EP0485991B1 - Elektrischer Verbinder aus leitfähigem Faserstoff und Verfahren zur Herstellung - Google Patents

Elektrischer Verbinder aus leitfähigem Faserstoff und Verfahren zur Herstellung Download PDF

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Publication number
EP0485991B1
EP0485991B1 EP19910119360 EP91119360A EP0485991B1 EP 0485991 B1 EP0485991 B1 EP 0485991B1 EP 19910119360 EP19910119360 EP 19910119360 EP 91119360 A EP91119360 A EP 91119360A EP 0485991 B1 EP0485991 B1 EP 0485991B1
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EP
European Patent Office
Prior art keywords
conductive layer
electrical connector
plug
receptacle
conductive
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP19910119360
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English (en)
French (fr)
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EP0485991A1 (de
Inventor
William R. Mattingly
Maurice P. Avoux
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MATRIX SCIENCE CORP
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MATRIX SCIENCE CORP
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Publication of EP0485991A1 publication Critical patent/EP0485991A1/de
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Expired - Lifetime legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
    • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
    • H01R13/6598—Shield material
    • H01R13/6599—Dielectric material made conductive, e.g. plastic material coated with metal

Definitions

  • the present invention relates to an electrical connector fabricated from a conductive fiber composite material; and more particularly to an electrical connector having nickel-coated graphite fibers in a resin providing increased electro-magnetic interference protection.
  • Self-locking electrical connector assemblies comprising a multi-part connector shell and a coupling nut are well known in the art.
  • US-A-4,500,153 entitled “Self-Locking Electrical Connector” describes a self-locking electrical connector assembly which incorporates a connector shell and coupling nut and provides a means for keeping a retention ring in a retention groove when the connector is subjected to high vibrational forces.
  • a structure is provided by this device, limiting axial movement of the coupling nut relative to the shell on which the coupling nut is mounted.
  • US-A-4 500 153 allows the wave spring to maintain a degree of compression such that the permanent deformation of the wave spring does not provide a loss of resiliency.
  • This connector provides an engagement mechanism preventing loosening of the coupling nut in high vibration environments requiring not only the dimples and the clutch plate as provided by the invention but the simultaneous rotation of the coupling nut.
  • the electrical connector assembly as disclosed in patent cited above is fabricated using tooled metal. Electrical connectors manufactured from metals incorporate expensive materials, are time-consuming to manufacture and extremely heavy in weight. The machine cutting, grinding, polishing and subsequent lengthy complicated manufacturing process necessary to fabricate the metal electrical connectors produce significant electro-magnetic interference protection, but at high per unit cost.
  • thermoplastic resin in which no electroconductive filler is mixed, and the other layer of thermoplastic resin in which electroconductive filler is mixed wherein one or more projections which penetrate said layer are formed on said layer.
  • the conductive aspects of the metallic coating provide some electromagnetic interference protection.
  • these metallic coatings can be easily chipped or abraded because glass fibers and resinous material do not bond well with the metal coating.
  • the resultant abrasion of the metal coated composite connector material produces "windows" in the metallic coatings which facilitate the connector body causing substantial noise and signal disruption for the leads within the electrical connectors.
  • the technical problem underlying the present invention is to provide a lightweight non-tooled electrical connector assembly having outstanding durability qualities.
  • a conductive fiber, composite, electrical connector having a composite mixture including up to 40% by weight conductive fibers in a resinous substance resolves the problem of electromagnetic leakage while providing a lightweight non-tooled electrical connector having outstanding durability qualities.
  • the invention provides an electrical connector having a receptacle, wherein this receptacle comprises a composite of up to 40% by weight of conductive fibers and up to 60% by weight of a resin.
  • the electrical connector further contains a plug wherein the plug contains a composite of up to 40% by weight of a conductive fiber and up to 60% by weight of a resin.
  • the receptacle has an alignment means or key, and the plug has an alignment or key which slidably interfits the key or alignment means of the receptacle when the receptacle and plug are mated.
  • the electrical connector contains a coupling nut which also comprises a composite of up to 40% by weight conductive fiber and up to 60% by weight of a resin. This coupling nut is operable to lockingly interfit and surround the receptacle and plug when the receptacle and plug are matingly engaged.
  • An electrical connector having up to 40% by weight of a nickel-coated graphite fiber conductively aligned within a matrix of a up to 60% by weight polyetheretherketone resin is also disclosed.
  • An electrical connector having up to 40% by weight of a conductive graphite fiber conductively aligned within a liquid crystal polymer resin up to 60% by weight is disclosed.
  • a method of fabrication for an electrical connector having a high fiber, conductive composition shell is disclosed.
