Interposer/electrical connector

Abstract

An electrical coupling for aerospace applications comprises an interposer arranged in use to electrically connect an electrical connector to an electrical circuit, the electrical connector comprising a plurality of electrical contacts and the electrical circuit comprising a plurality of electrical conductors. The interposer comprises a body arranged to surround each electrical contact within the connector.

Claims

1. An electrical coupling, the coupling comprising: an interposer arranged to electrically connect an electrical connector to an electrical circuit, the electrical connector comprising a plurality of electrical contacts and the electrical circuit comprising a plurality of electrical conductors, the interposer comprising a body arranged to surround each electrical contact at a portion of the body proximate to the electrical conductors, said body comprising a plurality of ducts each arranged around an electrical contact and configured to extend from the body along at least part of the length of each contact towards the electrical connector; and wherein the coupling further comprises a seal layer provided with a plurality of apertures each aperture aligning with a respective contact and wherein the seal layer is located at a portion of the body proximate to the electrical conductors.

2. The electrical coupling of claim 1, wherein the body and ducts are integral with each other.

3. The electrical coupling of claim 1, wherein each electrical contact comprises a biasing arrangement at a portion of the contact proximate to the electrical conductors, arranged to bias a distal end of the contact against a respective electrical conductor.

4. The electrical coupling of claim 3, wherein the biasing arrangement is a spring arranged to bias a distal portion of the contact towards a respective conductor.

5. The electrical coupling of claim 1, wherein each contact is an electrical conductor extending through the interposer and comprising a proximal end arranged for electrical contact with the electrical connector and a distal end arranged for electrical contact with an associated electrical conductor.

6. The electrical coupling of claim 1, wherein the electrical contacts and the ducts have a complementary shape.

7. The electrical coupling of claim 1, wherein inner surfaces of the ducts are in contact with outer surfaces of the contacts.

8. The electrical coupling of claim 1, wherein a length of each contact is longer than a distance measured between a portion of the electrical connector associated with a proximal portion of a respective contact and a surface of an electrical conductor associated with a distal portion of the respective contact.

9. The electrical coupling of claim 1, wherein the contacts are circular in cross-section and the ducts are arranged to surround each contact.

10. The electrical coupling of claim 1, wherein the interposer includes an electrically insulating material.

11. The electrical coupling of claim 1, wherein the interposer further comprises a peripheral wall surrounding and spaced from the ducts, said wall extending in a direction parallel with the ducts.

12. The electrical coupling of claim 11, wherein the peripheral wall is a ring surrounding the ducts and extending in a direction parallel with the ducts and further comprising a radial space between the ducts and the wall, said space arranged to receive a portion of the electrical connector.

13. The electrical coupling of claim 11, further comprising a peripheral ring arranged to surround a portion of the coupling adjacent to the peripheral wall, wherein the peripheral wall is integral with the body of the interposer.

14. The electrical coupling of claim 1, further comprising an end cap arranged to connect an end of the coupling and to define a cavity into which electrical conductors may extend, wherein the end cap further comprises the seal layer arranged to abut with a side of an electrical conductor layer opposite to a side against which the contacts abut.

15. An electrical coupling, the coupling comprising: a body configured to be integrated with a surface wherein the body comprises a plurality of ducts arranged to align with corresponding connections of an electrical connector at a first end and to align with a plurality of electrical conductors at a second end; wherein the conductors are integrated with the surface, the ducts extending through the body, wherein each duct comprises an electrical contact, each electrical contact comprising a biasing arrangement at a portion of the contact proximate to the electrical conductors, to bias a distal end of the contact against a respective electrical conductor; and wherein the coupling further comprises a seal layer provided with a plurality of apertures each aperture aligning with a respective contact and wherein the seal layer is located at a portion of the body proximate to the electrical conductors.

16. The electrical coupling of claim 15, wherein the biasing arrangement is a spring arranged to bias a distal portion of the contact towards a respective conductor.

17. The electrical coupling of claim 15, wherein a face of the body proximate to the electrical conductors comprises a convex profile corresponding to a predetermined curvature.

18. The electrical coupling of claim 17, wherein the face of the body proximate to the electrical conductors further comprises a peripheral flange extending from the body for attachment to a structure.

