coupling projection has a coupling structure on an outer surface thereof which is configured to engage with and electrically couple with the busbar. The contact assembly is mounted within the contact assembly receiving housing and is configured for movement relative thereto. The contact assembly is configured to receive and electrically couple with the pin.

[0005] In an embodiment, the coupling structure is formed of a plurality of spaced apart splines, which may extend vertically. In other embodiments, the coupling structure is formed of a plurality of spaced apart bumps or a screw thread.

[0006] In an embodiment, the socket connector is inserted into the busbar using a tool. The tool includes a body and a pin projection extending from the body. The contact assembly receives the pin projection with an end of the pin projection engaging against the lower wall surface of the main body of the contact assembly receiving housing.

[0007] In a further embodiment, a rigid backing member is configured to seat under the busbar and provide rigidity to the busbar during assembly of the socket connector with the busbar.

[0008] In an embodiment, a method of assembling the socket connector with the busbar is provided. The method includes placing the socket connector on the busbar with the coupling projection of the socket connector positioned over the through hole of the busbar; and pushing the coupling projection of the socket connector into the through hole of the busbar.

[0009] In a further embodiment, a tool is used to push the socket connector into the busbar.

[0010] In yet a further embodiment, a rigid backing member is placed under the busbar to provide rigidity to the busbar prior to assemble of the socket connector with the busbar.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, with emphasis instead being placed upon clearly illustrating the principles of the disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.

[0012] FIG. 1 illustrates a side elevation view of an assembly of a pair of connectors, each seated on a separate lower busbar, and each coupled to an upper busbar by pins;

[0013] FIG. 2 illustrates a cross-sectional view of the assembly of FIG 1;

[0014] FIG. 3 illustrates a top perspective view of a floating socket connector used in the assembly of FIG, 1;

[0015] FIG. 4 illustrates a bottom perspective view of the floating socket connector shown in FIG. 3;

[0016] FIGS. 4A and 4B illustrate bottom perspective views of alternative floating socket connectors;

[0017] FIG. 5 illustrates a cross-sectional view of the floating socket connector shown in FIG. 3;

[0018] FIG. 6 illustrates a cross-sectional view of another floating socket connector used in the assembly of FIG, 1 ;

[0019] FIG. 7 illustrates a perspective view of a first embodiment of a tool used to assemble the connectors with the busbars;

[0020] FIG. 8 illustrates a cross-sectional view of a second embodiment of a tool used to assemble the connectors with the busbars;

[0021] FIG. 9 illustrates a cross-sectional view of the connector, the busbar, the tool and the backer board showing the connector prior to assembly with the tool and busbar; and

[0022] FIG. 10 illustrates a cross-sectional view of the connector, the busbar, the tool and the backer board showing the connector seated on the busbar.DETAILED DESCRIPTION

[0023] While the disclosure may be susceptible to embodiment in different forms, there is shown in the drawings, and herein will be described in detail, specific embodiments with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that as illustrated and described herein. Therefore, unless otherwise noted, features disclosed herein may be combined to form additional combinations that were not otherwise shown for purposes of brevity. It will be further appreciated that in some embodiments, one or more elements illustrated by way of example in a drawing(s) may be eliminated and / or substituted with alternative elements within the scope of the disclosure.

[0024] The present disclosure relates to a floating socket connector 10 for high current, high voltage energy storage and power distribution units. The floating socket connector 10 may be used in high power applications such as computers, data servers, busbar applications, and electric vehicle (EV) systems.

[0025] As shown in FIGS. 1 and 2, the floating socket connector 10, 100 when used with a pin 600 mounted within the floating socket connector 10, 100 forms a connector and connects a component 620, such as a printed circuit board, flex circuit, busbar, to a busbar 630 in a parallel fashion to form an electrical connection. The busbar 630 may be rigid. In an embodiment, the floating socket connector 10, 100 is a power connector. As can be appreciated from the figures, the floating socket connector 10, 100 provides a floating connection configuration. By “floating connection configuration,” this means that a portion of the floating socket connector 10, 100 can move relative to the busbar 630. This floating design allows a certain degree of misalignment between the floating socket connector 10, 100 and the pin 600, and the floating socket connector 10, 100 automatically compensates for the misalignment while maintaining electrical contact.

