阅读说明：本技术 压接针电连接器 (Electric connector with press-connecting pin ) 是由 布莱恩·马修·莫平 约翰·S·米尔斯 于 2021-06-25 设计创作，主要内容包括：一种压接针电连接器,包括：壳体,其限定具有第一开口和第二开口的内部；法兰,其包围壳体；插入件,其位于内部中并且延伸通过第一开口。插入件包括至少一个压接针,该至少一个压接针包括压接件和针,该至少一个压接针设置在壳体内部包括的至少一个通道内。(A crimp pin electrical connector comprising: a housing defining an interior having a first opening and a second opening; a flange surrounding the housing; an insert is located in the interior and extends through the first opening. The insert includes at least one crimp pin including a crimp and a pin, the at least one crimp pin disposed within at least one channel included within the housing interior.)

1. A crimp pin electrical connector, comprising:

a housing defining an interior having a first opening and a second opening to define an axial path through the housing between the first opening and the second opening;

a flange surrounding an exterior of the housing; and

an insert located in the interior and including a first end corresponding to the first opening, a second end corresponding to the second opening, and at least one channel extending between the first end and the second end, the insert comprising:

at least one crimp pin corresponding to the at least one channel, at least some of the at least one crimp pin including a pin and a crimp;

wherein the at least one crimp pin is located within the at least one channel such that a portion of the at least one crimp pin is located on a first side of the flange and the crimp is located on a second side of the flange opposite the first side.

2. The crimp pin electrical connector of claim 1, wherein the flange is located between the first opening and the second opening.

3. The crimp pin electrical connector of claim 1, wherein the insert further comprises an electrical insulator and a lead.

4. The crimp pin electrical connector of claim 1, wherein the at least one crimp pin is included within a group of crimp pins and the at least one channel is included within a group of channels, wherein a total number of crimp pins included within the group of crimp pins corresponds to a total number of channels included within the group of channels.

5. The crimp pin electrical connector of claim 1, wherein the at least one crimp pin has a barrel located on the second side of the flange.

6. The crimp pin electrical connector of claim 5, wherein the barrel includes an access hole located on the second side of the flange.

7. The crimp pin electrical connector of claim 6, wherein the barrel comprises a slot or slit.

8. The crimp pin electrical connector of claim 1, wherein the at least one channel extends through a washer and at least a portion of the crimp is received within a portion of the at least one channel extending through the washer.

9. The crimp pin electrical connector of claim 8, further comprising a sealing barrier defining first and second sides of the sealing barrier.

10. A wall of an electrical assembly, comprising:

a first surface, a second surface opposite the first surface, and an aperture in the wall;

a housing defining an interior having a first opening and a second opening to define an axial path through the wall between the first opening and the second opening, the housing having a flange surrounding an exterior of the housing, at least a portion of the housing extending through the aperture and the flange abutting the first surface; and

an insert located in the interior and including a first end corresponding to the first opening, a second end corresponding to the second opening, and at least one channel extending between the first end and the second end, the insert comprising:

at least one crimp pin corresponding to the at least one channel, the at least one crimp pin including a pin and a crimp;

wherein the at least one crimp pin is located within the at least one channel such that a portion of the pin is axially located on a first side of the flange and the crimp is axially located on a second side of the flange.

Technical Field

The present disclosure relates generally to electrical connectors for electrical components, and more particularly to crimp pin (pin) electrical connectors.

Background

Modern aircraft use electrical machines, such as electric motors or generators for energy conversion. In the aircraft industry, motors are commonly found having a combination of motor and generator modes, wherein the motor is used in the motor mode to start the aircraft engine and also as a generator to supply electrical power to aircraft systems depending on the mode. The electrical machines contain electrical components that, in some cases, may require a crimp pin electrical connector or a crimp socket connector to electrically or communicatively couple the separate electrical components. Sometimes, these connections can leak fluid at the connector, which can contaminate local electrical components or leak fluid out of the sealed container. For crimp pin electrical connectors and crimp socket connectors, the leakage flow path extends from the wire insulation end near the crimp barrel to an inspection hole in the crimp barrel. The wire insulation end and the access hole are located on the outside of the seal, which would otherwise control fluid leakage.