  • a method of fabrication for an electrical connector having a receptacle, plug and coupling nut all comprising a conductive fiber composite mixture of conductive fibers within a resin is disclosed.
  • the invention is an electrical connector fabricated from a conductive fiber composite mixture of up to 40% by weight conductive fiber such as nickel-coated graphite fiber, non-coated graphite fiber and stainless steel in up to 60% of a resin such as polyetheretherketone or liquid crystal polymer.
  • the nickel-coated graphite fibers are aligned and fully interconnected as suspended within the mixture to maintain their conductive nature and to provide an electro-magnetic "shield" operable to prevent electro-magnetic leakage around the mated pins within the inserts of the receptacle and plug.
  • the conductive particles in this example nickel-coated graphite fibers, produce a smooth surface molded connector after molding.
  • the molded composite connector is then plated by metals such as nickel and copper to further enhance the electro-magnetic leakage protection capability of this improved lightweight connector. Abrasions on the plated connector will not facilitate electro-magnetic leakage of the transmitted electrical signals.
  • the alignment of the nickel-plated graphite conductive fibers within the mixture also serve as a backup electro-magnetic leakage "shield".
  • a fabrication process incorporating a multi-part mold and a center-loaded sprue, where the up to 40% by weight conductive fiber composition is center injected within the mold to individually produce the receptacle, plug and coupling nut is also described.
  • Figure 1 is an exploded perspective view of the conductive fiber composite electrical connector having a receptacle 12, plug 16 and self-locking coupling nut 14.
  • the composite connector 10 has a receptacle 12 which has a receptacle top 13 and a receptacle bottom 15.
  • This receptacle 12 contains a dielectric first insert 18 within the interior surface 52 of the receptacle 12.
  • Alignment means 30 is inscribed within the interior surface 52 of the receptacle 12.
  • An annular surface 50 is formed surrounding the top 13 of the receptacle 12. This annular surface 50 is operable to matingly engage and seal with the plug during mating.
  • a first threaded portion 32 is operable to interlock with the coupling nut 14.
  • a flange portion 46 on the receptacle 12 may be operably mounted to a wall by orifices 48 such that the bottom 33 of the connector 10 would appear on the opposing portion of the wall so that the bottom 15 would be operable to contain the pins within the insert 18 of the receptacle 12.
  • a coupling nut 14 has an interior threaded portion 42 and an exterior portion 36.
  • the interior surface 38 of the coupling nut 14 includes an engagement flange 40 which has a multiplicity of ratchet retaining means 39 inscribed within the annular circumference of the interior surface 38 of the coupling nut 14.
  • Each ratchet retaining means 39 comprises a pair of slanted surfaces with one surface extending from the engagement flange 40 at an angle of approximately 50° and the second slanted surface extending from the engagement flange 40 at an angle of approximately 10°.
  • the ratchet retaining means 41 engage rounded bars extending from the surface of the engagement plate (not shown here) to inhibit, but not prevent, rotational movement of the coupling nut 14 in one direction, while allowing relatively uninhibited rotational movement of the coupling nut in the opposing direction.
  • the interior threaded portion 42 of coupling nut 14 is operable to interlock with the receptacle 12 first threaded means 32.
  • An annular flange 44 is cooperable with retention spring 26 behind shoulder 35 of the plug 16 for retention of ring 14 to plug 16.
  • a multiplicity of protrusions or dimples 56 are evenly interspersed upon the surface of the locking ring 14 providing a means to manipulate the coupling nut 14 so that it interfits over and locks the mated receptacle 12 and plug 16. These protrusions 56 may be spaced regularly about the surface 36 of the coupling nut 14.
  • a wave spring 22 is operable while resting upon the surface of the plug 16 to compress against a rearwardly facing interior flange 45 of the coupling nut 14 to interlock the receptacle and plug, 12 and 16, respectively.
  • a flat spring 29 as shown in Figure 1 rests upon the wave spring 22 encircling the plug 16 and is compressible to assist in maintaining zero distance between the mated receptacle 12 and plug 16 upon mating.
  • a key fitting 24 fabricated of, for example, fiberglass is mounted between springs 22 and 29 to further enhance the locking capability of the wave spring, with key member 25 interfitting within the key ways cut within the shoulder 35 of the plug 16.
  • a second insert 20 and a third insert 21 are mounted within the plug 16 and are operable to retain within metal sleeves the individual pins from the receptacle which serve as the mating interconnects for the electrical connector 10.
  • the neck 17 of the plug 16 supports a retaining spring 26 which is further operable to interlock the receptacle 12, plug 16 and coupling nut 14.
  • the electrical connector 10 as shown in Figure 1 contains composite material parts such as the receptacle 12, plug 16 and coupling nut 14 which are not metal and tooled to specific configurations.
  • the molded composite material containing by weight of at least 10% and up to 40% of a conductive fiber, in this instance nickel-plated graphite, produces a connector 10 having an extreme light weight but also durability.
  • Alternative fiber fillers include but are not limited to stainless steel or non-plated graphite fibers. Due to its conductive properties, outstanding electro-magnetic interference protection for the electrical signals transmitted through the pins within the various inserts is provided.
