Replaceable Electrical Connector

Abstract

A cable connector permitting ease of replacement thereof with respect to its connections to a cable. One or more longitudinal conductors are permanently secured within the connector shell assembly, each conductor having a forward end including conventional contact means for releasably engaging a corresponding contact supplied by a mating connector component. The rearward end of each of the longitudinal conductors includes respective rearward contacts, to which secondary contacts (preferably crimped to the cable wires) are conductively and releasably securable.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention.

This invention relates to electrical connectors, and more particularly to a cable connector permitting ease of replacement with respect to its connections to a cable.

2. Description of the Prior Art.

Cable connectors ordinarily comprise mating plug and receptacle assemblies, for releasably coupling a plurality of conductors in predetermined arrangement. The plug and receptacle assemblies can each be attached to respective cables (in which case one of the assemblies is generally mounted to a panel), or one of the assemblies can be attached to the cable while the other is an integral part of an electrical instrument, such as a transducer apparatus.

In most cable connectors known to the prior art, the individual conductive wires of a cable are rigidly attached to individual contacts permanently carried by one of the connector components (i.e., the plug or the receptacle assembly). When this type of connector component experiences a mechanical failure, it cannot be easily replaced, causing the instrument to which it is coupled to be inoperative for extended periods of time. In applications where it is desirable that particular conditions be continuously monitored, it is important that periods of instrument inactivity caused by connector failure be decreased to a minimum.

In prior attempts to overcome "downtime" caused by connector failure, various cable connectors have been developed which can be replaced at the site of application. Generally, such connector components include removable mating conductors (i.e., conventional sockets or pins). A typical replacement procedure involves removing the damaged connector component from the cable, disassembling a replacement component (requiring the removal of the conductors and the associated insulator parts therefrom), soldering or otherwise attaching the cable wires to the new conductors, and reassembling the various parts. This procedure is both difficult and time-consuming requiring an adept manipulation of many small parts.

Moreover, for high-temperature applications (e.g., up to 800.degree. F.), ceramic insulation is generally provided for insulating the conductors from each other and from the conductive shell of the connector component. In high-temperature connector components containing removable conductors, the conductors cannot be rigidly secured with respect to the ceramic insulator. When a connector component of this type is operatively coupled to a mating connector component attached to a transducer which originates high-frequency signals (such as a vibration sensor, a velocity sensor or an accelerometer), high-frequency movement often occurs between the conductors and the ceramic insulator, increasing the connector's susceptibility to failure. In addition, particularly in accelerometer applications, such high-frequency movement produces an audible chatter which is impressed upon the transducer output signal.

SUMMARY OF THE INVENTION

The present invention provides a cable connector component which is easily replaceable at the site of application. In its preferred embodiment, the connector component can be utilized in high-temperature and high-frequency vibration applications without producing relative movement between the conductors and the refractory insulation securing the conductors to the shell of the connector component.

The connector component includes a conductive shell assembly having a longitudinal axis and including a transverse wall portion therein. One or more longitudinal conductors are permanently secured within the shell assembly, each conductor having a forward end including conventional contact means for releasably engaging a corresponding contact supplied by a mating connector component. Each of the longitudinal conductors further includes a rearward end having a rearward contact means, and the conductors are rigidly secured within the shell by an insulative bond between an intermediate portion of the conductors and axial bores in the wall portion.

The rearward contacts of the longitudinal conductors are insulated from each other by means of an apertured ceramic insert. Secondary conductor means are provided for attachment to each of the cable wires, preferably by crimping the secondary conductors to the conductive wires. The secondary conductors include secondary contacts for releasably engaging the rearward contacts of the connector conductors; for example, the secondary contacts can be of the socket type while the rearward connector contacts can be of a mating-pin type. Conventional clamping means is removably coupled to the shell assembly for preventing axial separation of the secondary contacts from the rearward contacts.

The replacement of the connector component is easily and rapidly performed. Upon removing a damaged component from the cable, new secondary conductors can be crimpt onto the cable wires and installed on the connector's rearward contacts. The cable is then secured by coupling the clamping means to the connector shell assembly.

BRIEF DESCRIPTION OF THE DRAWING

The novel features which are believed to be characteristic of the invention will be better understood from the following description considered in connection with the accompanying drawing in which a preferred embodiment of the present invention is illustrated by way of example. It is expressly understood, however, that the drawing is for the purpose of illustration and description only and is not intended as a definition of the limits of the invention.

The drawing is a cross section view of a preferred embodiment of an electrical cable connector component in accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning to the drawing, the preferred connector component 10 finds particular application for releasably coupling a pair of conductive wires 12 of a shielded cable 14 to conductive contacts (not shown) supplied by a connector component integral with a two-terminal instrument; e.g., a vibration-type transducer. It should be noted, however, that the preferred embodiment 10 can be adapted for connecting a single conductive wire to a supplied contact, as well as for connecting any plurality of wires to a corresponding plurality of supplied contacts.