Disclosure of Invention

In one aspect, the present disclosure is directed to a crimp pin electrical connector comprising: a housing defining an interior having a first opening and a second opening to define an axial path through the housing between the first opening and the second opening; a flange surrounding an exterior of the housing; and an insert positioned in the interior and including a first end corresponding to the first opening, a second end corresponding to the second opening, and at least one channel extending between the first end and the second end, the insert including: at least one crimp pin, the at least one crimp pin corresponding to the at least one channel, at least some of the at least one crimp pin including a pin and a crimp, wherein the at least one crimp pin is located within the at least one channel such that a portion of the at least one crimp pin is located on a first side of the flange and the crimp is located on a second side of the flange opposite the first side.

In another aspect, the present disclosure is directed to a wall of an electrical assembly, comprising: a first surface, a second surface opposite the first surface, and an aperture in the wall; a housing defining an interior having a first opening and a second opening to define an axial path through the wall between the first opening and the second opening, the housing having a flange surrounding an exterior of the housing, at least a portion of the housing extending through the aperture and the flange abutting the first surface; and an insert located in the interior and including a first end corresponding to the first opening, a second end corresponding to the second opening, and at least one channel extending between the first end and the second end, the insert including at least one crimp pin corresponding to the at least one channel, the at least one crimp pin including a pin and a crimp, wherein the at least one crimp pin is located within the at least one channel such that a portion of the pin is axially located on a first side of the flange and the crimp is axially located on a second side of the flange.

Drawings

A full and enabling disclosure of the present specification, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

fig. 1 is a perspective view of an aircraft having an avionics chassis with electrical components and a backup generator in accordance with various aspects described herein.

FIG. 2 is an enlarged view of a housing cover of the backup generator of FIG. 1 including a set of crimp pin electrical connectors.

Fig. 3 is an enlarged, partially exploded perspective view of the avionics chassis of fig. 1, with the cover removed for clarity and including a crimp pin electrical connector.

Fig. 4 is a perspective view of a crimp pin electrical connector for use in an electrical assembly included within the aircraft of fig. 1, in accordance with various aspects described herein.

FIG. 5 is a cross-sectional view of the crimp pin electrical connector of FIG. 4, including an extended crimp pin.

Detailed Description

Aspects of the present disclosure relate to an improved crimp pin electrical connector that includes a set of crimp pins extending through at least a portion of a first side to a second side of a housing. Avionics (including electrical components and other engine components) are continually challenged to dissipate the heat generated in the ever increasing heat production of aircraft environments, which may require the use of localized liquids or fluids for heat dissipation. Fluid may accumulate near a first side or sump region of a housing of the crimp pin electrical connector.

While the description generally refers to an avionics chassis or a backup generator (BUG) within an aircraft, it should be understood that the crimp pin electrical connector may be adapted to a myriad of elements or implementations, such as any electronics chassis, electronic components, electric motors (such as those in or out of an aircraft engine), or any other electrical assembly that uses a crimp pin electrical connector, for example. Accordingly, a crimp pin electrical connector as described herein would also be suitable for other environments where sealed electrical connections are desired, such as non-aircraft, terrestrial, or other environments, as well as any other electrical environment.

While a "set" of various elements will be described, it should be understood that a "set" can include any number of the corresponding elements, including only one element. Moreover, all directional references (e.g., radial, axial, up, down, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to their position, orientation, or use. Unless otherwise specified, connection references (e.g., attached, coupled, connected, and engaged) are to be construed broadly and may include intermediate members between a collection of elements and relative movement between elements. Thus, joinder references do not necessarily infer that two elements are directly connected and in fixed relation to each other. The exemplary drawings are for illustrative purposes only and the dimensions, locations, order and relative sizes reflected in the accompanying drawings may vary.

FIG. 1 schematically illustrates an aircraft 10 including gas turbine engines 12, and in particular, two gas turbine engines 12 disposed on respective sides of the aircraft 10. Each gas turbine engine 12 may be a turbofan engine commonly used in modern commercial aviation, or may be a variety of other known gas turbine engines, such as a turboprop or turboshaft engine. Each gas turbine engine 12 may include a BUG 14. As shown, the aircraft 10 may include two BUGs 20, one for each gas turbine engine 12. Each BUG20 may generally be defined as a motor such that it may be configured to provide or receive power to various avionics components or systems of the aircraft 10. For example, the BUG20 may provide mechanical power to an Accessory Gearbox (AGB) (not shown) for driving at least a portion of the gas turbine engine 12. Although the BUG20 is shown and described, it should be understood that the BUG20 can be any electric machine, including but not limited to an electric motor or a starter/generator.

