PRESSURE TOLERANT DEEP-SEA ELECTRICAL CONNECTOR

Abstract

A connector for sealably engaging contacts therein and permitting reliable disengagement thereof includes a first unit having one or more elongated shafts. Each elongated shaft includes at least one first contact. The connector further includes a second unit having a body with one or more channels therein. Each channel includes at least one second contact. Each channel is configured to receive at least a portion of one of the elongated shafts therein to permit electrical connection of the one or more first contacts to the respective one or more second contacts. The second unit further includes an axial slit extending radially outwardly from each channel toward an outer surface of the body of the second unit. Each slit of the second unit is a circumferentially discontinuous portion of the channel configured to prevent the second unit from forming a constrictive belt around the one or more elongated shafts therein.

Claims

1. A connector for sealably engaging contacts therein and permitting reliable disengagement thereof, the connector comprising: a first unit having a body with one or more elongated shafts extending therefrom, each elongated shaft including at least one first contact; and a second unit having an elastomeric body with one or more channels therein, each channel including at least one second contact, each channel being configured to receive at least a portion of an elongated shaft of the first unit therein to permit electrical connection of one or more first contacts on the elongated shaft to the respective one or more second contacts, the second unit being configured to prevent each channel of the second unit from forming a constrictive belt around the one or more elongated shafts therein.

2. The connector of claim 1, wherein the second unit comprises a circumferentially discontinuous portion in each channel.

3. The connector of claim 2, wherein the circumferentially discontinuous portion of each channel is an axial slit extending radially outwardly from each channel.

4. The connector of claim 3, wherein each axial slit of the second unit extends an entire length of the respective channel from one end of the second unit to an opposing end of the second unit.

5. The connector of claim 1, further comprising means for maintaining rotational alignment of the first and second units when the first and second units are engaged.

6. The connector of claim 5, wherein the means for maintaining rotational alignment comprises one or more alignment bores of the first unit spaced-apart from the one or more elongated shafts of the first unit, the means for maintaining rotational alignment further comprises one or more alignment pins of the second unit spaced-apart from the one or more receptacle channels of the second unit, each alignment pin being configured to enter one of the one or more alignment bores of the first unit when the first and second units are engaged.

7. The connector of claim 3, wherein each axial slit of the second unit extends completely through the second unit from one end thereof to an opposing end thereof.

8. The connector of claim 3, wherein each axial slit of the second unit does not extend radially to an outer surface of the second unit such that a portion of the second unit remains uncut.

9. The connector of claim 1, wherein each second contact of the second unit mates to the respective one of the first contacts of the first unit such that the first and second contacts remain sealed from the outside environment.

10. A connector receptacle unit for sealably engaging contacts therein and permitting reliable disengagement thereof, the receptacle unit comprising: a receptacle body including a channel therein, the channel including a contact configured to receive an elongated shaft of a plug unit of a connector, the contact of the channel being configured to electrically connect to a contact of the plug unit when the elongated shaft enters the channel; and a circumferential discontinuity extending outwardly from an outer surface of the channel.

11. The connector receptacle unit of claim 10, wherein the circumferential discontinuity is an axial slit configured to prevent the receptacle body from forming a constrictive belt around the elongated shaft.

12. The connector receptacle unit of claim 10, wherein the receptacle body is formed of an elastomer.

13. The connector receptacle unit of claim 10, wherein the receptacle unit is maintained in rotational alignment with the plug unit when mated to the plug unit.

14. A method for permitting sealable engagement and disengagement of plug and receptacle contacts, the method comprising forming a circumferentially discontinuous portion that extends radially outwardly from an outer surface of a channel within a receptacle unit, the channel housing one or more electrical contacts.

15. The method of claim 14, wherein a plug unit includes an elongated shaft, the plug unit being configured to engage the receptacle unit, the at least one elongated shaft including one or more electrical contacts.

16. The method of claim 15, wherein the channel of the receptacle unit is configured to receive at least a portion of the elongated shaft of the plug unit.

