Coupling Assembly for Resilient Electrical Connector Components

This invention relates generally to electrical connector coupling devices and more particularly to coupling assemblies for resilient connector components. Specifically, the subject invention relates to an improved and simplified assembly for coupling a resilient connector component to another mateable connector component wherein the elasticity of the resilient component is utilized for maintaining the coupling assembly elements in cooperative relation.

Numerous arrangements for interconnecting electrical connector components are known including a wide variety of assemblies employing coupling rings. Generally, such assemblies include a threaded coupling ring rotatably mounted on one connector component and threadably engageable to a second connector component to couple the components and inter-engage the contact members carried by the components. Frequently, the coupling ring is fixed for rotation about a rigid plug component which is engageable with a rigid receptacle component. Furthermore, the coupling ring often functions as a ferrule when interconnecting the components.

A number of different arrangements are also known for resisting loosening or unthreading of such a coupling ring after the connector components have been firmly coupled together. One such common arrangement utilizes intermeshing teeth disposed on washer rings incorporated within the coupling assembly. Other arrangements utilize various spring devices to create a resistive force against decoupling. U.S. Pat. No. 3,917,373, issued Nov. 4, 1975 to George Peterson, and assigned to the assignee of the subject invention, discloses a coupling ring assembly wherein a ratchet mechanism is utilized to inhibit decoupling.

Such coupling assemblies and means for inhibiting decoupling have generally been complex and relatively expensive to construct. Furthermore, they have generally been employed with connector components constructed from rigid inflexible materials, thus requiring additional structural elements to securely maintain an assembled coupling ring in place about the rigid connector component. These additional structural elements increase the complexity of assembly as well as the cost of construction.

Some electrical connectors, particularly those adapted for use in harsh environments, utilize connector components constructed from resilient materials, such as rubber or other elastomeric material. Examples of such connector components are disclosed in my U.S. Pat. No. 3,930,705, issued on Jan. 6, 1976, and assigned to the assignee of the present invention. Many of the coupling assemblies discussed above may not be utilized with such resilient connector components in that they are integral parts of the rigid connector components themselves. Previous coupling ring assemblies which are associated with a resilient component or component insert of some type generally require a number of rigid structural support elements and do not utilize the inherent elasticity of the resilient component in their construction or operation. Therefore, such assemblies are complicated to operate and maintain and costly to construct.

Therefore, the present invention is directed to an improved and simplified coupling assembly for use with a resilient connector component which overcomes the above-mentioned deficiencies of prior coupling assemblies.

Particularly, it is an object of the present invention to provide an improved coupling assembly for coupling a first connector component to a second mateable component wherein the first connector component includes a resilient insert.

It is another object of the present invention to provide an improved coupling assembly for coupling a resilient connector component to another mateable component which utilizes the inherent elasticity of the resilient component to maintain the coupling assembly elements in cooperative relation.

It is a further object of the present invention to provide an improved coupling assembly for coupling a resilient connector component to another mateable component which permits the assembly thereof without the use of additional structural elements to secure the coupling assembly elements in operative relation and which is inexpensive and simple in construction.

Yet another object of the present invention is to provide an improved coupling assembly for coupling a resilient connector component to another mateable component which utilizes the inherent resiliency of the resilient component to inhibit decoupling of the coupled connector components.

Accordingly, the present invention is directed to an electrical connector coupling assembly for coupling a first connector component to a second mateable connector component wherein the first connector component includes a resilient elastomeric insert. The coupling assembly preferably includes a tubular shell for engagement about the resilient insert and which has a plurality of axially cantilevered, circumferentially spaced fingers at one end thereof. A substantially rigid circumferential bearing surface is defined about the outer annular surface of the fingers by a plurality of latch members projecting radially outwardly from the free ends of the fingers and a plurality of stop members projecting radially outwardly proximate the fixed ends of the fingers.

An annular coupling ring is also provided with an inner annular flange. The flange is cooperatively engageable with the bearing surface for rotation about the shell, and the ring includes means for attachment to the second connector component, which is preferably constructed from a rigid material. The coupling ring and the bearing surface are configured and arranged such that the inherent resiliency of the elastomeric insert maintains the coupling ring and the bearing surface in cooperative engagement. In addition, the fingers and latch members are adapted such that axial assembly of the coupling ring onto the shell deflects the latch members and fingers inwardly so as to receive the ring until it is fully positioned about the bearing surface, the resiliency of the insert returning the fingers and latch members to an undeflected position and maintaining them therein.