The aircraft 10 may also include an onboard avionics chassis 30 (shown in phantom) for housing avionics, electronics, electrical components, or avionics components for use in the operation of the aircraft 10. Avionics chassis 30 houses and protects various avionics components from contaminants, electromagnetic interference (EMI), Radio Frequency Interference (RFI), vibrations, and the like. Although shown in a commercial passenger aircraft, the avionics chassis 30 may be used for any type of aircraft and any vehicle requiring similar protection. The avionics chassis 30 may be located anywhere within the aircraft, not just the nose as shown. Further, aspects of the present disclosure are not limited to aircraft aspects, and may be included in other mobile and stationary configurations. Non-limiting example mobile configurations may include ground-based, water-based, or additional air-based vehicles. Furthermore, aspects of the present disclosure are not limited to aspects of avionics chassis, but rather make aircraft electrical connections or utilize any portion of a crimp pin electrical connector. Furthermore, the electrical connections may be those made in an oil wet cavity (e.g., within an electric motor or generator on an engine (e.g., BUG 20)), where it is desirable to seal the wet cavity and allow for electrical connections.

Figure 2 shows the housing cover 22 or wall of the BUG20 of figure 1. The housing cover 22 can be defined as a portion of the BUG20 that separates the first and second portions of the BUG 20. The first portion of bun 20 can be defined as an area that includes one or more components (such as, but not limited to, circuit boards, leads, or other electronic components) located within the wet portion of bun 20. As used herein, the term "wet" may refer to any component of an aircraft that is susceptible to being exposed to or to exposure to a fluid (such as, but not limited to, a coolant, a lubricant, water, a gas, an oil, or any combination thereof). The first portion of the bun 20 can be defined as a wet area 24. The second region of the bun 20 can be defined as a portion of the bun 20 not intended to be in direct contact with a fluid. Fluids to which a portion of BUG20 may be exposed include, but are not limited to, a coolant, a lubricant, water, oil, gas, or any combination thereof. The second region may be defined as an environmental region 26. Environmental area 26 may be further defined as a location or portion of bun 20 exposed to environmental conditions surrounding an exterior portion of bun 20. For example, the ambient region 26 may be ambient air.

A set of electrical pin contacts, and in particular a set of crimp pin electrical connectors 40, may extend through the housing cover 22 of the BUG 20. The set of crimp pin electrical connectors 40 may be configured to establish an electrical connection between a set of electrical components within the BUG20 (specifically the wet area 24 of the BUG 20) and a set of external electrical components (such as, but not limited to, control systems, health monitoring systems, sensors, generator operation, Full Authority Digital Engine Control (FADEC), etc.). A set of apertures extending through the housing cover 22 from a first surface corresponding to the wet area 24 to a second surface corresponding to the environmental area 26 may be provided at various locations on the housing cover 22 to receive corresponding crimp pin electrical connectors 40. As shown, three apertures may be provided to receive a total of three crimp pin electrical connectors 40. The set of apertures may be configured to surround at least a portion of the crimp pin electrical connector 40.

Fig. 3 illustrates the avionics chassis 30 of fig. 1 with the front cover 50 removed, in accordance with an aspect of the present disclosure. The avionics chassis 30 includes a chassis housing 52 defining an interior 54 and an exterior 56 of the avionics chassis 30. Avionics chassis 30 may include a chassis frame 58, with chassis frame 58 having a top cover 60, a bottom wall 62, a rear wall 64, and opposing side walls 66, 68, collectively referred to as a set of walls. The enclosure frame 58 may further include the aforementioned front cover 50, the front cover 50 being selectively removable, providing access to the interior 54 of the avionics enclosure 30 when removed, and partially restricting access to the interior 54 when coupled or mounted with the enclosure frame 58. The sidewalls 66, 68 may include an inner surface 70 and an outer surface 72. As shown, a set of heat dissipating elements (e.g., fins 73) may protrude from the outer surface 72 of the sidewalls 66, 68. Although heat fins 73 are shown, the sidewalls 66, 68 may utilize a plurality of heat dissipating elements or heat dissipating configurations to remove or dissipate heat generated by or within the avionics chassis 30, or at least a portion of the heat stored by the avionics chassis 30.