  • the wave spring 22, the retaining ring 26 and the flat spring 29, are metal and the key fitting 24 is a fiberglass material.
  • the dielectric inserts are the only elements of the conductive composite connector 10 that are not composite materials.
  • the composite materials from which the receptacle 12 and the plug 16 and coupling nut 14 are fabricated are further protected through the layering of electrically conductive metals which enhance the electromagnetic protection capability of this device.
  • Figure 2 is a partial cross sectional view of the conductive fiber composite electrical connector plug 16 and coupling nut 14 having cross section 3-3.
  • coupling nut 14 has the composite layer 60 which further comprises by weight of up to 60% of a resin 62 which for this example is polyetheretherketone and conductive fibers 64.
  • An alternative example includes liquid crystal polymer as a bonding resin.
  • the conductive fibers 64 are nickel-coated graphite wherein the individual graphite fibers 64 are interconnected and aligned such that their conductive nature is maintained throughout the body of the composite material shell.
  • a first conductive coating of copper 66 is deposited upon the smooth surface of the composite layer 60 using a standard deposition process of metal on a non-metal connector.
  • a second coating of, for example, a nickel layer 68 is then deposited upon the first conductive coating of copper.
  • Subsequent successive coatings such as a third conductive coating 70 of copper and a fourth conductive coating 72 of nickel are made and further enhance the electromagnetic interference capability of the composite connector as shown through the example of the coupling nut 14.
  • the nature of the conductive composite material and layered conductive depositions upon the surface of the connector provide a barrier to stray electromagnetic leakage which may surround the connector from, for example, extraneous power sources.
  • the composite connector 10 maintains the integrity of the signals passing through the receptacle 12 into the plug 16 as surrounded by the coupling nut 14.
  • Figure 4 is a schematic representation cross section view of the conductive fiber composite connector 10 showing the alignment means and such as the master key 28 and other individual keys 28' as they are extended upon the exterior surface of the plug 16.
  • the plug 16 slidably interfits within the receptacle 12 and in turn the mated portions are surrounded by the coupling nut 14 which lockingly interfits after alignment due to the position of the various keys 28,28' including the master key 28 as shown.
  • spring 22 which engages shoulder 35 of plug 16 beneath the flange 45 of ring 14.
  • Figure 5 is a partial cross sectional view of the conductive fiber composite connector second shell 16 immediately after removal from a multi-part mold.
  • the multi-part mold having a top core, bottom core and two cavity halves, incorporates a center loaded sprue through the top or bottom cores.
  • Composite material injected into the multi-part mold through the sprue will produce webs which are removed after molding using a drill, or a single point tool and a lathe.
  • the web 41 formed within the cavity of the second shell 16 does not facilitate EMI leakage because the position of the web is beneath inserts added to the second shell 16.
  • Figure 5A is a top plan view of the conductive fiber composite connector second shell 16 immediately after removal from a multi-part mold.
  • the web 41 formed from the center-loaded sprue resides beneath any insert that is added after shell fabrication.
  • the center loaded molding of the second shell 16 reduces EMI leakage which occurs due to side injection molding which causes a deformation upon the exterior surfaces of the second shell 16.
  • Figure 6 is a partial cross sectional view of the conductive fiber composite connector first shell 12 immediately after removal from a multi-part mold.
  • the first shell 12 is fabricated in a manner not unlike the second shell 16.
  • the multi-part mold includes a top core, bottom core and at least two cavity halves, which when locked together form the entire first shell 12 in negative.
  • a center loaded sprue within the top or the bottom core injects composite material without forming excess material upon the exterior surfaces of the first shell 12.
  • Web 43 forms within the body of the first shell 12. Removal of this web 43 using a drill, or single point tool while the first shell 12 turns on a lathe, will not affect the texture and EMI permeability of the exterior surface of the first shell 12.
  • Figure 6A is a top plan view of the conductive fiber composite connector first shell 12 immediately after removal from a multi-part mold as previously described.
  • the web 43 formed within the cavity of the shell 12 is removed prior to the incorporation of an insert. Removal of the excess composite material in the form of web 43 does not affect the exterior surface of the first shell 12.
  • This multi-part mold incorporating a center-loaded sprue eliminates the possibility of "flash”, web or excess composite material occurring upon the exterior surfaces or the mating interior surfaces of the entire connector 10.
  • Electromagnetic signal leakage into the connector occurs due to, for example, power sources or electronic devices exterior to the connector.
  • a center-loaded molded sprue fabrication method produces a receptacle where the only web or "flash" occurs on the center of the receptacle beneath the after applied insert. The receptacle is machined out and excess composite material is removed from underneath the body of the insert where no leakage is likely to occur.
  • any additional material or excess flash is removed from the completed connector parts.
  • a series of depositions of conductive material on the composite connector facilitate increased EMI protection.