17. The method of claim 16, wherein the circumferentially discontinuous portion of the receptacle unit extends along an entire length of the channel of the receptacle unit from one end of the receptacle unit to an opposing end of the receptacle unit.

18. The method of claim 17, wherein the axial extending circumferentially discontinuous portion prevents the receptacle unit from forming a constrictive belt around an elongated shaft of a plug unit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] It will be easily understood that the described apparatus can be readily adapted to a wide variety of contact numbers and arrangements, sizes, materials, and/or configurations. Other features and advantages of the presently disclosed technology will become more readily apparent to those of ordinary skill in the art after reviewing the following detailed description and the accompanying drawings, in which like reference numbers refer to like parts.

[0023] FIG. 1 is an axial cross-sectional view of prior-art Nelson connector plug and receptacle units juxtaposed axially in position for mating;

[0024] FIG. 2 shows a heavy-walled elastomeric sleeve and a cylindrical shaft juxtaposed for insertion into the sleeve as known in the prior art;

[0025] FIG. 3 illustrates a heavy-walled elastomeric sleeve with a cylindrical shaft inserted into the sleeve as known in the prior art;

[0026] FIG. 4 is an end view of a heavy-walled elastomeric sleeve with a cylindrical shaft inserted into the sleeve as known in the prior art;

[0027] FIG. 5 is a perspective conceptual view of mated Nelson-like connector portions as known in the prior art with the rubber sleeve cutaway axially;

[0028] FIG. 6 shows a heavy-walled elastomeric sleeve with a cylindrical shaft inserted into the sleeve wherein the sleeve bore is partially slit radially, and the slit extending through axially;

[0029] FIG. 7 is a perspective view of connector plug unit in accordance with one embodiment of the presently disclosed technology;

[0030] FIG. 8 is a perspective view of a connector receptacle unit in accordance with one embodiment of the presently disclosed technology;

[0031] FIG. 9 is a partial axial cross-sectional view of the plug unit of FIG. 7;

[0032] FIG. 10 is a partial axial cross-section view of the connector receptacle unit of FIG. 8;

[0033] FIG. 11 is a partial axial cross-section view of the mated connector plug and receptacle units;

[0034] FIG. 12 is a radial cross-sectional view of the mated connector plug and receptacle units taken through the contact area;

[0035] FIG. 13 is a perspective view of connector plug unit having a recess in the plug tip in accordance with one embodiment of the presently disclosed technology;

[0036] FIG. 14 is a perspective view of two dual circuit connector units poised in juxtaposition for mating; and

[0037] FIG. 15 is a partial axial half-section perspective view of a dual circuit connector unit.

DETAILED DESCRIPTION

[0038] Certain terminology is used in the following description for convenience only and is not limiting. The words “forward” and “rearward” (and derivations thereof) designate directions in the drawings to which reference is made. The phrase “radially outwardly” as used herein is meant to cover any shape and/or configuration that extends in a direction outwardly in a radial sense and is not limited to shapes and/or configurations that extend radially along a straight line. Unless specifically set forth herein, the terms “a,” “an” and “the” are not limited to one element but instead should be read as meaning “at least one.” The terminology includes the words noted above, derivatives thereof and words of similar import. FIGS. 1 through 6 are for instructive purposes only and are included to allow the reader to more easily appreciate the fundamental characteristics of the disclosed technology.

[0039] To understand the shortcomings of Nelson's connector, and the technology herein disclosed to overcome them, imagine a heavy-walled sleeve and a shaft as shown axially aligned in proximity in FIG. 2. Thermal and other effects are ignored in this discussion.

[0040] In a first case, suppose that the FIG. 2 sleeve is essentially not compressible, as would be a metal pipe, but that the shaft is a compressible elastomer whose volume shrinks under pressure. The shaft is sized to just sealably slip fit into the sleeve at atmospheric pressure as in FIG. 3. Under high, uniform pressure, the elastomeric shaft would shrink and the metal sleeve would not; the shaft's diameter would become less than the inner diameter of the sleeve, and so would fit loosely within it, and therefore would not seal to it.