The avionics chassis may also include electrical pin contacts, in particular the crimp pin electrical connector 40 of fig. 2. As shown, the crimp pin electrical connector 40 may extend through the sidewall 66 from a first surface, which is an inner surface 70, to a second surface, which is an outer surface 72. A hole extending from the first surface to the second surface may be included within the sidewall 66 and configured to surround at least a portion of the crimp pin electrical connector 40. It is contemplated that the first surface and the second surface may be any opposing surfaces of a particular wall of the set of walls of avionics chassis 30. Although shown as a single crimp pin electrical connector 40, it should be understood that the crimp pin electrical connector 40 may be one of a set of crimp pin electrical connectors 40. The set of crimp pin electrical connectors 40 may be placed on any of the set of walls.

Each crimp pin electrical connector 40 may be operatively coupled to one or more electrical components of aircraft 10. The avionics chassis 30 may be configured to house a set of electronic components used in the operation of the aircraft 10. For example, interior 54 of avionics chassis 30 may house a set of processors, computers, tablets, Electronic Flight Bags (EFBs), and the like. Accordingly, avionics chassis 30 may be configured to house, support, or include a set of electronic components within interior 54.

Fig. 4 illustrates the crimp pin electrical connector 40 of fig. 2 and 3 for inclusion within an electrical assembly included in the aircraft 10 of fig. 1. As used herein, it should be understood that the electrical assembly may refer to any suitable electrical assembly of the aircraft 10 that is configured to utilize or otherwise receive the crimp pin electrical connector 40. Accordingly, it will be understood that the crimp pin electrical connector 40 may extend through any suitable wall of the electrical assembly, as described herein. Non-limiting examples of walls of electrical components through which the crimp pin electrical connector 40 may extend may include, but are not limited to, the housing cover 22 of the BUG20 and the side walls 66 of the avionics chassis 30.

The crimp pin electrical connector 40 may include a housing 42 having a first opening 44 and a second opening 46, the first opening 44 and the second opening 46 defining a longitudinal axis 76 extending between the first opening 44 and the second opening 46. Thus, the first opening 44 and the second opening 46 may define an axial path through the housing 42. Housing 42 may be any suitable crimp pin connector body or wire connector, such as any commercially available off-the-shelf or custom connector. A flange 48 or mounting flange may be included as part of the housing 42. The flange 48 may abut the first surface of the side wall 66 or any other wall of the set of walls facing the interior surface 70 of the avionics chassis 30, or any side of the housing cover 22 of the BUG20, such that the flange 48 may be fastened to the wall or housing cover 22 using a set of fastener apertures 78 provided in the flange 48. Although the flange 48 is specifically illustrated as a 4-bolt mounting flange, it should be understood that the flange 48 may be any type of mounting member for the crimp pin electrical connector 40. Specifically, the crimp pin electrical connector 40 may be configured to include a housing 42, the housing 42 being any environmentally resistant circular electrical connector having any kind of flange configured to be mounted to an external wall or surface by any suitable mounting means (e.g., without limitation, a lock nut, a weld bracket, etc.).

Disposed at the first opening 44 are a nut 80 and a cap 82, including a set of entrances 84 for receiving a set of wires connected to at least a portion of the crimp pin electrical connector 40 (specifically, a set of crimp contacts as described herein). For example, the nut 80 may be made of steel, although other materials are also contemplated, such as non-conductive materials, such as plastic. The cap 82 may be made of a dielectric material because it is proximate to the set of wires that may extend through the set of inlets 84. For example, the cap 82 may be made of polyamide-imide or the like.

FIG. 5 illustrates a cross-sectional view of the crimp pin electrical connector 40 of FIG. 4 taken from view V-V of FIG. 4, showing the housing 100 of the housing 42. The housing 100 of the enclosure 42 may include an interior 102. The interior 102 may include: an interfacial seal 104; a dielectric insert 106; a gasket 108 comprising at least one set of sealing barriers 110. The interior 102 may be divided into a first side 112 and a second side 114. In the example shown in fig. 2 and 3, first side 112 may be in the direction of exterior surface 72 of avionics chassis 30 or environmental region 26 of BUG 20. Second side 114 may be in the direction of interior surface 70 of avionics chassis 30 or wet area 24 of bun 20. Accordingly, at least a portion of the second side 114 may be defined as an area of the crimp pin electrical connector 40 where gases, liquids, or other substances may accumulate. It is further contemplated that the second side 114 may be defined as the wet side or the sump side of the crimp pin electrical connector 40, while the first side 112 may be defined as the environmental side of the crimp pin electrical connector 40.