Landscapes

  • Details Of Connecting Devices For Male And Female Coupling (AREA)
  • Connector Housings Or Holding Contact Members (AREA)

Claims (9)

  1. Elektrische Verbinderanordnung (10) des Typs mit einem Steckerelement und einem Buchsenelement;
    a) wobei das Steckerelement und das Buchsenelement miteinander verbindbar und durch eine Befestigungseinrichtung (14) aneinander befestigbar sind,
    b) wobei in jedem der Elemente eine Anzahl elektrischer Kontakte innerhalb einer dielektrischen Einrichtung (18, 20, 21) untergebracht ist, und
    c) wobei das Steckerelement und das Buchsenelement Manteleinrichtungen (12, 16) aufweisen, die um die dielektrischen Einrichtungen (18, 20, 21) herum vorgesehen sind und diese enthalten sowie dazu ausgelegt sind, die durch die Verbinderanordnung hindurch übertragenen Signale gegen elektromagnetische Interferenz abzuschirmen,
       dadurch gekennzeichnet,
       d) daß es sich bei jeder der Manteleinrichtungen um ein Mantelelement (12, 16) handelt, das aus Verbundmaterial (60) aus wenigstens 10 Gew.-% und nicht mehr als 40 Gew.-% leitfähigem Fasermaterial (64) und wenigstens 60 Gew.-% und nicht mehr als 90 Gew.-% Harz (62) geformt ist.
  2. Elektrische Verbinderanordnung (10) nach Anspruch 1,
    dadurch gekennzeichnet,
    daß die leitfähigen Fasern (64) aus der Gruppe bestehend aus nickelplattiertem Graphit, nichtplattiertem Graphit und nicht-rostendem Stahl ausgewählt sind.
  3. Elektrische Verbinderanordnung (10) nach einem der Ansprüche 1 und 2,
    dadurch gekennzeichnet,
    daß das Harz (62) aus der Gruppe bestehend aus Polyetheretherketon und Flüssigkristallpolymerharzen ausgewählt ist.
  4. Elektrische Verbinderanordnung (10) nach einem der Ansprüche 1 bis 3,
    dadurch gekennzeichnet,
    daß die Manteleinrichtung wenigstens eine darüber aufgebrachte Schicht (66, 68, 70, 72) aus elektrisch leitfähigem Material aufweist.
  5. Elektrische Verbinderanordnung (10) nach einem der Ansprüche 1 bis 4,
    dadurch gekennzeichnet,
    daß die Manteleinrichtung eine erste darüber aufgebrachte, leitfähige Schicht (66) aus Kupfer, eine auf der ersten leitfähigen Schicht aufgebrachte zweite leitfähige Schicht (68) aus Nickel, eine auf der zweiten leitfähigen Schicht aufgebrachte dritte leitfähige Schicht (70) aus Kupfer sowie eine auf der dritten leitfähigen Schicht aufgebrachte vierte leitfähige Schicht (72) aus Nickel aufweist.
  6. Elektrische Verbinderanordnung (10) nach einem der Ansprüche 1 bis 5,
    dadurch gekennzeichnet,
    daß die Befestigungseinrichtung eine Kopplungsmutter (14) aufweist, die aus einem Verbundmaterial (60) aus wenigstens 10 Gew.-% und nicht mehr als 40 Gew.-% Fasermaterial (64) und wenigstens 60 Gew.-% und nicht mehr als 90 Gew.-% eines Harzmaterials (62) geformt ist, und daß die Kopplungsmutter eine darauf aufgebrachte erste leitfähige Schicht (66) aus Kupfer, eine auf der ersten leitfähigen Schicht aufgebrachte zweite leitfähige Schicht (68) aus Nickel, eine auf der zweiten leitfähigen Schicht aufgebrachte dritte leitfähige Schicht (70) aus Kupfer sowie eine auf der dritten leitfähigen Schicht aufgebrachte vierte leitfähige Schicht (72) aus Nickel aufweist.
