Multi-environment in-line connector

[0001] The present invention claims priority to U.S. Provisional Application Ser. No. 60/528,019, filed Dec. 9, 2003, entitled “Multi-Environment In-Line Connector”, and hereby incorporated by reference in its entirety.

[0002] The invention relates to an electrical connector. More particularly, the invention describes an electrical connector incorporating protective features allowing the connector to function reliably for long periods of time under a wide range of environmental conditions.

[0003] A variety of electrical connector designs are available for use in electrically connecting components, for example sensors with transmitters. Depending upon the particular application, a user selects the appropriate connector based on any number of application-specific factors, for example, code requirements, exposure to specific environmental conditions and anticipated lifespan, to name a few.

[0004] An especially challenging environment for using electrical connectors is with water meters and transmitters that are located in below ground water pits. Such water pit installations are commonly used in geographic regions that are not typically subjected to freezing conditions and in which a majority of homes are generally not constructed on full slab foundations. As such, there is no basement or access space for mounting a water meter within the home.

[0005] Due to the nature of the application, electrical connectors used within water pits must be capable of resisting long term exposure to an environment ranging from high humidity to full submersion. In addition, the constraints associated with accessing and working within a water pit requires that the electrical connector be easy to assemble and install.

[0006] One known connector currently used in these types of environments is disclosed in U.S. Pat. No. 6,162,082 to Karsten et al., which is herein incorporated by reference to the extent not inconsistent with the present disclosure. While the Karsten et al. patent teaches an electrical connector for used in “wet” environments, the electrical connector suffers from the disadvantage of being permanently connected when assembled such that disassembly requires the use of a tool to fracture a locking component of the electrical connector. This locking component must then be replaced with a new locking component in order to complete the connection.

[0007] The electrical connector assembly of the invention includes features promoting both long-term reliability as well as ease of installation and maintenance. The electrical connector of the invention comprises a receptacle connector member and a plug connector member that interface to provide a dual radial seal substantially eliminating the possibility of moisture and water intrusion. Each connector member is individually potted to a wire to substantially eliminate the potential for water wicking up the wire while transferring the wire pull strength to the connector member. The receptacle connector member and plug connector member are retainably joined with a rotatably disassemblable locking member allowing for easy maintenance and reuse without the use of any tools. When connected, the electrical connector comprises dual radial seals, one to prevent dirt and contaminant infiltration, the second prevention moisture/water intrusion. The electrical connector can further comprise a security seal member to prevent and/or indicate unauthorized tampering with the electrical connector. The security seal member performs no joining or sealing function such that its size, shape and orientation can be varied so as to be economically provided without having any effect on the functionality of the electrical connector. Both the receptacle connector member and the plug connector member can further include individual protective covers allowing them to be maintained and stored for extended periods of time without degradation.

[0008] In one representative embodiment, the electrical connector of the invention can be used to electrically connect a water meter with a transmitter in a water pit installation, however the invention is not necessarily limited to such an application. In general, the electrical connector of the invention can be employed in conditions, ranging from high humidity to full submersion, in which a reliable connection is required between disparate electrical components.

[0009] In one aspect, the electrical connector of the invention comprises an improved seal design over presently available electrical connectors so as to substantially eliminate the possibility of moisture/water intrusion into the connector.

[0010] In another aspect, the electrical connector of the invention comprises alignment features that substantially eliminate the possibility of misassembling the electrical connector.

[0011] In another aspect, the electrical connector of the invention comprises assembly features allowing the electrical connector to be implemented and installed without requiring custom tools or specialized skills on the part of the installer.

[0012] In another aspect, the electrical connector of the invention comprises assembly features allowing the electrical connector to be factory installed to electrical devices such that field installation time is reduced.

[0013] In another aspect, the electrical connector of the invention comprises protective features allowing unassembled portions of the connector to be protected from moisture and water intrusion such that the connector does not experience corrosion and degradation during storage periods.

