U.S. patent number 3,643,207 [Application Number 05/067,867] was granted by the patent office on 1972-02-15 for sealed electrical connector.
Invention is credited to James L. Cairns.
United States Patent |
3,643,207 |
Cairns |
February 15, 1972 |
SEALED ELECTRICAL CONNECTOR
Abstract
A reusable electrical connector for making an electrical
connection in adverse environments in which the electrical
connection is made by passing a contact through a self-sealing,
precut opening into a sealed chamber filled with dielectric fluid
to electrically contact a contact position in the fluid and which
chamber has means for instantaneously adjusting in volume to
changes in the ambient pressure or with the insertion or removal of
the electrical contact to maintain interior portions in equilibrium
with the pressure of the environment and to prevent the loss of
fluid from the sealed chamber.
Inventors: |
Cairns; James L. (San Diego,
CA) |
Family
ID: |
22078949 |
Appl.
No.: |
05/067,867 |
Filed: |
August 28, 1970 |
Current U.S.
Class: |
439/201;
439/272 |
Current CPC
Class: |
H01R
13/523 (20130101) |
Current International
Class: |
H01R
13/523 (20060101); H01r 009/08 () |
Field of
Search: |
;339/96,117,118 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: McGlynn; Joseph H.
Claims
Having described my invention, I now claim:
1. A sealed electrical connector comprising,
first and second bodies, said first body having a sealed chamber
for containing dielectric fluid sealed therein,
a first electrical connector positioned in said sealed chamber,
said second body having a second electrical connector,
said second electrical connector including an insulated projection
with an exposed conductor tip,
sealable opening means in said chamber for passing said second
electrical connector into said sealed chamber for said conductor
tip to electrically contact said first electrical contact in the
dielectric fluid,
and said sealed chamber has means for increasing and decreasing the
volume of said chamber by changing the shape of a flexible member
without stretching said member or otherwise creating a pressure
differential from the inside to the outside of the chamber.
2. A sealed electrical connector as claimed in claim 1 in
which,
said sealed chamber has a nonexpandable housing,
and said volume increasing and decreasing means comprises a
flexible member sealably covering a hole through said housing.
3. A sealed electrical connector as claimed in claim 1 in which,
said increasing and decreasing means includes a flexible member
that is open to the environment outside said first body.
4. A sealed electrical connector as claimed in claim 1 in
which,
said increasing and decreasing means includes a flexible member
positioned in said chamber.
5. A sealed electrical connector as claimed in claim 1 in
which,
said second electrical connector has a given cross-sectional
configuration,
and said sealable opening means includes a resilient member having
a precut slit-shaped opening shaped to said given cross-sectional
configuration, the sides of which sealably compress to close said
opening.
6. A sealed electrical connector as claimed in claim 5 in
which,
said sealable opening means is spaced from said first electrical
connector a distance greater than the length of the exposed
conductor tip.
7. A sealed electrical connector as claimed in claim 1 in
which,
said sealed chamber has a nonexpandable housing with an opening
through the wall of said chamber,
a resilient diaphragm sealing member for being positioned in said
opening,
and said sealable opening means includes a compressed precut
opening through said diaphragm that is biased to the sealed
condition.
8. A sealed electrical connector as claimed in claim 7 in
which,
said precut opening comprises a slit having notched edge surfaces
for guiding said second electrical conductor to said slit.
9. A sealed electrical connector as claimed in claim 7
including,
backing means for holding said diaphragm member in position.
10. A sealed electrical connector as claimed in claim 9
including,
said backing means comprises plates positioned on each side of said
diaphragm,
and said plates having openings therethrough aligned with said
precut opening.
11. A sealed electrical connector as claimed in claim 10 in
which,
said increasing and decreasing means comprises a flexible member
that projects into said sealed chamber forming a cavity,
and said diaphragm and backing means having aligned openings that
open said cavity to the environment outside said first body.
12. A sealed electrical connector as claimed in claim 11 in
which,
said flexible member is integral with said diaphragm.
13. A sealed electrical connector as claimed in claim 12 in which,
said second electrical connector includes at least one thin blade
electrode.