The flange 48 may completely surround the exterior of the housing 100 and at least partially form a portion of the sump. The flange 48 may be positioned and secured such that it forms a seal between the first side 112 and the second side 114 of the crimp pin electrical connector 40 such that liquid does not leak from one side to the other. For example, in the case of the BUG20, the flange 48 forms a seal on the housing cover 22 such that oil, lubricant, or other fluid cannot transfer from the wet area 24 to the ambient area 26 through the set of holes formed in the housing cover 22.

The interfacial seal 104 can be on the first side 112 of the crimp pin electrical connector and configured to contact at least a portion of the crimp pin electrical connector 40, in particular, the set of crimp contacts as described herein. The interface seal 104 may be compressed between the dielectric insert 106 and the dielectric insert 106 of the external connector (not shown). The external connector may be defined as a connector that may be electrically coupled to a portion of the crimp pin electrical connector 40 through the second opening 46. The interfacial seal 104 may be located between the dielectric insert 106 and the second opening 46 of the housing 100. It is contemplated that the interfacial seal 104 may be mated or bonded to the dielectric insert 106. The interfacial seal 104 may be formed from any suitable sealing material, such as, but not limited to, fluorosilicone, and the like.

A dielectric insert 106 may be disposed between the interface seal 104 and a gasket 108. As shown, the dielectric insert 106 may span between a first side 112 and a second side 114 of the crimp pin electrical connector. The dielectric insert 106 may define a region of the interior 102 of the crimp pin electrical connector 40. However, it is contemplated that the dielectric insert 106 may span between the interface seal 104 and the gasket 108 along any portion of the interior 102. The dielectric insert 106 may comprise any suitable rigid dielectric material, such as, but not limited to, a glass-filled dielectric material. It will be further appreciated that in some cases, the interfacial seal 104 may be omitted such that the dielectric insert is retained within the interior 102 against the housing 100 toward the second opening 46.

The rear case gasket 83 may be connected to the case 100. The gasket 108 may be positioned between the rear shell gasket 83 and the dielectric insert 106 on a second side 114 (also referred to as a wet side or sump side) of the flange 48. The interface between the rear housing gasket 83 and the gasket 108 may be defined by the lower wall 116. The backshell gasket 83 may also include or abut a collar 86 surrounding at least a portion of the backshell gasket 83. The nut 80 may be coupled to or otherwise placed over a portion of the collar 86. Nut 80 may then be threaded to a portion of housing 100 (specifically to a set of housing threads 119) such that cap 82 is compressively held against a portion of collar 86. In this way, collar 86 and cap 82 may compressively hold back shell washer 83 against washer 108 by the threads of nut 80.

It should be understood that the backshell gasket 83 may be included in the gasket 108 such that they are integrally formed. Alternatively, the gasket 108 and the rear shell gasket 83 may be formed as two separate pieces. Both the gasket 108 and the backshell gasket 83 may be made of a compressible sealing material (e.g., fluorocarbon or fluorosilicone), while any suitable dielectric compressible material is contemplated, such as rubber, silicone, carbon, or other material that is resistant to leakage and corrosion.

The set of sealing barriers 110 may be disposed within the gasket 108 to provide a seal inside the crimp pin electrical connector 40. Specifically, the set of sealing barriers 110 may provide a primary seal through a set of channels 122 and may be located on the sump side or second side 114 of the flange 48. The set of sealing barriers 110 may include any suitable sealing material, such as, but not limited to, fluorosilicone or other sealing material. The set of seal barriers 110 can further divide the crimp pin electrical connector into a first side 118 or receptacle side of the seal barriers 110 and a second side 120 of the seal barriers 110. However, it will be further understood that the set of sealing barriers 110 may be defined as part of the gasket 108. Thus, the set of sealing barriers 110 may be integral with the gasket 108 and made of the same material as the gasket 108. The set of sealing barriers 110 can be further defined as a portion within the gasket 108 that compressively seals a portion of the crimp pin electrical connector 40 (specifically the set of crimp contacts as described herein) forming a barrier to prevent fluid transfer between the first side 118 and the second side 120 of the sealing barriers 110.