[0026] The pin 600 is conventional and is formed of a body 602 having a head 604 at a first end, a second opposite end 606, and an outer surface which defines an outer diameter. A centerline 608 of the pin 600 is provided along the length of the pin 600 between the ends and defines a vertical axis (as shown in the drawings; this does not denote a required orientation and is used for ease in description).

[0027] The component 620 is conventional and may be a printed circuit board, flex circuit, busbar and the like. The component 620 has opposite upper and lower surfaces 622, 624 and a through hole 626 therethrough. In an embodiment, the upper and lower surfaces 622, 624 are planar and are parallel to each other. The head 604 of the pin 600 is mounted to the component 620 through the through hole 626 and is electrically coupled to the component 620 in a conventional manner.

[0028] The busbar 630 is conventional, and has opposite upper and lower surfaces 632, 634 and a through hole 636 therethrough. In an embodiment, the surfaces 632, 634 are planar and are parallel to each other. The floating socket connector 10, 100 is mounted to the busbar 630 and is electrically coupled to the busbar 630.

[0029] An example floating socket connector 10, 100 is shown in the drawings, however, other connectors are within the scope of the present invention. By floating socket connector 10, 100, this means that a portion of the socket connector 10, 100 can move relative to other parts of the socket connector 10, 100 to accommodate the misalignment of the centerline 608 of the pin 600 with a centerline of the socket connector 10, 100 as described herein.

[0030] FIGS. 2-5 show a first embodiment of the floating socket connector 10 and FIG. 6 shows a second embodiment of the floating socket connector 100.

[0031] Attention is invited to the first embodiment of the floating socket connector 10 shown in FIGS. 2-5. The floating socket connector 10 includes a contact assembly receiving housing 12, and a contact assembly 14 mounted within the contact assembly receiving housing 12 and configured for movement relative thereto. The contact assembly receiving housing 12 is affixed to the busbar 630 and cannot move relative thereto as described herein. The contact assembly receiving housing 12 is herein called the fixed housing 12 for ease in description. In the embodiment shown herein, the contact assembly 14 is configured to move in three dimensions (x, y and z directions) relative to the fixed housing 12 and thus, relative to the busbar 630 to which the fixed housing 12 is affixed. In other embodiments, the contact assembly 14 isconfigured to move in two dimensions (x and z directions) relative to the fixed housing 12 and thus, relative to the busbar 630 to which the fixed housing 12 is affixed.

[0032] The fixed housing 12 is formed of a conductive material, such as metal. The fixed housing 12 includes a main body 16 and a lower coupling projection 18 extending downward from the main body 16. The main body 16 has upper and lower surfaces 20, 22, and an outer surface 24 extending therebetween. The outer surface 24 of the main body 16 may be cylindrical which defines an outer diameter. In an embodiment, the lower surface 22 is planar (although it is to be understood that the lower surface 22 is preferably configured to match a configuration of the upper surface 632 of the busbar 630). A recess 26 extends downward from the upper surface 20 and has an open upper end. In the embodiment as shown, the recess 26 includes a first part 28a formed from a vertical side wall surface 30 extending from the upper surface 20 and a horizontal lower wall surface 32, and a second part 28b which extends radially outward from the vertical side wall surface 30 of the first part 28a and is formed of upper and lower wall surfaces 34, 36 and an outer wall surface 38 extending therebetween. The first part 28a forms the open upper end of the recess 26. A vertical dimension A is defined between the lower surface 22 of the main body 16 and the horizontal lower wall surface 32 of the recess 26. The lower coupling projection 18 may be annular and has an outer surface 40 extending from the lower surface 22 of the main body 16 to a lower surface 42 at a lower end of the outer surface 40. The lower coupling projection 18 has a diameter which is less than the diameter of the main body 16. In an embodiment, the lower surface 42 is planar. A chamfer 44 may be provided at the intersection of the outer surface 40 and the lower surface 42. The outer surface 40 includes a coupling structure 46, 46a, 46b thereon which may be formed of splines 46 as shown in FIG. 4, a plurality of spaced apart bumps 46a as shown in FIG. 4A, a screw thread 46b as shown in FIG. 4B, or the like, which is used to attach the fixed housing 12 to the busbar 630, preferably in a permanent manner. The splines may be vertically spaced apart splines, and / or generally vertically spaced apart splines such that the splines are at an angle to the vertical which is not equal to 90 degrees. A centerline 48 of the fixed housing 12 extends between surfaces 20 and 42 and defines a vertical axis. A centerline of the lower coupling projection 18 aligns with the centerline of the fixed housing 12. The upper wall surface 34 is formed by folding a wall section 16a of the main body 16 over toward the centerline 48.