Key means are provided for cooperatively aligning the resilient insert, the shell and the second connector component such that the contact members disposed within the first and second connector components are in mating alignment. In preferred form, at least one of the fingers is absent so as to provide an axial key slot which engages a raised axial key member disposed on the resilient insert. Furthermore, at least one key projection is disposed on the shell in cooperative association with the key slot for engagement with a cooperating keyway disposed in the second connector component.

To inhibit decoupling of the ring from the second connector component when attached thereto, the stop members are disposed proximate the fixed ends of alternate fingers to provide gaps therebetween. A plurality of axially projecting detents are preferably spaced along one edge of the coupling ring's annular flange for intermeshing engagement with the spaced stop members. The resiliency of the elastomeric component provides a resistive force in opposition to coupling when the two connector components are brought into engagement such that rotation of the ring in a coupling direction interfaces the detents and stop members which inhibit decoupling of the ring unless the ring is intentionally rotated in a decoupling direction.

The novel features which are believed to be characteristic of the present invention are set forth in the appended claims. The invention itself, however, together with further objects and attendant advantages thereof, will become apparent and best understood by reference to the following detailed description taken in connection with the accompanying drawings, setting forth by way of illustration and example certain embodiments of the invention in the several figures of which like reference numerals identify like elements, and in which:

FIG. 1 is a perspective view of the coupling assembly of the present invention illustrating the shell engaged with a resilient connector component and the annular coupling member in its unassembled state;

FIG. 2 is a side elevation view, with some parts broken away, of an unasssembled coupling assembly of the present invention and resilient connector component;

FIG. 3 is a cross-sectional view taken substantially along line 3--3 of FIG. 2;

FIG. 4 is a cross-sectional view taken substantially along line 4--4 of FIG. 1;

FIG. 5 is a view similar to FIG. 4 but illustrating the coupling ring fully assembled on the shell of the present invention; and

FIG. 6 is a view similar to FIG. 5 but illustrating the resilient connector component and assembled coupling assembly of the present invention engaged with a rigid second connector component.

Referring to FIGS. 1 and 2, a coupling assembly 5 is provided for coupling a resilient electrical connector component 10 to a second mateable connector component 12 (FIGS. 4-6). The coupling assembly 5 includes a shell 14 and an annular coupling member 16 having a central aperture 17. The resilient connector component 10 is preferably constructed from any known elastomeric material such as rubber or the like and may comprise the entire resilient connector component as illustrated in FIGS. 1-6 or be in the form of an insert member in a composite connector component (not illustrated). The second connector component 12 is preferably constructed from a rigid material such as plastic or metal, although a resilient material having a rigid outer housing may also be utilized.

Referring to FIGS. 4-6, the resilient connector component 10 includes a plurality of axial channels 18 which contain a plurality of electrical contact members 20 which preferably include active pin contact elements 21. The second connector component 12 likewise includes a plurality of axial channels 22 which contain a plurality of electrical contact members 24, preferably including active socket contact elements 25 which are mateable with the pin contact elements 21. An electrical conductor 26 is electrically secured to each contact member 20 and projects outwardly from the resilient connector component 10. It should be noted that the particular arrangement of the contact members 20 and 24 and the conductor 26 illustrated herein is merely one of any number of different types of arrangements known to the art which may be utilized with the present invention, examples of other arrangements being illustrated in my previously described U.S. Pat. No. 3,930,705.

Referring to FIGS. 1-6, the resilient connector component 10 is preferably substantially cylindrical in shape and includes an annular groove 28 disposed thereabout and spaced from the mating end 30 which is adapted for mateable engagement with the second connector component 12. The shell 14 is preferably in the form of an open-ended, substantially rigid tubular body having a plurality of axially cantilevered, circumferentially spaced fingers 32 at one end thereof for surrounding the resilient component 10. As illustrated, the fingers 32 comprise approximately half the length of the tubular shell 14, which is preferably constructed from a rigid material such as plastic or metal.

The shell 14 is firmly engaged and maintained about the component 10 by a plurality of hook portions 34 projecting radially inwardly from the free ends of the fingers 32, each finger 32 preferably including one such hook portion 34. The hook portions 34 are sized and shaped to securely engage the groove 28 with the shoulder 36 of each hook portion 34 firmly abutting the inner annular edge 38 of the groove 28. The fingers 32 are constructed for flexibility in a radial direction yet are firmly supported along their inner surfaces in a substantially cylindrical position when engaged by the resilient component 10.