[0014] In another aspect, the electrical connector of the invention comprises tamper indication features that quickly and conveniently provide a visual indication of unauthorized tampering with the electrical connector.

[0015] In another aspect, the electrical connector of the invention comprises connecting and disconnecting features allowing the electrical connector to be repeatedly disassembled and reused without destroying the electrical connector or necessarily requiring the replacement of connector components.

[0016] The above summary of the various representative embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. The figures in the detailed description that follow more particularly exemplify these embodiments

[0029] While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

[0030] The invention relates to electrical connectors adapted for use in a variety of environmental conditions. The electrical connector of the invention can be used reliably in a wide variety of environmental conditions including high ambient temperatures, freezing temperatures, low humidity and high humidity settings. Furthermore, the connector of the invention can be successfully utilized in situations in which the connector is exposed to water by splashing or even when completely submerged. Furthermore, the connector of the invention can be quickly installed without any special skills or tools.

[0031] A connector assembly 100 of the invention is depicted in FIGS. 1, 2, 3, 4, and 5. Generally, connector assembly 100 is used to electrically connect a first cable 102 with a second cable 104. The cables can be present in a variety of forms and will most typically include a plurality of individual wires encased within an exterior, protective casing. The cables can be supplied by any number of different manufactures, for example Belden. For purposes of describing the connector assembly 100 of the invention, first cable 102 is described as including a first wire 102a, a second wire 102b, and a third wire 102c while second cable 104 includes a first wire 104a, a second wire 104b, and a third wire 104c. As shown in FIG. 3, connector assembly 100 is comprised of a receptacle connector member 105, a plug connector member 106, a first radial seal 107, and a second radial seal 108. In one representative example, radial seals 107, 108 can comprise o-rings made of a resilient rubber or rubber-like, flexible polymer such as, for example, Ethylene Propylene Diene Monomer (EPDM), nitrile (Buna-N), silicone and fluorinated polymers and copolymers.

[0032] Receptacle connector member 105 comprises a receptacle connector body 110 and a receptacle backshell 112. Receptacle connector body 110 includes an outer wall 116 having an outer wall groove 118 and an outer wall thread 119. Outer wall groove 118 is dimensioned to accommodate second radial seal 108. Receptacle connector body 110 further comprises a receptacle locking tab 120 having a receptacle locking throughbore 122. Receptacle connector body 110 is further defined by a receptacle mating flange 124 and a receptacle inner wall 126 comprising an inner wall flange 128. Receptacle inner wall 126 includes a plurality of keyed projections 129 as shown in FIG. 4. Receptacle connector body 110 also includes a receptacle projecting end 130 including a perimeter receptacle thread 132. Receptacle connector body 110 includes three contact throughbores 134a, 134b, 134c, each throughbore including its own pin contact 136a, 136b, 136c. Pin contacts 136a, 136b, 136c are solid except for a blind hole used to connect first wire 102a, second wire 102b and third wire 102c such that liquid cannot wick up the wires to the pin contacts. Receptacle backshell 112 comprises a hollow member having a receptacle end 138 and a cable end 139. Receptacle end 138 includes an internal backshell thread 140. Receptacle end 138 is dimensioned to accommodate projecting end 130.

[0033] In assembling receptacle connector member 105, first wire 102a, second wire 102b and third wire 102c are attached to the pin contacts 136a, 136b and 136c through crimping or other suitable attachment method. First cable 102 can then be slid through receptacle backshell 112. Once first cable 102 is positioned through receptacle backshell 112, pin contacts 136a, 136b, 136c are press fit into contact throughbores 134a, 134b and 134c. Receptacle connector body 110 and receptacle backshell 112 are then threadably engaged using projection thread 132 and backshell thread 138. Epoxy potting 141 is then injected into receptacle backshell 112 such that no voids are formed, which could allow liquid/moisture to bridge between the wires 102a, 102b, 102c. As it cures, epoxy potting 141 adheres to first cable 102 and receptacle connector body 110. Epoxy potting 141 eliminates any leak path between the wires (102a, 102b, 102c) and pin contacts (136a, 136b, 136c) on the backside of receptacle connector body 110. Epoxy potting 141 also aids in increasing the tensile pull strength of connector assembly 100.