[0033] The contact assembly 14 can take a variety of forms. In the example embodiment shown in the drawings, the contact assembly 14 includes a contact receiving housing 50, a contact 52, a cap 54, and a pair of springs 56, 58. The contact receiving housing 50, contact 52, and springs 56, 58 are each formed of a conductive material, such as metal. The cap 54 may be formed of a conductive or non-conductive material.

[0034] The contact receiving housing 50 is formed of a vertical wall 60 which defines an inner passageway 62 extending between upper and lower ends 64, 66 of the contact receiving housing 50. A flange 68 extends radially outward from an outer surface 34c of the contact receiving housing 50. The flange 68 has upper and lower parallel surfaces 70, 72 and an outer surface 74 therebetween. The outer surface 74 may be vertical. A centerline 76 of the contact receiving housing 50 is provided between the ends 64, 66 and defines a vertical axis. In some embodiments, the wall 60 has a circular cross-section, and the flange 68 is circular.

[0035] The contact 52 generally forms a hollow shape which generally conforms to the shape of the passageway 62 of the contact receiving housing 50. The contact 52 may be formed of an alloy with gold plating. In an embodiment, the contact 52 is formed from a ring-like connecting portion 78 having a plurality of separate flexible contact beams 80 cantilevered therefrom such that a passageway 82 is formed therein which extends from upper ends 84 of the contact beams 80 to a lower end 86 of the connecting portion 78. A centerline 88 of the contact 52 is provided between the upper ends 84 and the lower end 86 and defines a vertical axis.

[0036] The cap 54 has an annular wall and a lower flange extending radially outwardly from, and perpendicular to, the annular wall.

[0037] The contact 52 is seated within the passageway 62 of the contact receiving housing 50 such that the lower end of the contact 52 generally aligns with the lower end 66 of the contact receiving housing 50, the upper end of the contact 52 is spaced from the upper end 64 of the contact receiving housing 50, and the centerlines 76, 88 align when the contact 52 is not flexed. The outer surface of the connecting portion 78 is proximate to the inner surface of the wall 60 of the contact receiving housing 50. In an embodiment, the cap 54 secures the contact receiving housing 50 and the contact 52 together. The annular wall of the cap 54 engages against the connecting portion 78 and the flange of the cap 54 engages the ends of the connecting portion 78 of the contact 52 and the wall 60 of the contact receiving housing 50. In an embodiment, the cap 54 is press fit to the contact receiving housing 50 and contact 52. In an embodiment, the cap 54is crimped to the contact receiving housing 50 and contact 52. The cap 54 can be eliminated and the ring-like connecting portion 78 is permanently coupled to the lower end of the vertical wall 60 of the contact receiving housing 50.

[0038] The contact assembly 14 seats within recess 26 of the fixed housing 12. To insert the contact assembly 14 into the recess 26, initially the wall section 16a of the main body 16 is not folded over. The contact assembly 14 is inserted through the open upper end and the spring 58 rests on the lower wall surface. The vertical wall 60 of the contact receiving housing 50 seats within the first part 28a of the recess 26 of the fixed housing 12. Thereafter, the wall section 16a is folded over to form the upper wall surface 34 of the second part 28b of the recess 26 to seat the flange 68 of the contact receiving housing 50 and the springs 56, 58 within the second part 28b of the recess 26 of the fixed housing 12. The vertical wall 60 of the contact receiving housing 50 has an outer diameter which is less than the diameter defined by the first part 28a of the recess 26 such that a gap is defined therebetween when the centerline 76 of the contact receiving housing 50 aligns with the centerline 48 of the fixed housing 12. The vertical wall 60 of the contact receiving housing 50 may extend upwardly out of the recess 26 of the fixed housing 12, and the lower end of the cap 54 (or contact receiving housing 50 if the cap 54 is not provided) is spaced from the horizontal lower wall surface 32 of the recess 26 of the fixed housing 12 such that a gap is formed therearound when the centerline 76 of the contact receiving housing 50 aligns with the centerline 48 of the fixed housing 12.