The connector component 10 includes an electrically conductive shield assembly 16 having a longitudinal axis a-a and comprising a generally tubular shell member 18 having a rear annular shoulder 20 and a forward member 22 having a transverse wall portion 24 within the shell assembly 16. The shell member 18 and the forward member 22 are rigidly and conductively attached to one another, for example by means of welds 26.

The wall portion 24 of the forward member 22 is provided with axially directed bores 28 therethrough, the number of such bores depending upon the number of conductive wires included by the cable 14.

A pair of rigid longitudinal conductors 30 extend through the wall portion 24. The conductors 30 include separate contact means on each end thereof; for example, the forward end of the conductor 30 can include a conventional socket-type contact 32, while the rearward end of the conductor 30 can include a conventional pin-type contact 34. Accordingly, the connector component 10 shown in the drawing is a receptacle assembly, the socket contacts 32 adapted for mating with pin-type contacts supplied by a plug assembly (not shown).

Means are provided for rigidly and insulatably securing the longitudinal conductors 30 to the wall portion 24, axially through the bores 28, along portions of the conductors 30 between their respective socket contacts 32 and their respective pin contacts 34. For example, glass-bonding means 38 can be provided within the bores 28 and surrounding the intermediate portions 36 of the conductors 30, effecting a glass-to-metal seal between the wall portion 24 of the forward member 22 and the conductor intermediate portions 36. In such manner, the conductors 30 are permanently secured to the shell assembly 16 in a predetermined configuration, electrically insulated with respect to one another and with respect to the shell assembly 16, and including socket contacts 32 and pin contacts 34 axially extending from opposite faces of the wall portion 24.

The rearward pin contacts 34 are electrically insulated with respect to each other by means of a ceramic insert 40 retained by the shell assembly 16 by means of a shoulder 42 in cooperative engagement with the shell member shoulder 20, the forward face of the insert 40 in contact engagement with the rearward surface of the wall portion 24.

The ceramic insert 40 includes axially directed holes 44 therein for receiving the pin contacts 34. The holes 44 extend through the ceramic insert 40, and each hole 44 includes portions thereof which are variable in diameter (such as a forward portion 44a for accommodating the conductors 30) an intermediate hole portion 44b for accommodating a secondary socket contact 46 of a secondary conductor 48, and a rearward hole portion 44c for accommodating a crimp-type contact 50 of the secondary conductor 48. In such manner, the rearward pin contacts 34 are insulated from each other and from the shell assembly 16, while the secondary conductors 48 are similarly insulated from each other and from the shell assembly 16.

Although other insulation materials (such as epoxy or neoprene) can be substituted for ceramic in order to provide the insert 40, as well as for the glass 38, the use of these refractory materials permits the receptacle 10 to be employed in relatively high-temperature environments or where the coupled transducer generates a large amount of heat.

The secondary conductors 48 are secured to the cable wires 12 by means of the crimp-type contacts 50. Alternatively, the secondary conductors 48 can be soldered to the wires 12 if desired, provided operating temperatures are not produced which are sufficiently high to melt the solder. The secondary socket contact 46 comprising the forward portion of the secondary conductor 48 is releasably coupled to the pin contacts 34, for providing conductive communication between the wires 12 and the pin contacts 34.

The shielded cable 14 is removably secured to the shell assembly 16 by means of conventional static strain relief apparatus, such as a cable clamp 52 in clamping engagement with the conductive outer shield of the cable 14 and retained by a clamp nut 54 threadably engaging the shell member 18. The metal clamp 52 and clamp nut 54 provide conductive communication between the conductive outer shield of the cable 14 and the receptacle shell assembly 16, while preventing axial separation of the secondary socket contacts 46 from the rearward pin contacts 34.

In conventional manner, the shell assembly 16 includes a sleeve portion 56 (integral with the forward member 22), provided with a key 58, for cooperative engagement with associated parts included by the supplied plug assembly. The e receptacle 10 can be conductively and releasably coupled to the shell assembly of the plug by conventional means, such as an internally threaded coupling nut 60 threadably engaging external threads provided by the plug.

In the event of failure of a connector receptacle having contacts rigidly secured to the cable wires 12 (as in prior art connector configurations) or failure of the connector receptacle 10 of the present invention, a replacement receptacle 10 can be substituted therefor in a simple manner. After being decoupled from the supplied plug assembly, the damaged receptacle can be removed by cutting the cable 14, and the clamp nut 54 and clamp 52 can be slipped onto the cable 14. The ends of the conductive wires 12 are then bared by stripping a portion of the insulation therefrom, and the crimp-type contacts 50 of the secondary conductors 48 are crimped onto the ends of the wires 12. The secondary socket contacts 46 of the secondary conductors 48 are thereupon inserted into the appropriate holes 44 of the ceramic insert 40 and onto the rearward pin contacts 34. The clamp nut 54 is threadably secured to the shell member 18, causing the cable 14 to be retained by the cable clamp 52.