[0034] Referring again to FIGS. 1–5 and 6, plug connector member 106 is comprised of a plug connector body 150, a coupling nut 152 and a plug backshell 154. Plug connector body 150 is defined by a plug outer wall 156, a plug face 158 and a plug flange 162. Plug outer wall 156 includes an outer wall groove 161 and a plug projection 163 having a plug thread 164. Plug outerwall 156 further includes a plurality of keyed grooves 165 as shown in FIG. 5 corresponding to keyed projections 129. Plug connector body 150 includes three socket throughbores 166a, 166b, 166c, each throughbore including its own socket contact 168a, 168b, 168c. Socket contacts 168a, 168b, 168c are solid except for a blind hole used to connect first wire 104a, second wire 104b and third wire 104c such that liquid cannot wick up the wires to the socket contacts. Coupling nut 152 includes an outer nut surface 170 and an inner nut surface 172. Inner nut surface 172 includes an inner nut thread 174. Coupling nut 152 further comprises a nut locking tab 178 defining a nut locking face 176. Nut locking tab 178 includes a nut throughbore 179. Plug backshell 154 comprises a hollow member having a plug end 180 and a cable end 182. Plug end 180 includes an internal backshell thread 184. Plug end 180 is dimensioned to accommodate plug projection 163.

[0035] To assemble plug connector member 106, first wire 104a, second wire 104b and third wire 104c can be attached to the socket contacts 168a, 168b and 168c through crimping or other suitable attachment methods. Second cable 104 can then be slid through plug backshell 154. Once second cable 104 is positioned through plug backshell 154, socket contacts 168a, 168b, 168c are press fit into socket throughbores 166a, 166b, 166c. Plug connector body 150 and plug backshell 154 are then threadably engaged using plug thread 164 and backshell thread 184. Epoxy potting 141 is then injected into plug backshell 154 such that no voids are present, which could allow liquid/moisture to bridge between the wires 104a, 104b, 104c. As it cures, epoxy potting 141 adheres to second cable 104 and plug connector body 150. Epoxy potting 141 eliminates any leak path between the wires (104a, 104b, 104c) and socket contacts (168a, 168b, 168c) on the backside of plug connector body 150. Epoxy potting 141 also aids in increasing the tensile pull strength of the connector assembly 100.

[0036] After receptacle connector member 105 and plug connector member 106 are assembled, connector assembly 100 is assembled so a to facilitate electrical communication between first cable 102 and second cable 104. Second radial seal 108 is positioned within outer wall groove 118 while first radial seal 107 is positioned within outer wall groove 161. Receptacle connector member 105 and plug connector member 106 are approximated and aligned such that keyed projections 129 and keyed grooves 165 are in alignment. Preferably, keyed projections 129 and keyed grooves 165 are arranged so as to allow only a single possible orientation for connecting receptacle connector member 105 with plug connector member 106. Through the design and use of a single keying orientation, only a correctly aligned connection is possible, thus preventing the possibility of an unsuccessful or imperfect assembly of receptacle connector member 105 and plug connector member 106. Receptacle connector member 105 and plug connector member 106 are slidingly engaged such that keyed projections 129 engage the keyed grooves 165 prior to pin contacts 136a, 136b, 136c engaging their respective socket contact 168a, 168b, 168c. By aligning the keying features prior to the engagement of the contacts, the possibility of contact damage during alignment of the keying features is eliminated. Plug connector member 106 is inserted within receptacle connector member 105 such that plug flange 162 and inner wall flange 128 are in contact. The insertion of plug connector member 106 into receptacle connector member 105 causes radial compression of first radial seal 107 creating a watertight seal between plug connector member 106 and receptacle connector member 105.