14. A sealed electrical connector as claimed in claim 13
including,
coupling means for securing said first electrical connector with
said second electrical connector,
and said coupling means having an opening therethrough for
communicating with said cavity.
Description
BACKGROUND OF THE INVENTION
There are many different types of electrical connectors for making
electrical connections in adverse environments. Many of these
electrical connectors are merely directed to making electrical
connections in humid or wet conditions. Other connectors are
designed to make electrical connections, for example in underwater
environments or in explosive environments, and in these
environments, a more critically designed electrical connector is
required in order to perform satisfactory.
There are known connectors that allow for the electrical mating to
take place in a sealed nonconductive fluid medium. These types of
connectors attempt to use the nonconductive fluid to prevent water
contact with the electrical connection. While these connectors may
be able to operate in high humidity or wet conditions, they are not
satisfactory for use in underwater operations to any reasonable
depths. Further these connectors can not be repeatedly connected
and disconnected underwater without danger of shoring out the
female conductor through the environment or without puncturing
one-time usable seals. Also the known connectors of the
fluid-filled type are either not compensated for changes in
pressure or volume, which changes often occur when the male portion
of the connector is inserted into the sealed chamber or where
ambient pressure conditions change, or if they are compensated, it
is accomplished by displacing movable sealed piston-type parts. The
movable piston-type compensator requires that the piston seal fit
tightly in the barrel. Thus in operation, the piston will not
easily compensate for abrupt changes in fluid pressure or fluid
volume, such as caused by the rapid withdrawal or insertion of the
male portion of the connector and either a loss of nonconductive
fluid or an inclusion of a part of the outside air or water takes
place. In the case of grease-filled connectors, cavitation within
the grease may take place. In addition, the barrel must be
maintained clean and flawless for the compensator to work. Still
further, known fluid-type filled connectors must be precisely
filled and cannot tolerate any subsequent loss of the nonconductive
fluid to remain usable.
It is therefore advantageous to have a new and improved reusable,
electrical connector for making repetitive electrical connections
in adverse environments to charge electrical connectors in which
the pressure of the fluid is maintained with the environment and
the charged electrode is not open to either an explosive atmosphere
or a corrosive atmosphere.
SUMMARY OF THE INVENTION
In an exemplary embodiment of the sealed electrical connector of
this invention, a first body has a sealed chamber with a dielectric
fluid and a first electrical connector positioned in the chamber.
This connector is normally a female conductor and can in operation
be electrically charged. A second electrical connector, that
normally is a male conductor with an insulated body and an exposed
conductor tip, passes into the sealed chamber through a precut
opening in a resilient self-sealing, wiper diaphragm. The end of
the second electrical connector contacts the female conductor in
the fluid environment making the electrical connection. The precut
opening in the diaphragm functions as a wiper to wipe the second
electrical connector clean prior to entry into the dielectric fluid
in the sealed chamber. The diaphragm or flexible member is held in
position under compression by backing means, that aids in
maintaining a sealed condition either with or without the second
electrical connector positioned in the opening. The precut opening
is a slit with a notch at the outer edge to direct penetration of
the male conductor therethrough.
The sealed chamber has means for adjusting its volume in response
to pressure changes or in response to the second electrical
connector being inserted or removed from the chamber. With the
female connector positioned in the chamber, it can be maintained in
a charged condition at all times and the second or male electrical
connector may be inserted through the sealable opening into the
fluid to make an electrical connection even at considerable depths
underwater. The female connector is not subject to contact with the
outer environment and thus does not short during connection or
disconnection, and is not subject to corrosion in adverse
environments. Further the precut slits forming the sealable
openings make the connector reusable as the penetration of the male
connector therethrough does not damage the opening.
It is therefore an object of this invention to provide a new and
improved sealed electrical connector.
It is another object of this invention to provide a reusable
electrical connector in which the connection is made within a
nonconductive fluid medium such as a nonconductive oil, grease or
fluid gel.
It is another object of this invention to provide a new and
improved sealed electrical connector having an internal fluid
chamber in which all interior portions remain in equilibrium with
the ambient pressure of the environment.