19. The electrical coupling of claim 18, wherein the flange and/or body are formed from a composite material.

Description

SUMMARY OF THE DRAWINGS

(1) Aspects of the disclosure will now be described, by way of example only, with reference to the accompanying figures in which:

(2) FIG. 1 shows an exploded view of a connector system with an interposer according to a first example;

(3) FIG. 2 shows a perspective view of a cut out of the connector system with the interposer according to a first example;

(4) FIG. 3 shows an example end of a spring loaded contact;

(5) FIG. 4 is a perspective partly exploded view of an interposer according to a second example;

(6) FIG. 5 is a perspective view of the interposer according to the example; and

(7) FIG. 6 is a further perspective view of the interposer from below according to the second example.

(8) While the present teachings are susceptible to various modifications and alternative forms, specific embodiments are shown by way of example in the drawings and are herein described in detail. It should be understood, however, that drawings and detailed description thereto are not intended to limit the scope to the particular form disclosed, but on the contrary, the scope is to cover all modifications, equivalents and alternatives falling within the spirit and scope defined by the appended claims.

(9) As used in this specification, the words “comprises”, “comprising”, and similar words, are not to be interpreted in an exclusive or exhaustive sense. In other words, they are intended to mean “including, but not limited to”.

(10) It will be recognised that the features of the aspects of the invention(s) described herein can conveniently and interchangeably be used in any suitable combination. It will also be recognised that the invention covers not only individual embodiments but also combinations of the embodiments that have been discussed herein.

DETAILED DESCRIPTION

(11) The present teaching relates generally to an interposer and a method of manufacturing of such an interposer.

(12) An embodiment will be described in which the design of the interposer allows the termination of a standard aerospace electrical connector at termination pads or islands.

(13) A further embodiment will be described in which the design of the interposer allows direct application of the interposer to the wing of an aircraft. The interposer of the present application is suitable for any application where termination is needed of conductors. For example, the interposer may be used in extreme environments such as: engines, pylons, empennages, fairings and landing gears. Furthermore, the interposer may be used in mild environments such as: inside the pressure cabin in the cargo bay, in the passenger compartment, and in avionics bays. The solution is adaptable, scalable and modular and can be used for signals as well as power.

(14) Referring to FIG. 1, an exploded view of the electrical coupling of the first embodiment of the present application is shown.

(15) Referring to FIG. 2, from top to bottom of the drawing, a standard, off-the-shelf connector 1 is shown which includes contact cavities (not specifically shown) and a grommet seal 3 on the back. The grommet seal 3 is configured to prevent the ingress of moisture.

(16) The outer surface of a first length of the connector 1 comprises accessory threading. A cylindrical interposer installation ring 5 is shown beneath the connector 1. In use, the interposer installation ring is configured to be connected to the connector 1 to provide a fluid or sand and dust barrier between the connector 1 and an interposer 4. Furthermore, the interposer installation ring allows for axial dimensional tolerances to ensure the correct length of the contacts extend through the connector. In the present example, the inner surface of the installation ring comprises threading, wherein the threading on the outer surface of the connector is configured to be received by and mate with the threading on the inner surface of the interposer installation ring 5. In other examples other means may be used to connect the interposer installation ring to the connector. For example, spacer screws and bolts, clamping/ratcheting arrangements or adhesive potting could be used.

(17) In the present example, the interposer is made of an electrically insulating material. For example, the interposer may be made of any insulating thermoset or thermoplastic material. In the present example, the interposer body is made of one material and may be finished with a different material.

(18) The interposer installation ring 5 is configured to be received by the interposer of the present application. The interposer has a peripheral wall 8. In the present example, the peripheral wall 4 is formed of four sections or clamping tabs such that, when viewed in an axial direction of the peripheral wall, an incomplete ring is formed. In other examples, more or fewer sections or clamping tabs may be used to form the incomplete circumferential ring.

(19) In use, the interposer peripheral wall is arranged to surround the interposer installation ring 5. Once the interposer 4 is in position, a strap is positioned around the outside of the circumferential ring. The strap, once in position, is tightened to hold the interposer 4 in place. In use, the strap secures the interposer body on the interposer installation ring and prevents the adapter ring from unscrewing from the connector 1.

(20) In the present example, the strap is made of metal, for example steel. In other examples, the strap may be made of other materials.

(21) The interposer comprises a plurality of ducts 7 which extend from the main body of the interposer. Each duct has a through hole extending through the length of the duct.