Alternatively, a damaged receptacle 10 can be replaced by merely uncoupling the clamp nut 54, axially separating the secondary socket contacts 46 from the rearward pin contacts 34, connecting the secondary socket contacts 46 to the pin contacts 34 of the replacement receptacle 10 and coupling the clamp nut 54 thereto.

Thus, there has been described a preferred embodiment of a cable connector component permitting ease of replacement with respect to its connections to an electrical cable, the preferred embodiment being a high-temperature connector receptacle for combination with a connector plug integral with a transducer. Other embodiments of the present invention, and modifications of the preferred embodiment herein presented, may be developed without departing from the essential characteristics thereof.

For example, the connector component 10 can be of the plug type, for mating connection to a supplied connector receptacle. Similarly, the rearward contact means provided by the connector component can be of the socket type (instead of the pin contacts 34), whereupon the secondary conductors 48 will include secondary pin contacts (instead of the secondary socket contacts 46). In addition, both mating components of a connector can be constructed in accordance with the present invention, for releasably coupling the conductive wires of the cables; i.e., one of the connector components need not be an integral part of a supplied transducer or other instrument.

Accordingly, the invention should be limited only by the scope of the claims listed below.

Claims

What is claimed is:

1. In a connector for releasably coupling a plurality of conductive wires included by a cable to a corresponding plurality of supplied contacts, the combination comprising:

a shell assembly having a longitudinal axis and including a transverse wall portion therein;

a plurality of longitudinal conductors each having a forward end portion including forward contact means for releasably engaging a respective one of the supplied contacts, a rearward end portion including rearward contact means, and an intermediate portion between said forward and rearward end portions;

securing means in said wall portion insulatably securing each of said longitudinal conductors axially through said wall portion along respective ones of said intermediate portions;

insulating means carried by said shell assembly and having longitudinal apertures therein communicating with respective ones of said longitudinal conductors, said end portions respectively positioned within said apertures; and

a plurality of secondary conductors respectively secured to the wires and including secondary contact means releasably engaging said rearward contact means, said secondary conductors respectively fitted within said apertures for permitting said secondary conductors to be axially withdrawn from said apertures and removed from the connector.

2. The connector according to claim 1, above, wherein said rearward contact means comprises a pin contact, and said secondary contact means comprises a socket contact.

3. The connector according to claim 1, above, wherein each of said secondary conductors includes a crimpable contact for securing said secondary conductors to the wires.

4. The connector according to claim 1, above, wherein

said transverse wall portion includes a plurality of axial bores therein,

said intermediate portions of said longitudinal conductors are axially positioned within respective ones of said bores, and

said securing means comprises an insulating material within said bores bonding said intermediate portions to said wall portion.

5. The connector according to claim 4, above, further including means removably coupled to said shell assembly and securable to the cable, for preventing axial separation of said secondary contact means from said rearward contact means.

6. In a connector for releasably coupling a plurality of conductive wires included by a cable to a corresponding plurality of supplied contacts, the combination comprising:

a shell assembly having a longitudinal axis and including a transverse wall portion having a plurality of axial bores therein;

a plurality of longitudinal conductors each having a forward end portion including forward contact means for releasably engaging a respective one of the supplied contacts, a rearward end portion including rearward contact means, and an intermediate portion between said forward and rearward end portions axially positioned within a respective one of said bores;

a glass material within said bores insulatably bonding said intermediate portions to said wall portion;

a plurality of secondary conductors secured to respective ones of the wires and including secondary contact means axially engaging said rearward contact means; and

an insulating member carried by said shell assembly and insulating said rearward end portions from one another and from said shell assembly, said insulating means adapted for axially receiving said secondary conductors.

7. The connector according to claim 6, above, further including means removably coupled to said shell assembly and securable to the cable, for preventing axial separation of said secondary contact means from said rearward contact means.

8. In a connector for releasably coupling a plurality of conductive wires included by a cable to a corresponding plurality of supplied contacts, the combination comprising:

a shell assembly having a longitudinal axis and including a transverse wall portion therein, said transverse wall portion having a plurality of axial bores;

a plurality of longitudinal conductors each having a forward end portion including forward contact means for releasably engaging a respective one of the supplied contacts, a rearward end portion including rearward contact means, and an intermediate portion between said forward and rearward end portions said intermediate portions of said longitudinal conductors being axially positioned within respective ones of said bores;

securing means in said wall portion insulatably securing each of said longitudinal conductors axially through said wall portion along respective ones of said intermediate portions, said securing means comprising a glass within said bores bonding said intermediate portions to said wall portions;

a plurality of secondary conductors removable from the connector, said secondary conductors secured to respective ones of the wires and including secondary contact means axially engaging said rearward contact means; and

ceramic insulating means carried by said shell assembly and insulating said rearward end portions from one another and from said shell assembly, said ceramic insulating means adapted for axially receiving said secondary conductors.

9. The connector according to claim 8, above, further including means removably coupled to said shell assembly and securable to the cable, for preventing axial separation of said secondary contact means from said rearward contact means.