[0041] As a second case, now suppose the opposite circumstances wherein the FIG. 3 shaft is made of an incompressible metal, and the sleeve is a compressible elastomer. Once again, the shaft is sized to just sealably slip fit into the sleeve at atmospheric pressure.

[0042] Under high uniform pressure, the metal shaft would essentially not compress but the elastomeric sleeve would; the sleeve would shrink down tightly around the shaft exerting a radially directed inward force as indicated by the arrows in FIG. 4.

[0043] The preceding discussion makes it clear that for the interface between the sleeve and shaft in a Nelson style connector to remain sealed, a necessary condition is for the compressibility of the sleeve to be greater than or equal to that of the shaft. If the Nelson sleeve and shaft are molded from the same rubber, that condition is met due to the rigid spine within the plug shaft that reduces the shaft's overall compressibility.

[0044] FIG. 5 is an exaggerated conceptual illustration of a Nelson-like connector partially cut-away and otherwise shown as it might appear under very high pressure. It is composed of elastomeric sleeve and shaft portions and metal portions A, B, and C. The elastomeric sleeve and shaft portions are seen to be shrunk from the pressure. Under pressure, rubber can shrink volumetrically at a rate of about 4.0×10.sup.−6 per PSI (pounds per square inch). Pressure at the greatest working ocean depth is about 10.sup.4 PSI. At that pressure rubber would be shrunk by about 0.04 inches per inch.

[0045] Spine A, plug contact B, and split receptacle contact C in FIG. 5 are metal and are relatively incompressible, so that the elastomeric sleeve shrinks around them, as well as shrinking around the compressible shaft. A lump can be formed on the compressed shaft by plug contact B. For the plug and receptacle to disengage, the lump must be pulled through the shrunken sleeve, thereby increasing the disengagement force.

[0046] Additionally, mating surfaces of plug contact A and split receptacle contact B cannot conform exactly. Under high pressure, rubber will intrude into any uncompensated voids. Contrary to Nelson's statement that his connector is pressure compensated throughout, the non-conformities between the plug and receptacle electrical contacts are not pressure compensated and the surrounding rubber portions will intrude between the contacts such as at point D in FIG. 5. The intrusions further bind the plug and receptacle together under high pressure.

[0047] Suppose, as in the case of Nelson's connector, the shaft has significantly less compressibility than the sleeve. Under pressure the sleeve will shrink around the shaft; but now, further suppose that the sleeve's bore has been slitted along its length as indicated at the arrow in FIG. 6. Under uniform pressure, the sleeve will shrink around the less compressible shaft, and shrinkage will cause the slit to open somewhat; however, being circumferentially discontinuous around the shaft, the slitted sleeve cannot exert a belt-like grip on the shaft. The shaft can be withdrawn with little or no pressure-induced force. The sleeve remains elastic under pressure, and therefore its restoring force can resist changes in its shape. Even though the sleeve will shrink relative to the shaft, further opening of the slit beyond that caused by the shrinkage can meet some elastic resistance, and the heavy-walled sleeve can still conform to the shaft with approximately the same elastic force as it did in the unpressurized condition. The slit also allows the “lump” on the shaft caused by the uncompressed plug contact to be easily pulled through the sleeve, and although the slit cannot prohibit the intrusion of rubber into nonconformities between the plug and receptacle contacts, it will lessen their resistance to disengagement.

[0048] The foregoing discussion outlining why currently available rubber molded subsea connectors cannot be reliability disconnected at great depth can be useful in understanding the following description of the disclosed technology.