  7. Verfahren zum Herstellen einer Manteleinrichtung eines elektrischen Verbinders nach Anspruch 1, wobei das Verfahren folgende Schritte umfaßt:
    Formen eines Mantelelements, das ein Verbundmaterial (60) aus ca. 10 Gew.-% bis 40 Gew.-% leitfähigem Fasermaterial (64) und ca. 60 Gew.-% bis 90 Gew.-% eines Harzmaterials (62) aufweist, in einer mehrteiligen Form, in die ein in der Mitte eingebrachter Eingußkanal integriert ist, wodurch radial äußere Oberflächen des Mantelelements (12, 16) glatt ausgebildet werden; und
    Entfernen von überschüssigem Verbundmaterial (41, 43) von den Innenflächen des Mantelelements (12, 16) zur Bildung eines Einsatzaufnahmehohlraums.
  8. Verfahren zum Herstellen einer Manteleinrichtung eines elektrischen Verbinders nach Anspruch 7, wobei das Verfahren den weiteren Schritt einer Aufbringung wenigstens einer leitfähigen Materialschicht (66, 68, 70, 72) darauf beinhaltet.
  9. Elektrische Verbinderanordnung (10)
    a) mit einem Steckerelement und einem Buchsenelement, die an einer Verbindungsgrenzfläche verbindbar sind, die entlang von Innenflächen des Buchsenelements und Außenflächen des Steckerelements in der Nähe der Verbindungsseiten derselben gebildet ist, wobei das Steckerelement und das Buchsenelement durch eine Befestigungseinrichtung (14) aneinander befestigbar sind,
    b) wobei in jedem der Elemente eine Vielzahl elektrischer Kontakte innerhalb einer dielektrischen Einrichtung (18, 20, 21) untergebracht ist und das Steckerelement und das Buchsenelement eine Manteleinrichtung (12, 16) aufweisen, die die dielektrische Einrichtung (18, 20, 21) umgibt und diese enthält und dazu ausgelegt ist, die durch die Verbinderanordnung übertragenen Signale vor elektromagnetischer Interferenz zu schützen,
       dadurch gekennzeichnet,
    c) daß die Manteleinrichtung ein Mantelelement (12, 16) aufweist, das sowohl für das Steckerelement als auch für das Buchsenelement vorgesehen ist und aus einem Verbundmaterial (60) aus wenigstens 10 Gew.-% und nicht mehr als 40 Gew.-% leitfähigem Fasermaterial (64) und wenigstens 60 Gew.-% und nicht mehr als 90 Gew.-% eines Harzmaterials (62) geformt ist, und
    d) daß wenigstens eine Schicht (66, 68, 70, 72) aus elektrisch leitfähigem Material wenigstens auf der Innenfläche und der Außenfläche darüber aufgebracht ist,
    e) wodurch ineinander passende Flächen gebildet sind, die frei sind von Unregelmäßigkeiten und eine wirksame Abschirmung gegen elektromagnetische Interferenz an der Verbindungsgrenzfläche schaffen.
EP19910119360 1990-11-14 1991-11-13 Elektrischer Verbinder aus leitfähigem Faserstoff und Verfahren zur Herstellung Expired - Lifetime EP0485991B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US61478990A 1990-11-14 1990-11-14
US614789 1990-11-14