It is another object of this invention to provide a new and
improved sealed electrical connector in which one of the electrical
connections can remain electrically charged when disconnected in
the environment without danger of electrical inner action with the
environment.
It is another object of this invention to provide a new and
improved sealed electrical connector that is reusable and in which
one conductive member is never exposed to the corrosive properties
of the environment thus maintaining a clean mating surface.
It is another object of this invention to provide a new and
improved reusable, electrical, sealed connector having a fluid
chamber, in which the amount of fluid contained in the connector
need not be precisely measured or exactly maintained.
It is another object of this invention to provide a new and
improved sealed electrical connector in which the female portion of
the electrical connector can remain electrically charged during
repeated connecting and disconnecting in an explosive and
conductive environment and which device is pressure
compensated.
Other objects and many advantages of this invention will become
more apparent upon a reading of the following detailed description
and an examination of the drawings, wherein like reference numerals
designate like parts throughout and in which.
FIG. 1 is an exploded view of an embodiment of the sealed
electrical connector with portions sectioned along the axis.
FIG. 2 is an axial sectional view of the assembly sealed electrical
connector.
FIG. 3 is a top plan view of the lower body of FIG. 1.
FIG. 4 is a sectional view taken along line 4--4 of FIG. 1.
FIG. 5 is a sectional view taken on line 5--5 of FIG. 2.
FIG. 6 is a sectional view taken on line 6--6 of FIG. 2.
Referring now to the drawings, the embodiment 10 of the sealed
electrical connector has a first body 14 and a second body 12. The
second body 12 has male, blade-type, electrical connectors 28 that
are inserted through appropriate slit openings into a sealed
chamber in the first body 14 to make electrical contact with a
female electrical connector 62.
The second body normally forms the end of an electrical cable 16
and is made of neoprene or other suitable materials that are molded
with conductors 18 passing therethrough and being soldered or
otherwise electrically connected to electrical conductors 20.
Electrical conductors 20 comprise an electrical connection in which
a male conductor 28 is soldered into a female electrical conductor
22. The major portion of the length of the electrical connector or
conductor 28 is covered by a suitable insulating material such as
Teflon. The lower end of the second body 12 has a cylindrical
cavity 29 defined by a sidewall 31 that has a keyway 33 and a water
exit 32. A locking sleeve 26 is mounted on the body 12 and may be
held in position by, for example, rings 24 and has a threaded end
34 for engaging the threads 72 on the first body 14.
The first body 14 has a body portion 36 that may be made of
plastic, neoprene or other suitable materials. In this embodiment,
the first body is in the form of a bulkhead connector that fits
through a bulkhead 64 and is held in position by locknut 70 and
washer 68. O-ring 66 makes the necessary seal around the bulkhead
opening. It should be understood that this invention can be
employed in a female connector connected to the end of a cable or
in other suitable types of electrical connectors.
Positioned in the body or housing 36 is a sealed chamber 38 having
a dielectric fluid therein, which dielectric fluid may comprise a
nonconductive oil, grease or gel that is capable of flowing in the
manner of a fluid. The female electrical connector 62 is shaped to
receive the blade-shaped male connector 28 and is connected to
conductors that pass through the lower portion of the housing 36
for electrical connection to circuits within the bulkhead 64. In
this embodiment, the electrical power can normally be connected in
the "on" condition to the female connector. The outer end of the
housing 36 has an opening in which is positioned a wiper member 40
that has the general shape of a diaphragm and that is made of
suitable nonconducting material such as neoprene or other suitable
flexible and resilient materials. The wiper member 40 has precut
slits 51 cut therethrough that are shaped to the shape of the thin
blade electrical connectors 28. Backing plates 44 and 48 are
positioned above and below the wiper member 40 and are held in
position by lockring 54. The backing plates 44 and 48 have aligned
openings 46 and 50 that are also shaped to receive and pass the
electrical connectors 28. The precut slit 51 is notched at 52 for
directing the blade contact 28 into the precut slit 51. The precut
slit 51, coupled with the thickness of the wiper 40 and coacting
with the backing plates 44 and 48, seal the chamber 38 from leakage
of the fluid into the outer environment and for leakage from the
outer environment into chamber 38. Further when the male electrical
connector 28 is passed through slit 51, the slit 51 wipes the
electrical connector 28 relatively clean of corrosive fluids and
the like, which is aided by the Teflon surface 30, and further
seals the connector 28 in the slit 51 against passage of dielectric
fluid. Also the openings 46 in backing plate 44 are shaped to the
outer configuration of the upper ends of insulation 30, thereby
creating a sealing contact therebetween.