[0037] Next, coupling nut 152 is directed toward receptacle connector member 105 such that inner nut thread 174 threadably engages outer wall thread 119 . . . Coupling nut 152 is rotatably advanced to complete the mating of receptacle connector member 105 and plug connector member 106. As coupling nut 152 is rotatably advanced, second radial seal 108 is radially compressed creating a seal between coupling nut 152 and receptacle connector body 110. By rotating coupling nut 152 to radially compress second radial seal 108, the force required to compress both first radial seal 107 and second radial seal 108 is converted to a torque which is less than the axial force requirement if coupling nut 152 was merely pushed toward receptacle connector member 105. When compressed as described, second radial seal 108 prevents dirt and other miscellaneous debris from penetrating the connector assembly 100 such that operation of coupling nut 152 is not hindered following extended periods of field installation. Turning coupling nut 152 causes nut throughbore 179 to align with receptacle locking throughbore 122. The alignment of nut throughbore 179 with receptacle locking throughbore 122 provides a visual check to ensure that receptacle connector member 105 and plug connector member 106 are fully engaged. A security seal member 190, as shown in FIG. 6, is inserted through nut throughbore 179 and receptacle locking throughbore 122 to prevent tampering with installed connector assembly 100. While assembly of connector assembly 100 has been described, connector assembly 100 can be similarly disassembled by merely removing security seal member 190, rotatably uncoupling coupling nut 152 and pulling receptacle connector member 105 and plug connector member 106 apart if maintenance is necessary. This allows coupling nut 152, receptacle connector member 105 and plug connector member 106 to be reused without requiring a swap out of first cable 102 and second cable 104.

[0038] When fully assembled, connector assembly 100 of the invention includes a variety of sealing mechanisms to substantially eliminate the possibility of water/moisture intrusion as well as dirt and debris penetration. First radial seal 107 and second radial seal 108 provide dual radial seals with first radial seal 107 substantially eliminating any water leak potential at the contact interface while second radial seal 108 substantially prevents dirt and debris infiltration that could interfere with the operation of coupling nut 152. In addition, potting 141 within receptacle connector member 105 and plug connector member 106 provides a moisture impervious barrier to substantially eliminate water wicking up first cable 102 and second cable 104. Potting 141 serves a secondary purpose of substantially retaining the majority of the pull strength of first cable 102 and second cable 104 when connector assembly 100 is fully assembled.

[0039] Referring now to FIGS. 7, 8 and 9, there is illustrated one representative example application of connector assembly 100 of the invention. Connector assembly 100 depicted in this embodiment as connecting a water meter 200 with a transmitter 202 such as, for example, a radio frequency transmitter. As further depicted in FIGS. 8 and 9, water meter 200 can be located in a below ground water pit 204. Connector assembly 100 provides a dual radial seal to prevent moisture/water intrusion as well as dirt and debris infiltration that can cause other prior art connectors to fail. Transmitter 202 can be shipped from the factory with receptacle connector member 105 while water meter 200 can be installed with plug connector member 106. Connector assembly 100 allows for easy field installation as no special tools, strength, skills or dexterity are necessary to connect receptacle connector member 105 with plug connector member 106.

[0040] As shown in a related embodiment in FIG. 10, receptacle connector member 105 can include a receptacle cover 210 to protect receptacle connector member 105 prior to installation while plug connector member 106 can include a plug cover 212 as shown in FIG. 11, to similarly protect plug connector member 106. The use of receptacle cover 210 and plug cover 212 allow both receptacle connector member 105 and plug connector member 106 to have an effective life of twenty years in one example embodiment. For example, receptacle connector member 105 and plug connector member 106 can be effectively stored prior to use for 15 years using receptacle cover 210 and plug cover 212 followed by the successful mating of receptacle connector member 105 and plug connector member 106 for another five years.

[0041] Although various embodiments of the invention have been disclosed here for purposes of illustration, it should be understood that a variety of changes, modifications and substitutions may be incorporated without departing from either the spirit or scope of the invention.