High power electrical connector

Patent metadata

Field	Value
Publication number	US-9425541-B2
Application number	US-201314390251-A
Country	US
Kind code	B2
Filing date	Apr 5, 2013
Priority date	Apr 5, 2012
Publication date	Aug 23, 2016
Grant date	Aug 23, 2016

Abstract

A high power electrical connector is provided for transmitting electrical signals from a pair of cables, such as high current capable cables, to an associated member, such as a dash panel. The high power electrical connector includes an insulative housing and a pair of contact path assemblies therethrough for transmission of the electrical signals. The cables can be rotated relative to the housing and rotated relative to each other via the contact path assemblies. Ground path assemblies are also provided for grounding the cables. The cables can each be rotatable relative to a portion of the respective ground path assembly.

First claim

What is claimed is:

1. A high power electrical connector comprising:
an insulative housing;
a first electrical path formed through the housing for transmitting electrical signals through the housing to an associated member;
a first cable having an inner cable conductor attached to the first electrical path for transmitting electrical signals to the first electrical path;
a second electrical path formed through the housing for transmitting electrical signals through the housing to the associated member; and
a second cable having an inner cable conductor attached to the second electrical path for transmitting electrical signals to the second electrical path, wherein the first and second cables can rotate relative to the housing and relative to each other,
wherein the first electrical path comprises a first conductor mounted in the housing and affixed to the inner conductor of the first cable and a first contact non-rotatably mounted in the housing, the first conductor being rotatably connected to the first contact, and the second electrical path comprises a second conductor mounted in the housing and affixed to the inner conductor of the second cable and a second contact non-rotatably mounted in the housing, the second conductor being rotatably connected to the second contact, and
wherein the first conductor has a plurality of flexible legs which attach to the first contact, and the first electrical path further comprises a first c-clip for compressing the legs while still allowing relative rotation between the first conductor and the first contact, and wherein the second conductor has a plurality of flexible legs which attach to the second contact, and the second electrical path further comprises a second c-clip for compressing the legs of the second conductor while still allowing relative rotation between the second conductor and the second contact.

2. The high power electrical connector of claim 1 , further comprising a first seal between the housing and the first cable and a second seal between the housing and the second cable.

3. The high power electrical connector of claim 1 , wherein the first and second contacts comprise a cylindrical portion attached to the respective conductors and a flat blade portion extending from the housing for attachment to the associated member.

4. The high power electrical connector of claim 1 , wherein each cable includes a conductive shield and the connector includes a ground path assembly connected to each of the conductive shields, the ground path assemblies configured to form a ground path connection between the two conductive shields that has a resistance of between one (1) and one hundred (100) milliohms (mΩ).

5. The high power electrical connector of claim 4 , wherein the resistance is between five (5) and fifty (50) me.

6. A high power electrical connector of comprising:
an insulative housing;
a first electrical path formed through the housing for transmitting electrical signals through the housing to an associated member;
a first cable having an inner cable conductor attached to the first electrical path for transmitting electrical signals to the first electrical path;
a second electrical path formed through the housing for transmitting electrical signals through the housing to the associated member; and
a second cable having an inner cable conductor attached to the second electrical path for transmitting electrical signals to the second electrical path, wherein the first and second cables can rotate relative to the housing and relative to each other,
wherein each of the cables comprises an outer insulative skin, a conductive shield and an insulative sheath, the inner conductor and the conductive shield being exposed; and further comprising:
a first ground path assembly mounted in the housing, the first ground path assembly attached to the shield of the first cable, the first electrical path and the first ground path assembly being electrically isolated from each other by the housing and the first cable, the first cable and a portion of the first ground path assembly being rotatable relative to each other;
a second ground path assembly mounted in the housing, the second ground path assembly attached to the shield of the second cable, the second electrical path and the second ground path assembly being electrically isolated from each other by the housing and the second cable, the second cable and a portion of the second ground path assembly being rotatable relative to each other; and
a ground plate mounted on the housing, the first and second ground path assemblies being connected to the ground plate.

7. The high power electrical connector of claim 6 , wherein the first ground path assembly comprises a first conductive cap attached to the shield of the first cable, and a first conductive sleeve rotatably connected to the first cap, the first sleeve non-rotatably affixed to the housing; and wherein the second ground path assembly comprises a second conductive cap attached to the shield of the second cable, and a second conductive sleeve rotatably connected to the second cap, the second sleeve non-rotatably affixed to the housing.

8. The high power electrical connector of claim 7 , wherein each sleeve includes a plurality of flexible legs, and further comprising a c-clip engaging the legs for causing the legs to compress and engage the respective cap.

9. The high power electrical connector of claim 7 , wherein the ground plate comprises a plurality of fingers for engaging the sleeves, and the ground plate further comprises a plurality of fingers extending from a perimeter thereof for engaging an associated member.

10. The high power electrical connector of claim 7 , wherein the first sleeve surrounds the first electrical path but is electrically isolated therefrom, and the second sleeve surrounds the second electrical path but is electrically isolated therefrom.

11. The high power electrical connector of claim 7 , further including a first conductive ferrule attached to the first cable, the shield of the first cable being sandwiched between the first ferrule and the first cap, and a second conductive ferrule attached to the second cable, the shield of the second cable being sandwiched between the second ferrule and the second cap.

12. The high power electrical connector of claim 7 , wherein each sleeve is formed from first and second parts.

13. The high power electrical connector of claim 12 , wherein the first part of each sleeve includes a plurality of tabs which engage with the second part of the respective sleeve.

14. A high power electrical connector comprising:
first and second cables, each cable comprising an outer insulative skin, a conductive shield, an insulative sheath and an inner conductive conductor, the inner conductor and the conductive shield being exposed;
an insulative housing having a pair of passageways into which the cables are seated;
a first seal between the housing and the first cable;
a second seal between the housing and the second cable;
a first contact assembly formed through the housing for transmitting electrical signals through the housing, the first contact assembly comprising
a first conductor mounted in the housing and non-rotatably connected to the inner conductor of the first cable,
a first contact non-rotatably mounted in the housing, and
a first c-clip for connecting the first conductor and the first contact together,
the first conductor having a plurality of flexible legs which attach to the first contact, and the first c-clip compressing the legs while still allowing relative rotation between the first conductor and the first contact,
the

Assignees

• Molex Llc

Inventors

• Data Mark M
• Bleuel Eric P
• Carlson Robert
• Keyser Frank
• Stenstrom Eric J
• Bandura Michael A
• Patel Arvind
• Brunker David L
• Dunham David E
• Kulakowski Ronald
• Kinsley Ed
• Smid Robert

Classifications

• H01R13/565

  Torsion-relieving · CPC title

• H01R13/6315 Primary

  allowing relative movement between coupling parts, e.g. floating connection (for coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures, H01R12/91 takes precedence) · CPC title

• H01R24/28

  Coupling parts carrying pins, blades or analogous contacts and secured only to wire or cable · CPC title

• H01R2103/00

  Two poles · CPC title

• H01R2201/26

  for vehicles · CPC title