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Publication Number Publication Date
EP0485991A1 EP0485991A1 (de) 1992-05-20
EP0485991B1 true EP0485991B1 (de) 1997-01-29

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9324472B2 (en) 2010-12-29 2016-04-26 Syscom Advanced Materials, Inc. Metal and metallized fiber hybrid wire

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Publication number Priority date Publication date Assignee Title
GB9808141D0 (en) 1998-04-17 1998-06-17 Smiths Industries Plc Electrical connection and connectors
DE19823509C1 (de) * 1998-05-26 1999-11-18 Framatome Connectors Int Klemmverbindung in metallisierter Kunststoffausführung
DE19823519C1 (de) * 1998-05-26 2000-01-05 Framatome Connectors Int Klemmverbindung mit U-förmig ausgebildeter Feder
US6379795B1 (en) * 1999-01-19 2002-04-30 E. I. Du Pont De Nemours And Company Injection moldable conductive aromatic thermoplastic liquid crystalline polymeric compositions
DE10037084A1 (de) * 2000-07-27 2002-02-07 Conducta Endress & Hauser Kupplung oder Stecker für eine flüssigkeitsdichte Steckverbindung
DE102006046180A1 (de) * 2006-09-29 2008-04-03 Adc Gmbh Anschlusselement für die Kommunikations- und Datentechnik
FR3036860B1 (fr) * 2015-06-01 2018-06-01 Souriau Bague de verrouillage, de type baionnette d’un connecteur electrique circulaire

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GB2114981B (en) * 1982-02-09 1985-07-17 Plessey Co Plc Improvements in or relating to equipment housings
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Cited By (1)

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Publication number Priority date Publication date Assignee Title
US9324472B2 (en) 2010-12-29 2016-04-26 Syscom Advanced Materials, Inc. Metal and metallized fiber hybrid wire

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Publication number Publication date
DE69124467D1 (de) 1997-03-13
EP0485991A1 (de) 1992-05-20
DE69124467T2 (de) 1997-05-15

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