Separable insulated connector system

• US 7,568,927 B2
• Filed: 04/23/2007
• Issued: 08/04/2009
• Est. Priority Date: 04/23/2007
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Roscizewski, Paul Michael, Hughes, David Charles
• Primary Examiner(s): Leon; Edwin A.
• Application Number:
  US11/738,948
• Publication Number:
  US 20080261465A1
• Time in Patent Office: 834 Days
• Field of Search: 439/889, 439/88, 439/190, 439/912, 439/921, 439/206, 439/89, 439/181, 439/183, 439/184, 439/185, 439/198, 439/205
• US Class Current: 439/181
• CPC Class Codes: H01R 13/187 with spring member in the socket
• CPC Class Codes: H01R 13/53 Bases or cases for heavy duty; Bases or cases for high voltage with means for preventing corona or arcing
• CPC Class Codes: H02G 15/04 Cable-end sealings
• CPC Class Codes: Y10T 29/49204 Contact or terminal manufacturing

Abstract

Separable insulated connector systems for power distribution systems wherein the interfaces of the mating connectors are modified to reduce mating and separation force.

Claims

1. A separable insulated connector for a power distribution system, the connector comprising:

an electrical contact;

a conductive insert defining a faraday cage around a portion of the electrical contact;

an elastomeric insulating housing having an open end and a connector interface extending inward from the open end, the connector interface having an inner surface defining a passage dimensioned to slidably receive a mating connector along an axial insertion axis;

wherein the connector interface comprises a mouth;

wherein a circumferential dimension of the passage varies along the insertion axis;

wherein a region of the connector interface overlaps the faraday cage;

wherein the connector interface comprises at least one inflection extending circumferentially on the inner surface, the at least one inflection being located between the mouth and the region of the connector interface that overlaps the faraday cage; and

wherein a rate of change of the circumferential dimension is different before and after the inflection.

2. The connector of claim 1, wherein the rate of change of the circumferential dimension is greater before the inflection point than after the inflection point.

3. The connector of claim 1, wherein the rate of change of the circumferential dimension is constant before the inflection.

4. The connector of claim 1, wherein the inflection point generates an increased band of contact pressure with the mating connector.

5. The connector of claim 1, wherein the inflection marks a discontinuity in the inner surface.

6. The connector of claim 1, wherein the rate of change of the circumferential dimension is negative before the inflection and positive after the inflection.

7. A separable insulated connector for making or breaking an energized connection in a power distribution network, the connector comprising:

an electrical contact;

a conductive insert defining a faraday cage around a portion of the electrical contact;

an elastomeric insulation housing surrounding the electrical contact and the conductive insert, the housing defining an open ended connector interface comprising a mouth, the connector interface extending about the electrical contact forward of the conductive insert and having a tapered circumferential dimension along an axis of the electrical contact;

wherein the connector interface receives a mating connector;

wherein a region of the connector interface overlaps the faraday cage; and

wherein the connector interface comprises at least one inflection extending circumferentially on an inner surface thereof between the mouth and the region of the connector interface that overlaps the faraday cage, the inflection altering an amount of insertion force necessary to engage the mating connector.

8. The connector of claim 7, wherein a rate of change of the circumferential dimension is different before and after the inflection.

9. The connector of claim 8, wherein the rate of change of the circumferential dimension is constant before the inflection.

10. The connector of claim 8, wherein the rate of change of the circumferential dimension is greater before the inflection than after the inflection.

11. A separable insulated connector for a power distribution system, the connector comprising:

an elastomeric housing comprising an interior, an exterior, a mouth, and an open end the interior of the housing comprising a connector interface,

wherein the connector interface extends inward from the open end along the interior, the connector interface comprising;

a mouth;

an inner surface defining a passage dimensioned to slidably receive a mating connector along an insertion axis;

an inflection extending circumferentially on the inner surface and comprising an increased band of contact pressure with the mating connector;

wherein the rate of change of the circumferential dimension of the inner surface is greater along a first portion of the inner surface between the open end and the inflection than along a second portion of the inner surface between the inflection and an end opposite the open end and the circumferential dimension of the inner surface is greater along the first portion of the inner surface than along the second portion of the inner surface;

a probe assembly affixed to the interior of the elastomeric housing, the probe assembly comprising a contact probe having a first end and a second end, the first end of the contact probe coupled to the contact assembly and extending along a passage in the connector interface;

a semi-conductive insert coupled to the probe assembly, the semi-conductive insert comprising a faraday cage being overlapped by a region of the connector interface, the faraday cage comprising a first and a second end, wherein the inner surface extends from the first end of the faraday cage to the open end of the elastomeric insulating housing; and

a ground plane positioned along the exterior of the elastomeric housing,

wherein the inflection is located between the mouth and the region of the connector interface that overlaps the faraday cage.

12. The connector of claim 11, wherein the rate of change of the circumferential dimension is constant before the inflection.

13. A separable insulated connector for making or breaking an energized connection in a power distribution network, the connector comprising:

a contact means for extending along a passage in a connector interface and providing a contact point between the connector and a mating connector;

a means for preventing a corona discharge along an interface between the connector and the mating connector when the connector and the mating connector are mated, the means comprising a conductive insert positioned around a portion of the contact means;

a means for providing insulation around the contact means and the corona discharge prevention means, the insulation means defining an open ended interface having a mouth and an inner surface, the interface extending about the contact means forward of the corona discharge prevention means and having a tapered circumferential dimension along an axis of the contact means;

wherein a region of the interface overlaps the means for preventing corona discharge;

wherein the interface receives a means for slidable insertion into the interface; and

wherein the inner surface comprises at least one pressure means comprising an inflection located between the mouth and the region of the interface that overlaps the means for preventing corona discharge, and

wherein the pressure means extends into the interface from the insulation means and provides an increased amount of contact pressure on the means for slidable insertion into the interface.

14. The connector of claim 13, wherein a rate of change of the circumferential dimension is different before and after the inflection.

15. The connector of claim 14, wherein the rate of change of the circumferential dimension is constant before the inflection.

16. The connector of claim 14, wherein the rate of change of the circumferential dimension is greater before the inflection than after the inflection.

17. A method comprising:

providing an insulating housing, the housing configured to comprise an open end and a connector interface having a mouth;

positioning a contact assembly to an interior of the housing;

coupling a contact probe to the contact assembly inside the housing, the contact probe configured to have a first end and a second end, the first end affixed to the contact assembly and the probe extending along a passage in the connector interface;

providing a conductive insert defining a faraday cage around a portion of the contact probe such that the faraday cage is overlapped by a region of the contacts a region of the insulating housing;

associating a conductive extension member with the second end of the contact probe, the conductive extension member positioned to extend away from the connector interface; and

providing at least one inflection along a surface of the connector interface, the inflection pint generating an increased area of contact pressure with a mating connector,

wherein the at least one inflection is provided at a location between the mouth and the region of the connector interface that contacts the faraday cage.

18. The method of claim 17, wherein the surface of the connector interface comprises a tapered circumferential dimension.

19. The method of claim 18, wherein a rate of change of the circumferential dimension is different before and after the inflection.

20. The method of claim 19, wherein the rate of change of the circumferential dimension is greater before the inflection than after the inflection.