[0049] In embodiments of the presently disclosed technology the plug or a plug unit can house one or more elongated shafts including portions which can be overmolded onto an electrically conductive spine. The over-molded portions can be rubber or other dielectric material. One or more contact portions, or “plug contacts,” of the electrically conductive spine can be exposed from the over-mold along the length of the shaft to eventually mate with electrical contacts, or “receptacle contacts,” within the receptacle. The receptacle or a receptacle unit can house a respective one or more receptacle contacts over-molded within one or more rubber channels. The channels can have an axial cross-section in the form of a bore depicted herein as having a circumferential discontinuity, wherein the discontinuity is a split: however, circumferential discontinuities having other forms can accomplish the functionality of the split. It is sufficient that the discontinuity prevents a continuous belt-like portion of the bore from forming around a substantial length of the shaft. The receptacle contacts can be exposed from the rubber over-mold along the length of the channel. When the plug and receptacle units are joined, the one or more plug shafts can enter respective one or more receptacle channels, thereby sealably joining the one or more plug contacts to respective one or more receptacle contacts within the one or more receptacle channels.

[0050] The presently disclosed technology can include means for maintaining rotational alignment of the plug unit and the receptacle. For example, as described in detail below and shown herein, a cylindrical bore and corresponding cylindrical alignment pin can engage and/or complement one another to maintain rotational alignment of the plug unit and the receptacle when the plug unit and the receptacle are engaged. However, other means for maintaining rotational alignment can be employed, such as the use of shaped bodies (e.g., an obtuse triangular extension of the plug unit and a mating obtuse triangle socket shape of the receptacle), an extended flat side of the plug unity to mate to a flat side of the receptacle, or other ways to restrict mating to a single rotational alignment.

[0051] As one example, a simple one circuit embodiment of the technology is herein described. As a second example a dual circuit embodiment of the technology is also herein described. It will be obvious to those of ordinary skill that many multiple circuit embodiments can readily be constructed without departing from salient features of the disclosed technology.

[0052] FIG. 7 illustrates plug or plug unit 100 (sometimes referred to as the “first unit”). Plug unit 100 can include optionally molded body 103, cable strain relief 104, at least one through bore 105, with slit 106, shaft 107, plug contact 109, and cable 110.

[0053] FIG. 9 is a perspective view of plug unit 100 with an optionally rubber molded body 103 cutaway axially. Plug shaft 107, optionally formed of elastomer, is shown as having a circular radial cross-sectional shape, but can function equally well with other shapes. Electrical conductor 115 can extend forwardly from cable 110 and can be joined mechanically and electrically to plug spine 116 by routine means, such as but not limited to soldering or crimping. Plug contact 109 is shown as a portion of a cylindrical section (e.g., it does not extend around the entire shaft 107) with equal diameter to shaft 107, but it could have other shapes with portions that approximately conform to portions of the radial cross-sectional shape of shaft 107. Plug contact 109 can be formed as an integral portion of plug spine 116 and can be formed along plug spine 116 such that a portion of plug contact 109 is exposed from overmolded shaft 107 as seen in FIGS. 7 and 9. External surfaces of the various elements molded within rubber plug molded body 103 can be treated in routine ways, for example as by the application of bondable Chemlok substrates provided by Lord Corporation, such that they are both sealed and mechanically bonded within rubber plug body 103.

[0054] Receptacle unit 102 shown in FIGS. 8 and 10 can include optionally molded body 121, at least one channel 122 with slit entrance 123 leading into slit 124, cable strain relief 125, at least one alignment pin 127, and conductor 128 extending from cable 129. Each receptacle channel 122 can have the same radial cross-sectional shape as plug shaft 107 and can be sized so that plug shaft 107 has a slight interference fit into receptacle channel 122. Although bore 105 and alignment pin 127 are depicted herein as having a constant cross-sectional shape, other shapes can accomplish the functionality described herein.

[0055] Slit entrance 123 of molded receptacle body 121 can be a small radially directed channel that can provide a leak path for exterior environmental fluid to communicate with the forward end of slit 124 even when the plug and receptacle units are fully mated.

