Potting compound chamber designs for electrical connectors

Patent metadata

Field	Value
Publication number	US-9368905-B2
Application number	US-201414337985-A
Country	US
Kind code	B2
Filing date	Jul 22, 2014
Priority date	Jul 22, 2014
Publication date	Jun 14, 2016
Grant date	Jun 14, 2016

Abstract

An electrical chamber is disclosed herein. The electrical chamber can include at least one wall forming a cavity, where the at least one wall includes a first end and an inner surface. The electrical chamber can also include a first isolation zone disposed on the inner surface at a first distance from the first end, where the first isolation zone is formed by a first bridge, a first underhang, and a first isolation zone inner surface, where the first bridge protrudes inward toward the cavity from the inner surface, and where the first underhang extends from a distal end of the first bridge. The cavity can be configured to receive at least one electrical conductor. The cavity and the first isolation zone can be configured to receive a potting compound.

First claim

What is claimed is:

1. An electrical chamber, comprising:
at least one wall forming a cavity, wherein the at least one wall comprises a first end and an inner surface; and
a first isolation zone disposed in the at least one wall adjacent to the inner surface at a first distance from the first end, wherein the first isolation zone is formed by a first underhang, a first roof, and a first isolation zone inner surface, wherein the first roof extends from the first isolation zone inner surface toward the cavity, and wherein the first underhang extends toward the first roof along the at least one wall without contacting the first roof,
wherein the first isolation zone is in communication with the cavity,
wherein the first underhang and the first isolation zone inner surface are disposed at opposite ends of the first isolation zone, and
wherein the cavity is configured to receive at least one electrical conductor, and wherein the cavity and the first isolation zone are configured to receive a potting compound.

2. The electrical chamber of claim 1 , wherein the first underhang extends at an angle relative to the first isolation zone inner surface.

3. The electrical chamber of claim 1 , wherein the first underhang avoids contact with the first isolation zone inner surface, the roof, and a remainder of the inner surface.

4. The electrical chamber of claim 1 , wherein the first isolation zone inner surface is recessed relative to a remainder of the inner surface.

5. The electrical chamber of claim 1 , wherein the first isolation zone further comprises a first bridge that protrudes substantially perpendicularly from the inner surface, and wherein the first underhang extends substantially perpendicularly from the first bridge.

6. The electrical chamber of claim 1 , wherein the electrical chamber further comprises:
a second isolation zone disposed on the inner surface at a second distance from the first end, wherein the second isolation zone is formed by a second underhang, a second roof, and a second isolation zone inner surface, wherein the second roof protrudes inward extends from the second isolation zone inner surface toward the cavity, and wherein the second underhang extends toward the second roof along the at least one wall without contacting the second roof.

7. The electrical chamber of claim 6 , wherein the second distance is greater than the first distance.

8. The electrical chamber of claim 6 , wherein the first isolation zone further comprises a first bridge, wherein the second isolation zone further comprises a second bridge, wherein the first underhang extends from the first bridge in a first direction, and the second underhang extends from the second bridge in the first direction.

9. The electrical chamber of claim 6 , wherein the first isolation zone further comprises a first bridge, wherein the second isolation zone further comprises a second bridge, wherein the first underhang extends from the first bridge in a first direction, and the second underhang extends from the second bridge in a second direction, wherein the first direction is opposite the second direction.

10. The electrical chamber of claim 1 , wherein the first roof protrudes toward the cavity relative to the inner surface.

11. The electrical chamber of claim 1 , wherein the first roof comprises a top portion that forms an obtuse angle with the inner surface.

12. The electrical chamber of claim 1 , wherein the first underhang, the first roof, and the first isolation zone inner surface are formed by machining the at least one wall.

13. The electrical chamber of claim 1 , wherein the first underhang is mechanically coupled to the at least one wall.

14. The electrical chamber of claim 13 , wherein the first roof is mechanically coupled to the at least one wall.

15. An electrical connector, comprising:
an electrical chamber, comprising:
at least one wall forming a cavity, wherein the at least one wall comprises a first end and an inner surface;
an isolation zone disposed in the at least one wall adjacent to the inner surface at a distance from the first end, wherein the isolation zone is formed by an underhang, a roof, and an isolation zone inner surface, wherein the roof extends toward the cavity from the isolation zone inner surface, wherein the underhang extends toward the first roof along the at least one wall without contacting the first roof, wherein the isolation zone is in communication with the cavity, and wherein the first underhang and the first isolation zone inner surface are disposed at opposite ends of the first isolation zone;

at least one electrical conductor disposed within the cavity; and
a potting compound disposed within the cavity and the first isolation zone, and disposed around the at least one electrical conductor.

16. The electrical connector of claim 15 , wherein the potting compound creates a gas-tight seal within the first isolation zone.

17. The electrical connector of claim 15 , further comprising:
a mechanical sealing member disposed adjacent to the inner surface at a second distance from the first end.

18. The electrical connector of claim 16 , wherein the potting compound creates a flameproof barrier within the cavity of the electrical chamber.

19. The electrical connector of claim 16 , wherein the gas-tight seal withstands at least four times a pressure required to rupture the at least one wall of the electrical chamber.

20. An electrical chamber, comprising:
at least one wall forming a cavity, wherein the at least one wall comprises an end and an inner surface; and
an isolation zone disposed within the cavity at a distance from the end, wherein the isolation zone is formed by a bridge, an underhang, a roof, and an isolation zone inner surface, wherein the bridge and the roof each protrudes away from the inner surface toward the cavity, wherein the underhang extends from a distal end of the bridge toward the roof along the at least one wall without contacting the roof,
wherein the bridge and the roof are disposed at opposite first ends of the isolation zone,
wherein the underhang and the isolation zone inner surface are disposed at opposite second ends of the isolation zone, wherein the opposite first ends are substantially transverse to the opposite second ends,
wherein the cavity is configured to receive at least one electrical conductor, and wherein the cavity and the isolation zone are configured to receive a potting compound.

Assignees

• Ledgerwood Adam Douglas
• Aldrich Alvah Benjamin
• Manahan Joseph Michael
• Cooper Technologies Co

Inventors

• Ledgerwood Adam Douglas
• Aldrich Alvah Benjamin
• Manahan Joseph Michael

Classifications

• H01R13/527

  Flameproof cases (H01R13/70 takes precedence) · CPC title

• H01R13/5216 Primary

  characterised by the sealing material, e.g. gels or resins · CPC title