Each passage 122 of the set of passages 122 may extend from the first opening 44 to the second opening 46 of the housing 42. The set of channels 122 may extend in the direction of the longitudinal axis 76 (fig. 4) and be formed at least within the interfacial seal 104, the dielectric insert 106, and the gasket 108. The set of sealing barriers 110 may inscribe (inscribe) at least a portion of the set of channels 122. Although illustrated as a constant cross-sectional area, it should be understood that the set of passages 122 may have a cross-sectional area that varies along the longitudinal axis 76. For example, the set of channels 122 may have a smaller cross-sectional area or contact retention features, such as protrusions or ribs, in the dielectric insert 106.

A set of inserts or electrical inserts may be provided through the inlet 84 and into the passage 122. Each insert of the set of inserts may include a lead 134, an electrical insulator 124, and a crimp contact (specifically, a crimp pin 128) of the set of crimp contacts. Each insert may be defined by a first end 130 corresponding to the first opening 44 and a second end 132 corresponding to the second opening 46. As shown, there are two inserts such that two leads 134, two electrical insulators 124, and two crimp pins 128 are included within the crimp pin electrical connector and are configured to fit through at least a portion of the set of channels 122. It should be understood that the number of inserts may correspond to the number of channels 122. Thus, the total number of crimp pins 128 may correspond to the total number of channels 122. At least a portion of each insert may extend into the housing 100 or interior 102 at the second end 132 and through the cap 82, collar 86, and nut 80 proximate the first opening 44. It is contemplated that there may be any number of one or more inserts, and thus any number of one or more leads 134, electrical insulators 124, or crimp pins 128 passing through corresponding channels 122.

The set of electrical insulators 124 may be located entirely on the second side 114 of the flange 48. In particular, each of the set of electrical insulators may be provided on the first side 118 of the hermetic barrier 110. Each electrical insulator 124 of the set of electrical insulators 124 may include a lead 134 or an electrical lead having an insulating covering 136 extending around at least a portion of the outer circumference of the lead 134. The set of electrical insulators 124 may extend through at least a portion of a corresponding inlet 84 of the set of inlets 84, the cap 82, to a termination point within the back shell gasket 83. The set of leads 134 may terminate within a portion of the set of crimp pins 128 located within a portion of the gasket 108.

At least some of the set of crimp pins 128 may include a pin 138 and a crimp 140. The crimp pin 128 may be configured such that the pin 138 is the only portion of the crimp pin 128 that extends into the first side 112 of the flange 48. Thus, the needle 138 may extend within the set of channels 122 through at least a portion of the gasket 108, the dielectric insert 106, the interface seal 104, and ultimately a portion of the housing 100. The needle 138 may extend from the first side 112 of the flange 48 to at least a portion of the second side 114 of the flange 48, or to at least a portion of the first side 118 of the sealing barrier 110. Needle 138 may also include a retaining shoulder 148 defined as a portion of needle 138 that extends from an outer surface of needle 138 into channel 122. The retention shoulder 148 may be configured to fit within the channel 122 or a portion of the dielectric insert 106 to provide a locking or retention method for the crimp pin 128. Additionally, the channel 122 within the dielectric insert 106 may have a variable cross-sectional area that includes metal contact retention tines or other various contact retention features for retaining at least a portion of the crimp pin 128 (specifically the pin 138).

The crimp 140 is located entirely within the second side 114 of the flange 48. Specifically, the crimp 140 is located entirely within the first side 118 of the sealing barrier 110. Thus, the crimp 140 may extend along at least a portion of the crimp pin 128 on the first side 118 of the seal barrier 110. The crimp 140 may be configured to deform at least a portion of the barrel 142 that is located entirely on the second side 114 of the flange 48 or entirely on the first side 118 of the seal barrier 110. Specifically, the barrel 142 or crimp 140 may be at least partially located within the washer 108 and the backshell washer 83. In particular, it is contemplated that at least a portion of the crimp 140 can be received within a portion of the corresponding channel 122 extending through the washer 108. The barrel 142 may be configured such that it may surround at least a portion of the lead 134.

