Universal test connector and method of assembly
First Claim
1. A method of assembling a test connector to attach a test wire harness comprising at least one wire to a connector of an aircraft wire harness, the method comprising:
- joining the at least one wire of the test wire harness to an insert having a plurality of electrical contacts configured to mate with the aircraft wire harness connector;
packing each joined wire of the test harness with non-conductive potting material where each joined wire is joined to the insert; and
directly covering the non-conductive potting material with non-conductive, heat shrink tubing material, while maintaining the electrical contacts substantially exposed and not covered by the heat shrink tubing.
1 Assignment
0 Petitions
Accused Products
Abstract
A method of assembling an electrical test connector for testing connectivity in aircraft wire harness fitted with military specification or other electrical connectors. In a particular embodiment, the test connector is manually assembled on site by a technician from components that are readily and inexpensively available, providing ease and speed in completing connectivity or other wire testing. The test connector has a mating insert, selected and configured to mate with an identified aircraft connector present on the harness to be tested. Insulation and internal wire support is provided by packing the wire connections with a potting material and covering the test connector with an optional heat shrink tubing. Alignment to the aircraft connector may be keyed with the use of a visual indicator applied to the covering. The components as a kit and the assembled test connector are also provided.
36 Citations
29 Claims
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1. A method of assembling a test connector to attach a test wire harness comprising at least one wire to a connector of an aircraft wire harness, the method comprising:
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joining the at least one wire of the test wire harness to an insert having a plurality of electrical contacts configured to mate with the aircraft wire harness connector;
packing each joined wire of the test harness with non-conductive potting material where each joined wire is joined to the insert; and
directly covering the non-conductive potting material with non-conductive, heat shrink tubing material, while maintaining the electrical contacts substantially exposed and not covered by the heat shrink tubing. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method of manually assembling a test connector to attach a test wire harness having at least one wire to a connector of an aircraft wire harness, the aircraft wire harness connector having an alignment key, the method comprising:
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joining the at least one wire of the test wire harness to an insert having a plurality of electrical contacts configured to mate with the aircraft wire harness connector;
packing each joined wire of the test wire harness with non-conductive potting material where each joined wire is joined to the insert;
directly covering the non-conductive potting material and joined wires with non-conductive, heat shrink tubing material while maintaining the electrical contacts substantially exposed and not covered by the heat shrink tubing material; and
forming an alignment indicator on the heat shrink tubing. - View Dependent Claims (13)
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14. A test connector assembly for use in connecting a test wire harness having test wires to a connector of an aircraft wire harness, the test connector assembly comprising:
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a mating insert configured to mate with the aircraft wire harness connector, the insert having a first side, an opposed second side, and a plurality of electrical contacts, each contact having one end configured to mate with an aircraft connector and another end joined to a test wire from the test wire harness;
a non-conductive potting material manually inserted between the joined test wires proximate to the insert; and
non-conductive, heat shrink tubing installed directly around the potting material and joined test wires, wherein the plurality of electrical contacts are substantially exposed and not covered by the heat shrink tubing. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21)
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22. A kit for assembling at least one test connector for use in connecting a test wire harness comprising at least one wire to at least one predetermined connector of an aircraft wire harness, the kit comprising:
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at least one conductive mating connector insert having a plurality of electrical contact configured to mate with the predetermined aircraft wire harness connector;
non-conductive potting material to support the at least one wire of the test wire harness wires when joined to the insert; and
non-conductive heat shrink tubing to directly cover the potting material and joined test wires, while maintaining the electrical contacts substantially exposed and covered by the heat shrink tubing. - View Dependent Claims (23, 24, 25, 26, 27, 28, 29)
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Specification