(22) The ducts extend parallel to the peripheral wall away from the main body of the interposer. The ducts have an external diameter which is sized to fit in the holes of the grommet seal. The interference between the outer surface of the ducts and the grommet seal ensures the ducts are sealed inside the connector. The connector has contact cavities which are configured to receive these ducts. The length of the ducts is chosen so that the end of each of the ducts reach the end of their respective contact cavity in the connector. This allows the contacts to protrude to the desired length to ensure a correct connection with a (to be) mated contra connector. When pin (male) contacts are used as is shown in FIGS. 1 to 3, the contacts also extend through the contact cavities and through an elastomer interfacial seal of the connector (not shown in the figures).

(23) The height of the peripheral wall 8 is dimensioned such that the ducts of the interposer are able to extend to the desired amount into the grommet seal without the peripheral wall coming into contact with the connector when the peripheral wall is arranged around the interposer installation ring. For example, the height of the interposer peripheral wall is such that a sufficient surface is provided by which to clamp the wall to the connector with the strap whilst allowing insertion of the ducts into the grommet seal to the required extent.

(24) Each duct is configured to receive an electrical contact 2. In the present example, the contacts are spaced from the inner surface of the ducts. This provides some freedom of movement to the contact to absorb small contact misalignments. In other examples, the inner surfaces of the ducts are in contact with the outer surface of the contacts. This results in a restricted movement of the contacts to prevent side loads on the contacts.

(25) In the present example, the electrical contacts are spring loaded contacts. Each electrical contact comprises an elongate electrically conductive rod. Each electrical contact comprises a head wherein the head is situated at one end of the electrical contact. In use, the head of the electrical contact is located adjacent to an electrically conductive surface 20.

(26) In the present example, the electrical contacts are gold plated for corrosion resistance and good electrical connection.

(27) A contact retaining bushing 17 surrounds the head of the electrical contact when in use. The bushing is in place in order to retain the contact in its cavity during assembly or maintenance and to retain the elastomer seal during assembly.

(28) In some examples, different types of contacts may be used in each duct. For example, normal contacts, or thermocouple contacts.

(29) The electrical contact is configured to be brought into contact with an electrically conductive surface. In the present example, the electrically conductive surface is a surface of a PCB. In other examples the electrically conductive surface may be any mechanically stable surface such as a solid round conductor or conductive foil, tape or strip.

(30) In the present example, a first elastomer seal 11 is positioned on the electrically conductive surface. The first elastomer seal 11 has holes extending through its depth which are configured to receive the heads of the electrical contacts. The first elastomer seal provides an environmental seal for the heads of the electrical contacts.

(31) A PCB retaining cover is arranged to be attached to the end of the interposer. A second elastomer seal 12 lies between the PCB and the PCB retaining cover.

(32) The interposer is configured to be attached to the PCB retaining cover by means of a connecting means 13. In the present example the connecting means is a bolt. In other examples, other forms of connecting means may be used.

(33) In the present example, the connector comprises a square flange receptacle. In other examples this could be a jam-nut receptacle, box mount receptacle, a connector plug or any other connector variant.

(34) In FIG. 2, a perspective cut out view of the assembled electrical coupling is shown. The electrical coupling shows the standard, off-the-shelf connector 1 connected to the interposer 4.

(35) FIG. 2 shows the ducts 7 extending axially from the body of the interposer 4 and being received in the grommet seal 3. The electrical contacts are configured to extend through the through hole of the duct and beyond the open end of each duct through the connector contact cavity (not specifically shown in the picture) into the space within the cylindrical connector 1.

(36) The interposer body has a first face from which the ducts extend and a second face which is configured to be brought into contact with the electrically conductive surface. The second face has a cavity which is configured to receive a first elastomer seal 11. In the present example, the cavity for receiving the first elastomer seal is circular and has a depth which is equal to or (slightly) larger than the thickness of the first elastomer seal.

(37) The PCB retaining cover has a cavity which is configured to receive a second elastomer seal.

(38) The cavity in the PCB retaining cover for receiving the first elastomer seal is circular. In the present example, the cavity has a stepped edge such that the depth of the cavity at the circumference of the cavity, a first depth, is less than the depth of the cavity at the centre of the cavity, a second depth. In this way a second cavity is formed within a first cavity wherein the second cavity is formed in the PCB retaining cover from a surface which is the first depth from the surface of the PCB retaining cover.

(39) The thickness of the second elastomer seal is the same as or (slightly) less than a depth of the second cavity in the PCB retaining cover such that the second elastomer seal is fully received by the PCB retaining cover. In the present example, the second cavity additionally comprises a central protrusion extending from the base of the cavity and configured to be received by a centrally located hole in the second elastomer seal. In the present example, the height of the protrusion is the same as the depth of the second cavity. The protrusion is configured to hold the second elastomer seal in the desired location.