The barrel 142 may also include an access hole 144 that may extend through one or both walls of the crimp pin 128 at the barrel 142. The inspection holes 144 may be formed as circular holes or any other holes such as, but not limited to, slots or slits. The access hole 144 may be located entirely on the second side 114 of the flange 48, specifically on the first side 118 of the seal barrier 110. It will be further understood that each cartridge 142 may include a set of access holes 144. Accordingly, any number of one or more access holes 144 may be included on the barrel 142.

The crimp 140 may be further defined as a portion of the crimp pin 128 that may compressively retain at least a portion of the lead 134. The crimp 140 may reduce the local cross-sectional area of the barrel 142 such that the barrel 142 presses up against the lead 134 and compressively retains the lead 134. Thus, the crimp may operably couple the crimp pin 128 to the electrical insulator 124. It is contemplated that crimp 140 may also be positioned around another portion of electrical insulator 124, such as insulation cap 136. Additionally or alternatively, it is contemplated that the crimp 140 is one of a set of crimps 140 located at various suitable locations along the crimp pin 128. For example, there may be a first crimp 140 positioned around the lead 134 and a second crimp 140 positioned around a portion of the insulating cover 136 as shown.

The crimp pin electrical connector or crimp contact described herein provides an improved environmental seal compared to conventional crimp pin electrical contacts. For example, in connection with a BUG during operation, internal pressure and fluids may be exerted on the crimp pin electrical connector. In conventional crimp pin electrical connectors, liquids, gases, or other substances may leak along a portion of the stranded wire of the lead exposed to the fluid and within the insulating covering surrounding the lead. There may be a space between the end of the contact and the insulating cover of the lead so that fluid may leak into the contact or into portions of the crimp pin electrical connector. In addition, the barrel open end and the access hole in conventional crimp pin electrical connectors may provide a fluid leakage path. Since the terminal end of the insulating cover, crimp, inspection hole, and any other leakage path described herein in conventional crimp pin electrical connectors are located on the second side of the sealing barrier, any leakage fluid will flow out around the pins of the crimp pin and into the area of the crimp pin electrical connector on the first side of the flange or environment. The crimp pin electrical connector is extended as described herein such that leakage caused by a pressure vent (vent) across the connector is eliminated by establishing a crimp, an inspection hole and a termination of the insulating cover of the crimp pin electrical connector on the second side of the flange, in particular the first side of the sealing barrier. Pressure and fluids (such as those generated from a BUG operation) may be maintained entirely within the first side of the sealing barrier on the second side of the flange. Thus, internal pressure and fluid remain sealed within the pressure vessel by eliminating the standard contacts in the crimp pin electrical connector or the unresolved leakage path of the crimp pin electrical contacts. Furthermore, although there is no pressure vent across the connector, any fluid that wicks along the stranded leads feeding into the connector will be confined to the interior of the sump where the fluid has been expected.

Further benefits of the crimp pin electrical connector as described herein include increased stability of the crimp pin. The increased stability compared to conventional crimp pins is due in part to the extended design of the crimp pin. For example, a conventional crimp pin design may extend only partially onto the second side of the flange and terminate completely within the second side of the sealing barrier. When compared to the crimp pin of the present disclosure, the lead crimped to the crimp pin is relatively unsupported by the sealing barrier. If the insert or crimp pin electrical connector is subjected to an external load, which can create side loading, fluid can bypass the seal between the lead and the seal barrier. Furthermore, if no leads are connected to the crimp pins of a conventional crimp pin electrical connector, the sealing barrier will not engage and fluid will leak around the conventional crimp pins to the external environment. The crimp pin as described herein extends completely through the second side of the flange, the channel on the first side of the sealing barrier, through the gasket and into the backshell gasket. Thus, the gasket and additional backshell gasket can act as a restraint to better stabilize the crimp pin as compared to conventional crimp pin designs. The increased stability of the extended crimp pin as described herein ensures that the extended crimp pin remains engaged with the sealing barrier through lateral loading of the lead, insert or crimp pin electrical connector.

It is further contemplated that the crimp pin electrical connectors described herein may allow for improved installation and removal of the crimp pin as compared to conventional electrical connectors, particularly sealed electrical connectors. For example, sealing an electrical connector may require soldering between the crimp pin and the lead. This adds another layer of difficulty to manufacturing when connecting the sealed connector to the assembly, as welding may require skilled and certified operators. However, a crimp pin electrical connector as described herein is configured such that it can be repeatedly installed and removed from the crimp pin electrical connector without soldering. Thus, the extended crimp pin may be installed and removed from the crimp pin electrical connector using the same tools and in the same manner as conventional crimp pins.