[0056] Slit 124 can optionally pass axially completely through molded receptacle body 121 (either axially or radially) so that slit 124 can be in communication with environmental fluid on both ends. In one optional embodiment, slit 124 that extends nearly the entire length of receptacle channel 122, but not the entire length of receptacle channel 122, could achieve the desired functionality described herein. Optionally, slit 124 can be interrupted in places along the length and still achieve the desired functionality described herein. In one embodiment, if slit 124 does not extend completely through receptacle unit 102 axially, slit 124 would extend completely through receptacle unit 102 radially and/or radially outwardly. Slit 124 and slit entrance channel 123 can be very narrow so as to limit fouling of slit 124 by marine organisms or debris. Slit 124 in receptacle molded body 121 can extend radially completely through molded body 121; however, it can be desirable in some cases to leave a portion 130 of body 121 uncut so as to add strength and shape stability to molded body 121. Uncut portion 130 can also help restrict marine growth and other sorts of contamination from entering slit 124.

[0057] Electrical conductor 128 can extend forwardly from cable 129 and can be joined mechanically and electrically to electrical contact 131 by routine means, such as but not limited to soldering or crimping. External surfaces of the various elements molded within rubber receptacle body 121 can be treated in routine ways, for example as by the application of bondable Chemlok substrates provided by Lord Corporation, such that they are both sealed and mechanically bonded within rubber receptacle body 121.

[0058] During the mating of plug unit 100 and receptacle unit 102, each plug shaft 107 first enters one channel 122 of receptacle unit 102, forcing any environmental fluid ahead of plug shaft 107 out the opposite end of channel 122. As engagement of units 100 and 102 proceeds, each receptacle alignment pin 127 enters one bore 105 of plug unit 100.

[0059] The full insertion of alignment pin 127 and plug shaft 107 respectively into plug bore 105 and receptacle channel 122 guarantees axial, rotational, and tilt alignment of the mated plug and receptacle units. Slit 106 in plug body 103 can prohibit channel 105 from forming a constrictive belt around pin 127.

[0060] FIG. 10 is an axial cross-section of the mated connector illustrating some of the major components of plug unit 100 and receptacle unit 102 in the mated condition.

[0061] FIG. 11 is a radial cross-sectional view through the mated connector at a point where plug contact 109 and receptacle contact 131 are engaged or contact each other. The portion of receptacle contact 131 that engages plug contact 109 can be shaped so as to conform to plug contact 109 with an interference fit, but not to completely surround it. That leaves elastomeric surface portion 135 (FIG. 12) of plug shaft 107 exposed. External surface portion 135 of plug shaft 107 of plug unit 100 can sealably engage elastomeric wall portions 136 of channel 122 (FIG. 10) of receptacle unit 102 on either side of slit 124, thereby prohibiting environmental fluid within slit 124 from contacting receptacle contact 131 or plug contact 109, and simultaneously electrically isolating the electrical contacts from the outside environment.

[0062] Plug shaft 107 can be molded onto spine 116 from either rigid or elastomeric dielectric material. In the case where the overmolded material of plug shaft 107 is an elastomer, plug shaft 107 can have a slightly flared wall portion 139, as shown in FIG. 13. Wiping action of flared wall portion 139 on the distal end of plug shaft 107 can add to the flushing action of environmental fluid from channel 122. Recess 140 in the end of plug shaft 107 allows flared wall portion 139 to have a diameter greater than the diameter of channel 122 while still allowing flared end 140 to squeeze radially inward as it passes into channel 122.

[0063] In an alternate embodiment 200A, shown in FIGS. 14, 15, alignment pin 127 of FIG. 11 has been replaced by a second plug shaft having the same attributes as plug shaft 107 of FIG. 9. Additionally, through bore 105 of FIG. 9 has been replaced in the alternate embodiment of FIGS. 14, 15 by channel 205 having along its length contact 231 which is the equivalent of channel 122 of FIG. 10 having along its length contact 131.

[0064] The above description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles described herein can be applied to other embodiments without departing from the spirit or scope of the presently disclosed technology. Thus, it is to be understood that the description and drawings presented herein represent presently preferred embodiments of the disclosed technology and are, therefore, representative of the subject matter, which is broadly contemplated by the presently disclosed technology. It is further understood that the scope of the presently disclosed technology fully encompasses other embodiments that may become obvious to those skilled in the art and that the scope of the presently disclosed technology is accordingly limited by nothing other than the appended claims.