Means are provided on the shell 14 for defining a rigid bearing surface 40 and preferably include a first annular shoulder 42 and a second annular shoulder 44, each of which has an outer diameter greater than the diameter of the bearing surface 40. The first annular shoulder 42 is composed of a plurality of latch members 46 which project radially outwardly from the free ends of alternately spaced fingers 32. Each latch member 46 includes a longitudinal beveled cam surface 48 for slidably engaging the annular member 16 as described in detail below. The second shoulder 44 preferably includes a plurality of annular spaced stop members 50 which project radially outwardly from the shell 14 proximate the fixed ends of the cantilevered fingers 32. In preferred form, the stop members 50 are disposed proximate the fixed ends of the alternate fingers 32 which are spaced between the latch members 46 thereby forming gaps 51 between the stop members 50.

The annular member 16 is preferably in the form of a tubular coupling ring which includes an inwardly projecting flange 52 on the inner surface thereof. The flange 52 is sized and shaped for secure rotating engagement about the bearing surface 40 between the annular shoulders 42 and 44. The mating end 54 of the coupling ring 16 includes threads 56 for rotatably coupling the ring 16 to the second connector component 12. The threads 56 are preferably disposed on the inner annular surface of the ring 16 adjacent one edge 82 of the flange 52. It should be noted that any known means for coupling the ring 16 to the second component 12 may be utilized such as the described rotatable threads, a bayonet-type engagement mechanism, and the like.

To assemble the coupling assembly 5 of the present invention onto the resilient insert 10, the shell 14 is first slidably inserted onto the component 10 until the hook portions 34 engage the annular groove 28. The conductors 26, which are secured to the contact members 20, are then passed through the central aperture 17 of the ring 16, and the ring 16 is slidably inserted over the shell 14. As the flange 52 engages the cam surfaces 48, the latch members 46 and the fingers 32 are deflected radially inwardly so as to compress the resilient connector component 10, thereby permitting the flange 52 to slide over the latch members 46 until it completely engages the bearing surface 40. Once the flange 52 has fully engaged the bearing surface 40, the inherent resiliency of the connector component 10 forcibly returns the latch members 46 and the fingers 32 to their undeflected, cylindrical position about the component 10 so as to engage and maintain the flange 52 within the bearing recess defined by the bearing surface 40 and the annular shoulders 42 and 44. The flange 52 and the bearing surface 40 are, therefore, configured and arranged such that the resiliency of the first connector component 10 maintains the ring 16 and the bearing surface 40 in cooperative engagement whereby the ring 16 is securely maintained in engagement with the bearing surface 40 yet is free to rotate thereabout to provide the coupling function described below.

Referring particularly to FIGS. 1 and 3, means for keying and properly aligning the shell 14 with the resilient connector component 10 are provided and include at least one and preferably a plurality of raised key members 58 disposed axially along the outer surface of the component 10, and an equal number of key slots 60 disposed along the length of the shell 14 in annular alignment with the members 58. In preferred form, the keying members 58 are composed of the same resilient material from which the component 10 is constructed, and each key slot 60 is a void space dreated by eliminating a finger 32. By this arrangement, the key members 58 align and aid in firmly maintaining the shell 14 in place about the resilient connector component 10.

Cooperatively associated with the key members 58 and the slots 60 are a plurality of keying projections 62 axially disposed along the outer surface of shell 14 for engagement with cooperating keyways 61 (FIG. 6) disposed in the second connector component 12. The keying projections 62 are cooperatively associated with the members 58 and the slots 60 such that the plurality of contact members 20 are in proper alignment for mating engagement with the plurality of contact members 24 when the connector components 10 and 12 are coupled together.

Turning to FIGS. 4-6, the resilient connector component 10 may be in the form of either a plug or a receptacle with the second connector component 12 being of the opposite form. In the illustrated embodiment, the component 10 is in the form of a receptacle, and the mating end 30 includes a tubular recess 64 having internal resilient annular ribs 66 for creating friction resistance against the plug member 68 of the component 12 during mating engagement of the two components 10 and 12. An inner transverse resilient face 70 at the base of the recess 64 includes at least one and preferably a plurality of resilient compressible knob members 72 in the form of sleeves which extend outwardly from the face 70 and surround portions of the mating ends of the contact elements 20. The sleeves 72 function to aid in sealing the internal contact area between the contact members 20 and 24 as well as provide a variable resistive force in opposition to mating of the components 10 and 12, the plug 68 preferably being of a rigid plastic material. As the plug 68 is inserted within the recess 64, the forward face 74 of the plug 68 contacts and compresses the sleeves 72 as the contact elements 20 and 24 interengage, thereby creating the resistive force against mating.

