Field-attachable in-line signal connector with protective molded cover

[0002] This application claims the benefit of the filing date of copending U.S. Provisional Application No. 60/188,966, filed Mar. 10, 2000.

[0003] The present invention relates to electrical connectors; and more particularly, the invention relates to electrical connectors of the type used to connect conductive leads adapted to carry electrical signals, as distinguished from connectors designed to carry, for example, electrical power. Of particular interest are in-line electrical signal connectors of the type widely used to interface with the “EtherNet” communications network and the Universal Serial Bus (USB) connector, both of which are in widespread use in offices and other sites, but not in industrial applications such as manufacturing plants. These connectors are characterized as having a plurality (typically, eight) connector elements arranged side-by-side and parallel to one another or in a rectangular pattern for the USB connector. Hence, the connector elements are arranged in a line transverse of the direction of elongation of the associated conductor leads, and this type of connector is commonly referred to as an “in-line” connector.

[0004] Conventional in-line signal connectors of the type described above and in connection with which the present invention is concerned, are not manufactured to meet the more rigorous conditions of use for industrial applications—that is, for use in factories and other manufacturing facilities. Typically, such in-line signal connectors are used in residential, office, or other commercial applications where they were not normally subjected to being twisted, stepped on and exposed to various fluids, as might typically occur in an industrial environment, such as an automated manufacturing facility. As the use of electronics and computer-centered control automation systems has entered the manufacturing environment, the use of communications networks has greatly expanded into the workplace as well. This has created a need for a more industrialized in-line signal connector for communications networks, capable of meeting the standard electrical specifications for existing in-line signal connectors, yet rugged enough to withstand the rigors of an industrial environment.

[0005] Another problem arises in connection with industrial grade electrical connectors used in customized communications networks, such as commonly occurs in factories. The problem is that the network cable and end connectors typically are not custom manufactured to a given length. Some installations prefer to route the master cable first and then cut it to size and attach the connectors after the cable has been cut. There are no commercially available, industrial quality EtherNet connectors for assembly to the cable on site (i.e., in the “field”).

[0006] The present invention is illustrated in the context of a widely used and accepted multiple-lead connector assembly known as an RJ45 connector. RJ45 connectors are well known in the industry and have been used widely for connecting multiple-lead cable assemblies to equipment, specifically to printed circuit boards mounted within equipment cabinets. The invention however, is equally adaptable for use with USB connectors, and other electrical data connectors such as those referred to as “Firewire” connectors, as well as to connectors for optical cable.

[0007] The present invention provides a pre-molded connector body or cover molded to one half (the threaded portion in the illustrated embodiment) of a conventional compression seal for an electrical cable. The end of the molded connector body not attached to threaded portion of the cable compression seal provides a nesting region for the electrical connector, and a clip anchors the electrical connector to the molded connector body. A threaded coupling collet or nut is located on the molded connector body for securing the connector to a mating electrical panel mount connector.

[0008] With this combination, the master cable can be cut to length as desired. The female portion of the compression seal and the molded connector body (with a coupling nut) are then placed on the cable. Next the connector is crimped onto the cable, individual connections being made by insulation displacement techniques. The molded connector body, coupling nut and compression nut are positioned to seat the connector in the molded connector body, and a clip anchors the connector housing to the molded connector body. The compression nut is then tightened to seal against the cable.

[0009] There is thus provided a combination of elements which permit field installation of conventional electrical connectors and which add protection and mechanical stability for those connectors which renders them suitable for industrial use, even though the connectors themselves, without the added protection would not be suitable for industrial communication networks.

[0010] Other features and advantages of the present invention will be apparent to persons skilled in the art from the following detailed disclosure of the preferred embodiment accompanied by the attached drawing where identical reference numerals will refer to like parts in the various views.

[0011] FIG. 1 is a perspective view of a conventional in-line data connector connected to a conventional cable;

[0012] FIG. 2 is an upper rear perspective of an in-line connector provided with a protective connector body and compression seal according to the present invention;

[0013] FIG. 3 is a view of the inventive connector assembly similar to FIG. 2 and including a coupling nut for assembly to a mating connector;

[0014] FIG. 4 is a frontal perspective view of a partial assembly of the inventive connector assembly illustrating assembly in the field;

[0015] FIG. 5 is a lower frontal perspective view of the inventive connector assembly illustrating the use of a coupling clip to secure the molded connector body to the inline connector; and

[0016] FIG. 6 is a longitudinal cross section view of the molded body, threaded male bushing, seal and compression nut in assembled relation.

[0017] Turning first to FIG. 1, reference numeral 10 generally designates a prior art cable assembly including a cable 11 and a male in-line signal connector generally designated 12. As shown, the cable assembly is a standard assembly, available commercially in the form shown as a pre-assembled cord or as separate components for assembly on site. The cable 11 preferably may be a Category-5 or Category-5ecable or equivalent having a plurality of insulated leads (typically, eight leads) and is provided with an outer sheath 13 which may, depending upon the application, be polyurethane in order to provide increased resistance to oil and gas.

[0018] The male in-line connector includes a molded base 14 of standard construction and including a locking tab 15, for purposes to be later described. A plurality (again, eight) of male contact elements 16 are mounted in the base 14.