[0039] The springs 56, 58 may be circular wave springs or take other spring forms. The springs 56, 58 may be integrally formed with each other. In the embodiment as shown, spring 56 seats between the upper surface 70 of the flange 68 and the upper wall surface 34 of the second part 28b and surrounds the vertical wall 60, and spring 58 seats between the lower surface 72 of the flange 68 and the lower wall surface 36 of the second part 28b and surrounds the vertical wall 60. The springs 56, 58 may extend into the first part 28a. The springs 56, 58 fill portions of the gaps. The springs 56, 58 enable the contact receiving housing 50, contact 52 and cap 54 to move relative to the fixed housing 12. A single spring may be provided instead of the pair of springs 56, 58.

[0040] A vertical dimension B is provided between the lower surface 22 of the main body 16 and the upper end 64 of the contact receiving housing 50 when the springs 56, 58 are not flexed.

[0041] FIGS. 1 and 6 also show floating socket connector 100 which is identically formed to floating socket connector 10, except that the vertical dimension A in the floating socket connector 100 is substantially larger than the vertical dimension A in the floating socket connector 10. Like elements are denoted by like reference numerals, but in the one hundred series. The larger vertical dimension A provides for a greater height floating socket connector 100. This allows for a second busbar 630 to be placed underneath the busbar 630 on which the floating socket connector 10 is mounted, while using the same configuration of a pin 600 in each floating socket connector 10, 100. The larger vertical dimension A also increases the vertical dimension B provided between the lower surface 22 of the main body 16 and the upper end 64 of the contact receiving housing 50 when the springs 56, 58 are not flexed. As shown, the floating socket connector 100 is mounted to the same upper component 620 in a separate through hole 626. The floating socket connector 100 is mounted to the second busbar 630 in the same manner as described herein for the floating socket connector 10 and busbar 630.

[0042] In use, the head 604 of the pin 600 is mounted into the through hole 626 of the component 620 in a conventional manner.

[0043] In use, the floating socket connector 10 is mounted to the busbar 630 by the lower coupling projection 18 being inserted into the through hole 636 in the busbar 630 such that the coupling structure 46, 46a, 46b fixedly engages with the busbar 630 as described herein with regard to FIGS. 7-10. The coupling structure 46, 46a, 46b bites into the material of the busbar 630 to provide an interference fit, and to securely couple the floating socket connector 10 to the busbar 630 and electrically couple the floating socket connector 10 to the busbar 630. The lower surface 22 of the floating socket connector 10 may seat against the upper surface 632 of the busbar 630. The lower surface 22 provides a positive stop to prevent the further passage of the lower coupling projection 18 through the through hole 636 when the main body 16 contacts the busbar 630. As a result, the contact assembly 14 can move relative to the fixed housing 12 and relative to the busbar 630, but the fixed housing 12 cannot move relative to the busbar 630. The contact receiving housing 50 can move within the recess 26 of the fixed housing 12 while always maintaining electrical contact with the fixed housing 12 via the springs 56, 58. Since the contact receiving housing 50 and contact 52 can move relative to the fixed housing 12, a certain degree of misalignment between the floating socket connector 10 and the pin 600 is automaticallycompensated for, while maintaining electrical contact. When misaligned, the centerline 608 of the pin 600 does not align with the centerline 48 of the fixed housing 12 during insertion.

[0044] To couple the component 620 to the busbar 630, the end 606 of the pin 600 is inserted into the passageway 82 of the contact 52 in the z-direction and the body 602 of the pin 600 is engaged with the contact beams 80. The centerline 608 of the pin 600 and the centerline 76 of the contact receiving housing 50 align. If there is a misalignment of the centerline 608 of the pin 600 relative to the centerline 48 of the fixed housing 12, the contact assembly 14 will move relative to the fixed housing 12 in the x-direction and / or the y-direction and / or the z-direction (if directions of movement are provided, otherwise the contact assembly 14 will move relative to the fixed housing 12 in the x-direction and / or the y-direction) via flexing of the springs 56, 58 to accommodate the misalignment, while maintaining the electrical contact via the springs 56, 58. The gaps between the fixed housing 12 and the contact assembly 14 accommodate this movement. Electrical signals flow, and / or current flows, from the component 620, through the pin 600, through the contact beams 80, through the connecting portion 78, through the contact receiving housing 50, through the springs 56, 58, through the fixed housing 12, and to the busbar 630.