A cylindrical housing 76 projects longitudinally from the component 12 and is spaced radially outwardly from the plug 68 to provide an annular gap 77 therebetween for reception of the shell 14 and the mating end 30 of the component 10. Radial threads 78 are provided about the outer surface of the housing 76 for engagement with the threads 56 of the ring 16. Thus, to achieve coupling of the components 10 and 12, the plug 68 of the component 12 is inserted within the recess 64 of the component 10 with the shell 14 and the ring 16 disposed thereabout. As the plug 68 is so inserted, the coupling ring 16 is rotated in a coupling direction so as to engage the threads 56 with the threads 78. As the ring 16 is rotated in a coupling direction, the plug 68 is drawn further into the recess 64 until the contact elements 20 and 24 engage and mate, the plug 12 being in proper alignment due to the keying components 62, 61, 60 and 58. A slignt resistive force against coupling is initially provided by the annular ribs 66 so as to create a slight resistance against coupling rotation of the ring 16. Upon engagement of the forward face 74 of the plug 68 with the sleeve members 72, a considerable resistive force against coupling is created. The greater the compression of the resilient sleeve members 72 of the resilient component 10, the greater the resistive force against coupling. This compression of the sleeve members 72 and the resultant resistive force is due to the inherent resiliency of the connector component 10 and is utilized to inhibit decoupling of the ring 16 as described below.

Anti-decoupling mechanisms for connector coupling assemblies are highly desirable when such connectors are subjected to considerable vibration and the like. With particular reference to FIGS. 2 and 3, the present invention achieves this function by including a plurality of axially projecting detents 80 circumferentially spaced along the edge 82 of the flange 52, the edge 82 being the edge closest to the mating end 30 of the resilient connector component 10. The detents 80 are spaced in such a manner as to fit within the gaps 51 between the stop members 50 when the coupling ring 16 is subjected to a resistive force against coupling. Thus, as the coupling ring 16 is rotated in a coupling direction, the resistive force offered by the annular ribs 66 is sufficient to interface the detents 80 with the stop membesr 50 so that the interfacing arises from the actual coupling of the components 10 and 12. However, such interfacing is slight and is overcome by minor axial force directed away from the component 12 when rotating the ring 16 in a coupling direction. This permits easy coupling of the ring 16 to the component 12.

However, when the plug 68 has been inserted within the recess 64 so that its face 74 engages and compresses the resilient sleeve members 72 to create a large resistance against mating and coupling, the force between the intermeshed detents 80 and stop members 50 is sufficiently great to limit additional rotation of the coupling ring 16 in a coupling direction. Likewise, however, this same intermeshing force between the detents 80 and the stop members 50 caused by the large resistive force of the sleeve members 72 inhibits rotation of the ring 16 in a decoupling direction thereby inhibiting decoupling of the ring 16 from the connector component 12, the detents 80 and the stop members 50 tending to remain in one intermeshed position. This state can be overcome to permit disassembly of the mated components 10 and 12 only by considerable axial force exerted on the ring 16 in conjunction with rotation of the ring 16 in a decoupling direction. Thus, the simple addition of the detents 80 to the flange 52 such that they intermesh with the stop members 50 provides an effective yet simple anti-decoupling mechanism.

As can be seen from the above, the present invention provides an effective yet simple and inexpensive coupling assembly for interconnecting a resilient connector component with a second mateable component. The present invention avoids the complex design and construction of prior coupling assemblies due to its use of the inherent elasticity of the resilient connector component for maintaining the coupling assembly in engagement therewith as well as maintaining the coupling ring and shell in cooperative relation. Furthermore, the present invention also utilizes the inherent elasticity of the resilient component to inhibit decoupling of the coupled connector components. Finally, inasmuch as the subject coupling assembly is not integral with the connector component, it may be utilized with any number of different resilient connector components having the same basic dimensions.

It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein but may be modified within the scope of the appended claims.