(40) The elastomer seals provide environmental and cavity to cavity sealing in order to prevent electrical short circuits between the individual contacts. The elastomer seals also provide electrical isolation between individual contacts and the PCB and prevent moisture ingress to the PCB.

(41) In the present example, the first cavity with the first depth is configured to receive the PCB 10. The PCB is thereby used as a hard stop to ensure controlled compression of the elastomer seals in order to obtain the desired seal integrity.

(42) FIG. 3 shows an enlarged view of the head of the electrical contact when a spring loaded contact is used and is installed in the interposer. The head of the spring loaded contact comprises a shoulder 19. The head has a spring cavity 16 and a spring loaded pogo 15. In use, the spring loaded pogo is configured to absorb vibrations by being compressed and is received by the spring cavity when in compression. Furthermore, the use of spring loaded contacts provides a flexible termination to the PCB. When in its resting position, the spring loaded pogo is extended outside of the spring cavity.

(43) Each duct has a through hole with a first diameter D1. Each through hole extends at least partially into the main body of the interposer. Each through hole is in communication with a second through hole with a second diameter D2, wherein the second diameter is larger than the first diameter. Each second through hole extends from the end of the first through hole to the second face of the interposer body.

(44) Each second through hole is configured to receive a head of the electrical contacts. Retention bushing 17 surrounds the inner surface of the increased diameter through hole. This retains the contact and the elastomer seal during assembly and disassembly.

(45) Interposer body ridges 18 extend from the body of the interposer into the first elastomer seal. Ridges in the interposer body ensure controlled seal compression and thereby seal performance whilst keeping the overall compression force low. In the present example, the ridges have a fluid ‘wave-like’ shape to prevent air pockets. Air pockets are undesirable because they may result in partial discharges when exposed to high electrical stress. Therefore, the ridges 18 are designed such that they cause the deformation of the seal without any voids being formed between the interposer and the seal.

(46) The spring loaded pogo head is configured to contact with the electrically conductive surface of the PCB. The PCB may be formed with indentations to locate the heads of the contacts and prevent sideways movement of the contacts. This ensures alignment of the contacts with the PCB.

(47) In some examples, the interposer may be rectangular in order to provide a connection with a standard rectangular electrical connector.

(48) FIG. 4 shows an interposer combined with a connector interface according to a second embodiment. In the present example, the interposer according to the second embodiment is for use in the wing of an aircraft. The interposer may be used in any application where conductors embedded in a structure need to be terminated.

(49) The connector 30 of the second aspect is configured to be laminated into a composite wing leading edge to become an integral part.

(50) The connector 30 comprises a plurality of ducts 37 which are each configured to receive an electrical contact 31. In the present example 8 ducts are used. However, in other examples, more or less than 8 ducts maybe used. In each duct, an electrical contact 31 is installed. In the present example, the electrical contacts are spring loaded contacts. The spring loaded contacts comprise a pin connected to a pogo head.

(51) FIG. 4 shows some of the ducts with a spring loaded contact within the duct and one of the spring loaded contacts in an exploded view. A locking spring clip 34 locks the contact in its cavity so that it cannot fall out or be pushed out by the pogo whilst ensuring compression of the pogo.

(52) The interposer comprises an upper surface 35 and a lower surface 36. The lower surface of the interposer 30 comprises a flange 32. The flange 32 is laminated into the leading edge of an aircraft wing in order to integrate the connector with the leading edge structure. When in use and laminated into the aircraft wing, the flange will be captured in between layers of the composite lay-up. In the present example, the flanged lower surface of the interposer is curved such that, in use, the shape of the lower surface follows an internal contour of a wing of an aircraft. In use, the contacts are inserted from the front of the connector, i.e. the non curved side, so that the contacts can be installed after the leading edge is cured. The curved lower surface of the interposer is shown in FIG. 6.

(53) Connector holes 33 extend from the upper surface of the interposer. The connector holes 33 include threaded inserts that accept bolts of a mating connector. These bolts will hold a mating connector plug (not shown in the drawings) in place.

(54) The module is shown in see-through form in FIG. 5 to illustrate the spring loaded contacts when they are installed in the interposer.

(55) In some examples, the spring loaded contacts are inserted after the interposer has been installed. When installed, the spring loaded contacts are configured to land on busbars of the PCB.

(56) The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the spirit and scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.