[0045] As shown in FIGS. 7-10, a tool 700, 700’ and a backing member 702 are used to seat the floating socket connector 10 onto the busbar 630. A first embodiment of the tool 700 is shown in FIGS. 7, 9 and 10, and a second embodiment of the tool 700’ is shown in FIG. 8.

[0046] With reference to the first embodiment of the tool 700 shown in FIGS. 7, 9 and 10, the tool 700 includes an anvil 704 and an outer sheath 706 which are integrally formed.

[0047] The anvil 704 includes a body 708 having upper and lower surfaces 710, 712 and a pin projection 714 extending from the lower surface 712. The pin projection 714 extends downward from the lower surface 712 at the center thereof. The pin projection 714 is elongated and has a cylindrical outer surface 716 and a planar lower end 718. A diameter is defined by the outer surface 716 of the pin projection 714 which is less than the diameter of the body 708 and which is less than the passageway 82 formed by the contact beams 80 of the contact 52. A centerline 720 is defined through the center of the pin projection 714.

[0048] The outer sheath 706 is annular and surrounds the body 708 and the pin projection 714. The outer sheath 706 has an upper end 722 which aligns with the upper surface 710 of the body 708, an opposite lower end 724, an outer surface 726 extending between the ends 722, 724and an inner surface 728 extending between the lower surface 712 of the body 708 and the lower end 724 of the outer sheath 706. The lower end 724 may aligns with the lower end 718 of the pin projection 714 or the lower end 718 of the pin projection 714 may be spaced upwardly from the lower end 724 of the outer sheath 706. The outer sheath 706 is spaced from the pin projection 714 such that an open ended recess 730 is defined by the lower surface 712 of the body 708 and the area between the outer surface 716 of the pin projection 714 and the inner surface 728 of the outer sheath 706. The inner surface 728 of the outer sheath 706 defines a diameter which is slightly larger than the outer diameter defined by the main body 16 of the fixed housing 12. A vertical dimension C is defined between the lower surface 712 of the body 708 and the lower surface 724 of the outer sheath 706; the vertical dimension C is the same as, or substantially the same as, the dimension B defined by the floating socket connector 10.

[0049] The second embodiment of the tool 700’ shown in FIG. 8 is identically formed to the tool 700 except that the anvil 704’ and the outer sheath 706’ are formed as two separate components. Like elements are denoted by like reference numerals with a prime after the reference numerals. Since the anvil 704’ and the outer sheath 706’ are formed as two separate components, the body 708’ additionally has a cylindrical outer surface 732 extending between the upper and lower surfaces 710’, 712’ and which may be cylindrical, and the inner surface 728’ of the outer sheath 706’ extends between the surfaces 722’, 724’.

[0050] The backing member 702 is rigid and has opposite upper and lower surfaces 732, 734 and a through hole 736 therethrough. The surfaces 732, 734 are planar and are parallel to each other. The through hole 736 of the backing member 702 may be slightly larger than the through hole 636 of the busbar 630.

[0051] To assemble the floating socket connector 10 with the busbar 630 using the tool 700, the busbar 630 is placed on top of the backing member 702 such that the upper surface 732 of the backing member 702 lays flat against the lower surface 634 of the busbar 630. The backing member 702 provides rigidity to the busbar 630. The centers of the through holes 636, 734 are aligned or substantially aligned. The floating socket connector 10 is placed on the upper surface 632 of the busbar 630 with the coupling projection 18 over the through hole 636 of the busbar 630. The coupling projection 18 may partially sit within the through hole 636 as a result of the chamfer 44. Next, the tool 700 is assembled with the floating socket connector 10. The pin projection 714 is inserted into the passageway 82 of the contact assembly 14, but is preferablysized so that the contact beams 80 are not flexed. The tool 700 is pushed downward onto the floating socket connector 10 until the planar lower end 718 of the pin projection 714 engages against the lower horizontal wall surface 32 of the main body 16. The housings 12, 50 and the contact 52 partially seat within the recess 730. This assists in preventing substantial movement of the floating socket connector 10 within the tool 700. The tool 700 and floating socket connector 10 are then pushed downward onto the busbar 630. Upon continued movement, the coupling structure 46, 46a, 46b on the coupling projection 18 bites into the wall forming the through hole 636 of the busbar 630. Downward movement is continued until the lower surface 724 of the outer sheath 706 of the tool 700 and the lower surface 22 of the main body 16 of the floating socket connector 10 engage against the upper surface 632 of the busbar 630. The lower surface 22 forms a shoulder which rests on the upper surface 632 of the busbar 630. The coupling projection 18 may extend into the through hole 736 of the backing member 702. Thereafter, the tool 700 is pulled off of the floating socket connector 10 and the busbar 630 is lifted off of the backing member 702.

