Method of forming connector with isolated conductive paths

• US 8,413,325 B2
• Filed: 06/21/2011
• Issued: 04/09/2013
• Est. Priority Date: 02/17/2005
• Status: Active Grant

• Current Assignee: GREENE, TWEED OF DELAWARE, INC., Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Finke, Michael Dewayne, Hensarling, Jesse Kevin, Beste, Randal Thomas, Burke, Charles Pence, Spence, James Neal
• Primary Examiner(s): PHAN, THIEM D
• Application Number:
  US13/165,314
• Publication Number:
  US 20110252643A1
• Time in Patent Office: 658 Days
• Field of Search: 298/83, 298/76, 298/79, 298/82, 285/342, 285/348, 439/190, 439/194, 439/271, 439/448, 439/506, 439/578, 439/581, 439/607.41, 439/700
• US Class Current: 29/883
• CPC Class Codes: H01R 13/516 Means for holding or embracing insulating body, e.g. casing , hoods
• CPC Class Codes: H01R 13/52 Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
• CPC Class Codes: H01R 13/5221 having cable sealing means
• CPC Class Codes: H01R 13/6315 allowing relative movement between coupling parts, e.g. floating connection for coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures, H01R12/91 takes precedence
• CPC Class Codes: H01R 43/16 for manufacturing contact members, e.g. by punching and by bending
• CPC Class Codes: Y10T 29/49123 Co-axial cable
• CPC Class Codes: Y10T 29/49204 Contact or terminal manufacturing
• CPC Class Codes: Y10T 29/49208 by assembling plural parts
• CPC Class Codes: Y10T 29/49213 Metal
• CPC Class Codes: Y10T 29/49218 with deforming
• CPC Class Codes: Y10T 29/4922 with molding of insulation
• CPC Class Codes: Y10T 29/5193 Electrical connector or terminal
• CPC Class Codes: Y10T 29/53209 Terminal or connector

Abstract

A method of forming a connector with isolated conductive paths can include using a flexible member. An example of a method of forming a connector with isolated conductive paths can include forming a bulkhead assembly including two-or-more isolated bulkhead conductive paths. A non-bulkhead assembly can be formed including two-or-more isolated non-bulkhead conductive paths. A flexible coupling can be formed between each of the two-or-more isolated bulkhead conductive paths and each of the two-or-more isolated non-bulkhead conductive paths to form a flexible connector. Another example method can include assembling, at least partially, a connector having a groove, securing a flexible member in the groove, and flowing solder into the flexible member in the groove. Additional methods and associated apparatus and systems are disclosed.

Claims

1. A method comprising:

forming a bulkhead assembly including two-or-more isolated bulkhead conductive paths;

forming a non-bulkhead assembly including two-or-more isolated non-bulkhead conductive paths; and

forming a flexible coupling between each of the two-or-more isolated bulkhead conductive paths and each of the two-or-more isolated non-bulkhead conductive paths to form a flexible connector, wherein forming the flexible coupling includes forming a flexible sleeve substantially surrounding a flexible member, the flexible member separated from a conductive flexible member in the non-bulkhead assembly by a flexible insulative material.

2. The method of claim 1, wherein forming the bulkhead assembly including the two-or-more isolated bulkhead conductive paths comprises:

forming a first assembly including one of the two-or-more isolated bulkhead conductive paths, the one of the two-or-more isolated bulkhead conductive paths is an inner path;

forming a second assembly including one of the two-or-more isolated bulkhead conductive paths, the one of the two-or-more isolated bulkhead conductive paths is an outer path; and

assembling the first and second assembly.

3. The method of claim 1, wherein forming the non-bulkhead assembly including the two or more isolated non-bulkhead conductive paths comprises:

assembling the conductive flexible member and an inner conductive socket; and

injection molding insulative material to provide insulation between the inner conductive socket and an outer socket.

4. The method of claim 3, wherein assembling the conductive flexible member and the inner conductive socket comprises:

coupling a spring to the inner conductive socket.

5. The method of claim 4, wherein coupling the spring to the inner conductive socket comprises coupling the spring to the inner conductive socket by crimping or by soldering.

6. The method of claim 1, wherein forming the bulkhead assembly comprises:

using beryllium copper.

7. The method of claim 1, wherein forming the bulkhead assembly comprises:

forming a torque member including an insulative material.

8. The method of claim 7, wherein forming the torque member including the insulative material comprises:

using polyetherether-ketone as the insulative material.

9. A method comprising:

forming a bulkhead assembly including two-or-more isolated bulkhead conductive paths, comprising;

forming a first assembly including one of the two-or-more isolated bulkhead conductive paths, the one of the two-or-more isolated bulkhead conductive paths is an inner path;

forming a second assembly including one of the two-or-more isolated bulkhead conductive paths, the one of the two-or-more isolated bulkhead conductive paths is an outer path; and

assembling the first and second assembly;

forming a non-bulkhead assembly including two-or-more isolated non-bulkhead conductive paths; and

forming a flexible coupling between each of the two-or-more isolated bulkhead conductive paths and each of the two-or-more isolated non-bulkhead conductive paths to form a flexible connector, wherein forming the first assembly comprises;

injection molding an insulative material around the inner conductive path to form an inner conductive path assembly;

injection molding an insulative material around the outer conductive path to form an outer conductive path assembly;

machining the inner conductive path assembly and the outer conductive path assembly to form a machined inner path assembly and a machined outer path assembly; and

assembling the machined inner path assembly and the machined outer path assembly including an O-ring to provide seal between the inner path assembly and the outer path assembly.

10. A method comprising:

forming a bulkhead assembly including two-or-more isolated bulkhead conductive paths;

forming a non-bulkhead assembly including two-or-more isolated non-bulkhead conductive paths, comprising;

assembling a conductive flexible member and an inner conductive socket; and

injection molding insulative material to provide insulation between the inner conductive socket and an outer socket; and

forming a flexible coupling between each of the two-or-more isolated bulkhead conductive paths and each of the two-or-more isolated non-bulkhead conductive paths to form a flexible connector, wherein forming the flexible coupling between each of the two or more isolated bulkhead conductive paths and each of the two or more isolated non-bulkhead conductive paths to form the flexible connector comprises;

coupling the conductive flexible member to a substantially rigid inner conductor of the bulkhead assembly to form a bulkhead and non-bulkhead assembly having an inner conductive path;

forming a flexible material around the inner conductive path;

assembling conductive braid over the conductive flexible material; and

forming flexible sleeve outside the conductive braid.