Positioned in the chamber 38 is a flaccid boot member 60 that may
be made of neoprene or other suitable materials and is normally
integral with the wiper member 40. The boot 60 has a cavity volume
58 that communicates through vent 56 to the outer environment. This
boot that has a bellows-type structure, allows volume changes of
the chamber 38 in response to changes in the pressure of the outer
environment thus maintaining an equalized pressure condition
between the fluid in chamber 38 and the pressure in the outer
environment. This prevents pressure differential problems within
the connector that occur, for example, underwater. Further the boot
60 quickly changes shape upon the insertion or removal of the
electrical connector 28 preventing fluid loss. It is to be
recognized that the boot 60 is immediately responsive to any
changes in pressure or volume and movements of expansion or
contraction or changes in shape occurs quickly without substantial
force and friction.
The backing plate or retaining plate 44 has a key portion 41 that
coacts with a key slot in the wiper 40, which wiper 40 in turn has
a key portion 43 that coacts with the key slot in backing plate 48.
This allows quick and easy alignment of the slits 51 with the
female connectors 62 and to be retained in this aligned position by
the locking ring 54.
In operation, the male connectors 28 are inserted through the slits
51 in the manner previously described with body 14 passing into the
cylindrical cavity 29 of body 12. The locking sleeve 26 is then
threadably engaged with the bulk head connector, drawing the two
bodies together at 73 forming a rigid connection. The key
projection 63 on the housing 36 fits into the keyway 33 of the
second body holding the male connectors 28 in alignment with slits
51 and with the female connectors 62. The hole 32 allows for water
exit during the making of the electrical connection, which water
escapes through the space between body 14 and housing 36 and
backing plate 44.
The male connectors pass through the slots 51 with the electrical
contact area 28 making the electrical connection. It may be
observed that in FIG. 2, the insulator coating 30 is well within
the chamber 38 before an electrical connection is made, and in
complete insertion sealably contacts opening 46. Since the slit 51
is precut, then the opening through the wiper 41 is not made by
puncturing or the like and accordingly the slit does not have
ragged edges and can be reused. Further the Teflon coating 30 tends
to reduce tearing of slit 51 in movement therethrough. Thus the
electrical connection can be made repeatedly without adversely
effecting the sealing capability of the wiper 40. Since the
electrical connection is made at all times in the dielectric fluid
38, the female connectors may be electrically connected to a power
source at all times and the electrical connection to the male plug
can be made or disconnected in an adverse environment, such as
underwater, without danger of electrical inner action with the
environment. Further it is to be noted that the female connector is
never exposed outside the dielectric fluid in chamber 38 and thus
is not exposed to corrosive properties in the environment and
always provides a clean mating surface. With the insertion of male
connectors 28, the fluid 38 in chamber 29 moves to compress the
boot member 60. With the expansion and contraction and
volume-adjusting capabilities of the boot 60, the amount of fluid
in chamber 38 need not be precisely measured or exactly maintained.
It is possible to insert additional fluid in chamber 38 in the
embodiment of FIG. 1, in the normal filling operation, to cover
possible losses of dielectric fluid 38 through openings 51 and 52
that might occur during use in removing male connectors 28. The
capabilities of the system are such that the boot 60 will allow for
sufficient volume changes to equalize pressure at large depths
underwater and allow for displacement of the fluid with the
connection and disconnection of the electrical coupling. While two
electrical connectors are illustrated, it should be understood that
a single electrical connector can be used or other multiple numbers
of electrical connectors can also be used in the sealed electrical
connector of this invention.
* * * * *