Electrical connectors – With insulation other than conductor sheath – Plural-contact coupling part
Reexamination Certificate
1999-05-28
2001-02-27
Nguyen, Khiem (Department: 2839)
Electrical connectors
With insulation other than conductor sheath
Plural-contact coupling part
C439S372000
Reexamination Certificate
active
06193563
ABSTRACT:
FIELD OF THE INVENTION
This invention generally relates to the art of electrical connectors and, particularly, to an electrical connector assembly for connecting a large number of electrical wires in a modular system.
BACKGROUND OF THE INVENTION
There are various applications in which a large number of electrical wires must be terminated in a single electrical connector which, in turn, is mated with a complementary connector that also is terminated to the same large number of electrical wires. One such example of this type of application is in machine tools and robotic applications, such as in the automotive industry. In a typical example, six electrical wires may be required for each axis of a hexaxial robot, resulting in a total of thirty-six wires having to be terminated to thirty-six terminals mounted on an insulative housing. These wires must be connected individually, and care must be taken that they are connected in their designated groups of six wires.
It can be understood from the above that problems often can be encountered in terminating such electrical connectors having such large numbers of wires and terminals. The connecting process may be difficult and inefficient. This is particularly true if the lengths of the respective wires, such as in a wiring harness, are different due to the difference in positions of the axes of a robot, for instance. Other problems are encountered in the inefficiency of using such wiring systems when maintenance or replacement must be performed. Other problems encountered with such connectors include the difficulty in polarizing such large connectors, in grounding such connectors and in ensuring that the connectors are fully mated. Often, lever-type assisting mechanisms are used to ensure that the connectors in a connector assembly are fully mated.
The present invention is directed to solving one or more of the problems discussed above.
SUMMARY OF THE INVENTION
An object, therefore, of the invention is to provide a new and improved electrical connector assembly which incorporates a modular termination system.
In the exemplary embodiment of the invention, a first connector, such as a receptacle connector, includes a housing defining a mating portion, such as a mating receptacle. A dielectric wafer is mounted in the housing. A plurality of terminal pins are mounted through the wafer. The terminal pins include mating ends projecting from one side of the wafer into the mating receptacle and connector ends projecting from an opposite side of the wafer. A plurality of discrete first connector modules are mounted on the housing for termination to selected ones of the connector ends of the terminal pins.
The connector assembly also includes a plug connector having a shell defining a mating plug for insertion into the receptacle of the receptacle connector. A plurality of discrete second connector modules are mounted on the shell for termination to selected ones of the mating ends of the terminal pins when the plug connector is mated with the receptacle connector.
As disclosed herein, both the first and second connector modules are substantially identical. The housing of the receptacle connector includes a plurality of discrete recesses within which the first connector modules are mounted. The shell of the plug connector also includes a plurality of discrete recesses within which the second connector modules are mounted.
The terminal pins are mounted through the wafer at locations defining a plurality of clusters of pins. One pin cluster corresponds to each of a plurality of pairs of the first and second connector modules. Each module includes a dielectric housing mounting a plurality of female terminals corresponding to one of the clusters of terminal pins. For instance, in relation to the robotic example set forth in the “Background”, above, there may be six clusters of six terminal pins, with each cluster of pins being provided for each axis in a hexaxial robot.
Other objects, features and advantages of the invention will be apparent from the following detailed description taken in connection with the accompanying drawings.
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Ikesugi Hiroshi
Ito Yoshikazu
Yagi Masanori
Molex Incorporated
Nguyen Khiem
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