In addition to the configurations shown in the above figures, the present disclosure contemplates many other possible configurations. To the extent not already described, the various features and structures of the various aspects may be used in combination with other features and structures as desired. A feature that is not described in all aspects is not meant to be construed as being absent but for simplicity of description. Thus, various features of the different aspects may be mixed and matched as desired to form new aspects, whether or not the new aspects are explicitly described. Combinations or permutations of features described herein are covered by this disclosure.

This written description uses examples to disclose aspects of the invention, including the best mode, and also to enable any person skilled in the art to practice aspects of the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Further aspects of the invention are provided by the subject matter of the following clauses:

a crimp pin electrical connector comprising: a housing defining an interior having a first opening and a second opening to define an axial path through the housing between the first opening and the second opening; a flange surrounding an exterior of the housing; and an insert located within the interior and including a first end corresponding to the first opening, a second end corresponding to the second opening, and at least one channel extending between the first end and the second end, the insert comprising: at least one crimp pin corresponding to the at least one channel, at least some of the at least one crimp pin including a pin and a crimp, wherein the at least one crimp pin is located within the at least one channel such that a portion of the at least one crimp pin is located on a first side of the flange and the crimp is located on a second side of the flange opposite the first side.

The crimp pin electrical connector of any preceding claim, wherein the flange is located between the first opening and the second opening.

The crimp pin electrical connector of any preceding item, wherein the insert further comprises an electrical insulator and a lead.

The crimp pin electrical connector of any preceding claim, wherein the at least one crimp pin is included within a set of crimp pins and the at least one channel is included within a set of channels, wherein a total number of crimp pins included within the set of crimp pins corresponds to a total number of channels included within the set of channels.

The crimp pin electrical connector of any preceding claim, wherein the at least one crimp pin has a barrel located on the second side of the flange.

The crimp pin electrical connector of any preceding claim, wherein the barrel includes an inspection aperture located at the second side of the flange.

The crimp pin electrical connector of any preceding item, wherein the barrel comprises a slot or slit.

The crimp pin electrical connector of any preceding claim, wherein the at least one channel extends through a washer, and at least a portion of the crimp is received within a portion of the at least one channel extending through the washer.

The crimp pin electrical connector of any preceding item, further comprising a sealing barrier defining first and second sides of the sealing barrier.

The crimp pin electrical connector of any preceding claim, wherein the crimp member is located entirely on the first side of the sealing barrier.

A wall of an electrical assembly comprising: a first surface, a second surface opposite the first surface, and an aperture in the wall; a housing defining an interior having a first opening and a second opening to define an axial path through the wall between the first opening and the second opening, the housing having a flange surrounding an exterior of the housing, at least a portion of the housing extending through the aperture and the flange abutting the first surface; and an insert located in the interior and including a first end corresponding to the first opening, a second end corresponding to the second opening, and at least one channel extending between the first end and the second end, the insert including at least one crimp pin corresponding to the at least one channel, the at least one crimp pin including a pin and a crimp, wherein the at least one crimp pin is located within the at least one channel such that a portion of the pin is axially located on a first side of the flange and the crimp is axially located on a second side of the flange.

The wall of any preceding claim, wherein the wall is a housing cover of a backup generator.

The wall of any preceding claim, wherein the flange is located between the first opening and the second opening.

The wall of any preceding claim, wherein the insert further comprises an electrical insulator and a lead.

The wall of any preceding claim, wherein the at least one crimp pin is included within a group of crimp pins and the at least one channel is included within a group of channels, wherein a total number of crimp pins included within the group of crimp pins corresponds to a total number of channels included within the group of channels.

The wall of any preceding claim, wherein the at least one crimp pin has a barrel located at the second side.

The wall of any preceding claim, wherein the cartridge comprises an inspection aperture at the second side.

The wall of any preceding claim, wherein the canister comprises a slot or slit.

The wall of any preceding claim, further comprising a gasket comprising a sealing barrier defining a first side and a second side.

The wall of any preceding claim, wherein the crimp is located entirely on the first side of the sealing barrier.