[0052] To assemble the floating socket connector 10 with the busbar 630 using the tool 700’, the busbar 630 is placed on top of the backing member 702 such that the upper surface 732 of the backing member 702 lays flat against the lower surface 634 of the busbar 630. The backing member 702 provides rigidity to the busbar 630. The centers of the through holes 636, 734 are aligned or substantially aligned. The floating socket connector 10 is placed on the upper surface 632 of the busbar 630 with the coupling projection 18 over the through hole 636 of the busbar 630. The coupling projection 18 may partially sit within the through hole 636 as a result of the chamfer 44. Next, the outer sheath 706’ is placed around the floating socket connector 10. The anvil 704’ is assembled with the floating socket connector 10 by inserting the pin projection 714’ into the passageway 82 of the contact assembly 14. The anvil 704’ is pushed downward onto the floating socket connector 10 until the planar lower end 718’ of the pin projection 714’ engages against the lower horizontal wall surface 32 of the main body 16. The housings 12, 50 and the contact 52 partially seat within the recess 730’. This assists in preventing substantial movement of the floating socket connector 10 within the tool 700’. The anvil 704’ and floating socket connector 10 are then pushed downward onto the busbar 630. Upon continued movement, the coupling structure 46, 46a, 46b on the coupling projection 18 bites into the wall forming the through hole 636 of the busbar 630. Downward movement is continued until the upper surface710’ of the anvil 704’ aligns with the upper surface 722’ of the outer sheath 706’. In this position, the lower surface 22 of the main body 16 of the floating socket connector 10 engages against the upper surface 632 of the busbar 630. The lower surface 22 forms a shoulder which rests on the upper surface 632 of the busbar 630. The coupling projection 18 may extend into the through hole 736 of the backing member 702. Thereafter, the tool 700’ is pulled off of the floating socket connector 10 and the busbar 630 is lifted off of the backing member 702.

[0053] While a particular contact assembly 14, 114 is shown and described herein, other contact assemblies such one or more of those disclosed in Indian Application Nos.202421005045, 202421005152, 202321059205, 202321081652, 202321059130, 202321054898, 202321068977, 202321075647, 202321058110 and 202321056167 and in United States provisional application Nos. 63 / 539,596 and 63 / 544,641, may be used with the present contact assembly receiving housing 12, 112.

[0054] Directional terms such as front, rear, horizontal, vertical and the like are used for ease in explanation, and do not denote a required orientation in use.

[0055] While a particular embodiment is illustrated in and described with respect to the drawings, it is envisioned that those skilled in the art may devise various modifications without departing from the spirit and scope of the appended claims. It will therefore be appreciated that the scope of the disclosure and the appended claims is not limited to the specific embodiments illustrated in and discussed with respect to the drawings and that modifications and other embodiments are intended to be included within the scope of the disclosure and appended drawings. Moreover, although the foregoing descriptions and the associated drawings describe example embodiments in the context of certain example combinations of elements and / or functions, it should be appreciated that different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the disclosure and the appended claims. Further, the foregoing descriptions describe methods that recite the performance of a number of steps. Unless stated to the contrary, one or more steps within a method may not be required, one or more steps may be performed in a different order than as described, and one or more steps may be formed substantially contemporaneously. Finally, the drawings are not necessarily drawn to scale.

Claims

What is claimed is:

1. A floating socket connector for receiving a pin and which is mountable in a through hole in a busbar, the floating socket connector comprising: a contact assembly receiving housing including a main body defining an outer diameter, a recess within the main body, and a coupling projection extending from the main body, the coupling projection having an outer diameter which is less than the outer diameter of the main body, the recess being defined by a side wall surface and a lower wall surface, the coupling projection having a coupling structure on an outer surface thereof which is configured to engage with and electrically couple with the busbar; and a contact assembly mounted within the contact assembly receiving housing and configured for movement relative thereto, the contact assembly being configured to receive and electrically couple with the pin.

2. The floating socket connector of claim 1, wherein the coupling structure is formed of a plurality of spaced apart splines.