[0019] The eight contact elements 16 are identical in shape, in that they are mounted in side-by-side relation, electrically insulated from one another and spaced to form an in-line construction when viewed from the side. That is, the contact elements 16 are aligned, one behind the other when viewed along a plane perpendicular to the direction of extension of the cable 11. As used herein, “front” or “distal” refer to the connection end of the connectors and “rear” or “proximal” refer to the cable end.

[0020] The connector 12 is also commercially available individually. It meets the standards set by AT&ET for an RJ45 connector, and it is licensed by AT&T throughout the communications network industry, primarily for residential, personal, office and light commercial applications, such as data processing or inter-office communications usage.

[0021] The assembly of FIG. 1 is not suitable for use in industrial environments because the connection between the leads of the cable 11 and the contact elements 16 of the connector 12 cannot withstand the rigors of use in an industrial environment. In order to strengthen and protect the interface between the cable 11 and the connector 12, the present invention provides a molded connector body or cover generally designated by reference numeral 18. The molded connector body 18 is provided, at its rear end, with a two-piece compression seal generally designated 20. The compression seal is of a type generally known in the art and includes an externally threaded male portion 21 having a compressible, conical seal 35 received in a domed female compression nut 23. Both the male portion 21 and the female portion 23 of the compression seal 20 are received on the cable 11, as will be described. When the domed female portion 23 (which is internally threaded to provide a nut) is tightened onto the male portion 21 of the compression seal, it compresses the flexible sealing member of the male portion 21 which is received in the female portion 23 and engages and seals against the outer surface of the cable 11 under compression.

[0022] Turning now to the molded connector body or cover 18, it may be injection-molded of any number of suitable materials having sufficient strength to provide an adequate protection for the interface between the connector 12 and the cable 11. However, it may be of a polycarbonate ABS blend to provide a cushioning, but fairly hard substance. In molding the protective connector body or cover 18, the male portion 21 of the compression seal 20 is placed as an insert into the mold and the protective connector body 18 is then molded integrally with the male portion 21 to provide a suitable attachment of the body 18 to the male portion 21. This provides not only a seal, but mechanical stability as well.

[0023] The protective connector body 18 includes a cylindrical sidewall 25 which has a cylindrical axial cavity sized to received the cable 11. At the forward end of the sidewall 25 is a radially, outwardly extending flange 26, the purpose of which is to restrain further forward movement of a coupling nut generally designated 28 in FIG. 3 and having a radial rear partial wall 29 defining a central opening sized to slide over the sidewall 25 of the molded protective body 18. The coupling nut 28 may be of conventional design having internal threads for coupling to a corresponding external thread on a mating female connector adapted to connect to the male connector 12.

[0024] Returning to FIG. 2, just forward of the flange 26, the molded protective body 18 includes a semi-circular portion 30 which is better seen in FIG. 4, and is provided with a radially inwardly extending slot 31. The forward portion 30 of the molded protective member 18 defines a rectangular cavity generally designated 33 and forming a receptacle for the rear end of the connector 12. The receptacle 33 is dimensioned such that, in combination with the material out of which the protective body 18 is molded, they form a tight slip fit with the rear end of the connector 12. By this, it is meant that the fit between the connector 12 and the receptacle 33 approaches that of a press fit, yet it falls short of a press fit, but does require more than a mere sliding force to assemble or disassemble, the connector.

[0025] Turning to FIG. 5, when the connector 12 is assembled to the molded protective body 18, the individual connector elements 16 project forwardly, as seen in FIG. 5 for connection to corresponding mating connector elements.

[0026] A clip, which is in the form of an E-clip in the illustrated embodiment and generally designated 36 in FIG. 5, is placed in the slot 31 formed in the extension 30 of the molded protective body 18 to couple the base 14 of the connector 12 to the protective molded body 18.

[0027] It will be observed that the E-clip 36 includes a central tab 37 and a pair of side flexible tines 38, 39. The tab 37 is received in a slot shown at 40 in FIG. 1 which prevents connector 12 from axial motion relative to the cylindrical protective body 18, and the tines 38, 39, which are provided with inwardly turned latch members, couple directly to corresponding recesses in the base 14 of the connector 12.

[0028] Field assembly of the connector 12 to the cable 13 will now be described. The cable 13 is cut to the desired length, and a connector 12 is provided separately of the cable 13. The domed compression nut 23 is placed on the cable 13 and then coupling nut 28 and molded protective body 18 are similarly slid on the cable 13. The cable 13 is then connected to the connector 12 using a conventional crimping apparatus which connects an associated lead from the cable 13 with each of the eight connector elements 16 of the connector 12.

[0029] Next, the E-clip 36 is snapped into the slot 31 to attach the connector 12 to the molded protective body 18, and the domed compression nut 23 is tightened under the male portion 21 of the compression seal 20. After the connector 12 is attached to a mating connector, the coupling nut 28 is available to form a mechanical coupling with the mating connector. Thus, field attachment of the connector 12 is conveniently provided with the present invention, and the final, assembled juncture between the cable 13 and the connector 12 is provided with a protective molded body or cover 18, the rear end of which is sealed to the cable 13.

[0030] While particular embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation.