Convertible Cylindrical Electrical Connector

This invention relates to cylindrical modular electrical connectors. More particularly, it relates to electrical connectors having a plug and receptacle with a plurality of cavities adapted to receive replaceable modules with a predetermined number of holes for receiving a predetermined number of contacts and means for securing the modules in the cavities.

Multiple contact cylindrical electrical connectors are usually constructed with a fixed number of holes through the plug and receptacle for receiving a fixed number of contacts. Once the array of holes has been constructed, the usage of that connector is more or less limited to a particular purpose. If a different pattern of holes is needed, then the connector must be redesigned and retooling for the manufacture of such a connector must be done. Even if the contacts are easily replaced, the hole positions are fixed. A large amount of inventory of connectors therefore must be maintained in order to provide the various electrical connections required. This retooling and high inventory requirement is wasteful since quite often various industries use the same size connector but different contact arrays. The differences could be the location of the contacts, the number of contacts, or the contact size needed for a particular function.

One object of the invention is to provide a cylindrical electrical connector with replaceable modules for different connector functions.

Another object of the invention is to provide an electrical connector with replaceable modules, each module having replaceable contacts.

Another object is to provide a cylindrical electrical connector having a plurality of relatively large cavities for receiving removable modules as well as a plurality of relatively small holes for receiving a plurality of electrical contacts.

Another object is to provide a plastic electrical connector having replaceable modules.

Another object is to provide an electrical connector having a plurality of cavities in its plug and receptacle for receiving a plurality of modules, the modules being extractable from the plug or receptacle in only one direction.

Another object is to provide a cylindrical electrical connector having a plug and receptacle, each having a plurality of cavities for receiving a plurality of replaceable modules, the cavities being symmetrical about a horizontal and vertical axis with respect to the faces of the plug and receptacle.

Another object is to provide an electrical connector having receptacle modules so that a single connector may be used with various modules to perform various connector functions with less need for retooling and maintenance of high inventories.

In accordance with one form of this invention, there is provided a cylindrical electrical connector having a plug and a receptacle, each having at least one cavity therethrough. At least one removable module is adapted to be received in each cavity. Each module has at least one hole therein for receiving an electrical contact. The cavity is adapted to receive various modules which may perform different electrical connector functions, whereby a single plug or receptacle may be used for a plurality of purposes.

The subject matter which is regarded as the invention is set forth in the appended claims. The invention itself, however, together with further objects and advantages thereof may be better understood by referring to the following description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a diagram showing a perspective view of the rear of the connector plug having one module inserted in one cavity incorporating one embodiment of the present invention;

FIG. 2 is a diagram showing a front plan view of a receptacle having one module inserted incorporating one embodiment of the present invention;

FIG. 3 is a diagram showing a front perspective view of a receptacle module incorporating other aspects of the present invention;

FIG. 4 is a diagram showing a tab portion of the module shown in FIG. 3 and the recess portion of a cavity shown in FIG. 1; and

FIG. 5 is a diagram showing a side plan view of the coupling nut used to couple the plug shown in FIG. 1 and the receptacle shown in FIG. 2 together.

Referring now more particularly to FIG. 1, there is provided a plastic connector plug 1 adapted to mate with a plastic receptacle 22 shown in FIG. 2. Plug 1, in this embodiment, has five cavities extending longitudinally therethrough. Cavity 2 is shown, in this embodiment, receiving plastic removable module 3. The other cavities, for example cavity 4, are shown to be empty and not receiving modules. In other embodiments of the invention there may be many other numbers of cavities in the connector plug and the receptacle of FIG. 2.

Cavity 4 included recess 5 for receiving shoulder 6 of tab 7 which protrudes from the rear module 3. This shoulder-recess connection is to prevent the module from sliding in the forward direction of the plug. This will be easier seen in reference to FIG. 3. Cavity 4 also has shoulders 8 which prevent the module from moving in the rearward direction of the plug.

There is further provided a plurality of holes 9 extending longitudinally through plug 1 for receiving a predetermined number of contacts. The plug further includes screw threads 10 for attaching suitable accessories such as cable adaptors and clamps. Raised portion 11 surrounds the plug and includes a plurality of wedged shaped slots 12. The bottoms 13 of these slots 12 taper up toward the front of the shell. Slots 12 are adapted to receive the non-decoupling protrusions 15 on coupling nut 14. They are tapered up at an angle so that the coupling nut positively snaps into area 16 when the coupling nut is in its final position. Area 16 includes protrusions 17 having ramps of two different steepnesses. They include ramp 18, having a gradual slope, and ramp 19, having a more steep slope. Ramp 18, having the gradual slope, would be in initial contact with protrusion 15 of coupling nut 14 in the direction of tightening the coupling nut. Ramp 19, having a steep slope, would be initial contact with protrusion 15 in the direction of loosening thus inhibiting the decoupling of the connector during vibration. This would make it more difficult to turn the coupling nut in the loosening direction as opposed to the tightening direction. Use of these ramps of two different steepnesses will cause a coupling nut to actually tighten rather than loosen during a vibration situation. This features eliminates the need for safety wiring for the connector when it is exposed to shock and/or vibration environment during its service life.

Plug 1 further has a plurality of raised rails 20 which are placed in predetermined locations along the outer circumference of the cylindrical plug in a key relation with the elongated detents 21 of receptacle 22 shown in FIG. 2. These rails and detents are arranged non-symmetrically so that the cavities which contain the modules in the plug and receptacle will align in only a single predetermined manner.

In FIG. 2 there is provided a receptacle 22 having flange 23 and mounting holes 24 for mounting the receptacle. The receptacle includes a plurality of cavities 25 which correspond to the cavities 4 shown in FIG. 1. In this embodiment four of the empty cavities 25 show the shoulders 26 which correspond to the shoulders 8 shown in the plugs 1 of FIG. 1. Again these shoulders 26 prevent the module from being moved in the direction rearward of the receptacle. The rear side of the receptacle (not shown) would also have at least one recess adjacent to each cavity to prevent the forward motion of a module as previously described in reference to FIG. 1. Cavity 27 is filled by module 28. The triangular shape markings 29 on the receptacle and markings 30 on the module 28 are provided to key the proper insertion of the modules in cavities. Furthermore, each module may be numbered to correspond with a numbered cavity on the plug or receptacle. The holes 9 and 38 may be lettered with letters corresponding on the plug and receptacle for contact alignment.

Referring now more particularly to FIG. 3, there is shown module 31 having five holes 32 therethrough for receiving electrical contacts which in this embodiment are male contacts 33. The rear of the male contacts are connected to wires 34 providing electrical signals to the contacts. The module includes spring biased tabs 35 extending rearwardly from the module. The tabs 35 are spring biased in that they taper away from the longitudinal axis of the modules. The relationship between the tabs and the shoulders in the cavities of the plug and receptacle may be seen more clearly in reference to FIG. 4.

As can be seen in FIG. 4 tab 35 includes a shoulder 6 which snaps into recess 37 of either the plug or receptacle cavity when the module is inserted. This prevents the module from moving in the forward direction while the connector is in use. However, when it is desired to extract any module, both tabs 35 should be pressed inwardly thus freeing the shoulders 6 away from the recess 37. The module then may be pressed forward and out of the plug or receptacle.

The plug, receptacles and modules are all made of a plastic material, thus the contacts are electrically insulated from one another. The voltage levels on adjacent contacts may therefore vary be substantial amounts without fear of electrical shorts.

The openings of the cavities on both the plug and receptacle are substantially symmetrical about the horizontal and vertical axis of the front surface of the receptacle plug and receptacle; however, these cavities may be symmetrical about other axes. This symmetry allows for ease of alignment for mating respective plugs and receptacles. In this embodiment, the plugs and receptacles are a monolithic piece of plastic which is molded or preformed; however, the connector may include a core which includes the modular features set forth herein but adapted to be inserted in a connector shell.

From the foregoing description of this embodiment of the invention, it would be apparent that many modifications may be made therein. It will be understood that this embodiment of the invention is intended as an exemplification of the invention only and the invention is not limited thereto. It is to be understood, therefore, that it is intended in the appended claims to cover all such modifications which fall in the true spirit and scope of this invention.