3. The floating socket connector of claim 2, wherein the splines extend vertically.

4. The floating socket connector of claim 1, wherein the coupling structure is formed of a plurality of spaced apart bumps or a screw thread.

5. The floating socket connector of claim 1, wherein the coupling projection extends from the center of the main body.

6. The floating socket connector of claim 1, wherein the contact assembly is movable relative to the contact assembly receiving housing in two dimensions or in three dimensions.

7. The floating socket connector of claim 1, in combination with a tool comprising a body and a pin projection extending from the body of the tool, wherein the contact assembly isconfigured to receive the pin projection with an end of the pin projection engaging against the lower wall surface of the main body of the contact assembly receiving housing.

8. The floating socket connector and tool of claim 7, wherein the tool further includes an outer sheath surrounding the body of the tool, wherein a recess is formed between the outer sheath and the pin projection.

9. The floating socket connector and tool of claim 8, wherein a portion of the floating socket connector seats within the recess of the tool.

10. The floating socket connector and tool of claim 8, wherein the outer sheath and body of the tool are formed as two separate components.

11. The floating socket connector and tool of claim 8, in combination with a rigid backing member configured to seat under the busbar and provide rigidity to the busbar.

12. An assembly comprising: a floating socket connector configured to receive a pin, the floating socket connector including a contact assembly receiving housing having a main body defining an outer diameter, a recess within the main body, and a coupling projection extending from the main body, the coupling projection having an outer diameter which is less than the outer diameter of the main body, the recess being defined by a side wall surface and a lower wall surface, the coupling projection having a coupling structure on an outer surface thereof, and a contact assembly mounted within the contact assembly receiving housing and configured for movement relative thereto, the contact assembly being configured to receive and electrically couple with the pin; and a busbar having a through hole into which the coupling projection is configured to be seated.

13. The assembly of claim 12, wherein the coupling structure is formed of a plurality of spaced apart splines.

14. The assembly of claim 13, wherein the splines extend vertically.

15. The assembly of claim 13, wherein the coupling structure is formed of a plurality of spaced apart bumps or a screw thread.

16. The assembly of claim 12, wherein the coupling projection extends from the center of the main body.

17. The assembly of claim 12, wherein the contact assembly is movable relative to the contact assembly receiving housing in two dimensions or in three dimensions.

18. The assembly of claim 12, in combination with a tool comprising a body and a pin projection extending from the body of the tool, wherein the contact assembly is configured to receive the pin projection with an end of the pin projection engaging against the lower wall surface of the main body of the contact assembly receiving housing.

19. The assembly of claim 18, wherein the tool further includes an outer sheath surrounding the body of the tool, wherein a recess is formed between the outer sheath and the pin projection.

20. The assembly of claim 19, wherein a portion of the floating socket connector seats within the recess of the tool.

21. The assembly of claim 20, wherein the outer sheath and body of the tool are formed as two separate components.

22. The assembly of claim 20, in combination with a rigid backing member configured to seat under the busbar and provide rigidity to the busbar.

23. A method of assembling a floating socket connector with a busbar comprising: placing a floating socket connector on a busbar, the floating socket connector including a contact assembly receiving housing having a main body defining an outer diameter, a recess within the main body, and a coupling projection extending from the main body, the coupling projection having an outer diameter which is less than the outer diameter of the main body, the recess being defined by a side wall surface and a lower wall surface, the coupling projection having a coupling structure on an outer surface thereof, and a contact assembly mounted within the contact assembly receiving housing and configured for movement relative thereto, the contact assembly being configured to receive and electrically couple with a pin, the busbar having a through hole, wherein the coupling projection of the floating socket connector is positioned over the through hole of the busbar; and pushing the coupling projection of the floating socket connector into the through hole of the busbar.

24. The method of claim 23, further comprising using a tool to push the floating socket connector into the busbar.

25. The method of claim 24, wherein the tool comprises a body and a pin projection extending from the body of the tool, wherein the pin projection is inserted into the contact assembly and the tool is pushed to engage an end of the pin projection against the lower wall surface of the main body of the contact assembly receiving housing.

26. The method of claim 25, further comprising placing a rigid backing member under the busbar to provide rigidity to the busbar.

27. The method of claim 26, wherein the tool further comprises an outer sheath, and further comprising placing the outer sheath around the floating socket connector and engaging the outer sheath with the busbar, and moving the body of the tool and the pin projection relative to the outer sheath.

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