Title: Modular electrical device
Abstract: A modular base for an electrical device and an electrical device including same and also removable modules are disclosed. The modular base comprises a plurality of base components adapted to be arranged relative to each other to define a backplane comprising a plurality of module mounting locations, wherein each mounting location comprises a first electrical base connector of one base component and a second electrical base connector of another base component. A plurality of removable modules are adapted to be respectively removably connected to the backplane in the mounting locations to provide a modular electrical device. Each of the modules comprises a first module connector adapted to be mated with a first base connector of a mounting location and a second module connector adapted to be mated with a second base connector of the mounting location The backplane comprises one or more coupling devices for releasably engaging a module.
Patent Number: 7,021,974 Issued on 04/04/2006 to Sichner, et al.
| Inventors:
|
Sichner; Gregg M. (Mentor, OH);
Lostoski; Douglas A. (Richfield, OH);
Hager; Robert J. (Windsor, OH);
Kozlowski; Robert A. (Twinsburg, OH);
Wünsche; Torsten (Leopoldshöhe, DE);
Püschner; Klaus (Detmold, DE);
Hanning; Walter (Detmold, DE);
Höing; Michael (Lemgo, DE)
|
| Assignee:
|
Rockwell Automation Technologies, Inc. (Mayfield Heights, OH)
|
| Appl. No.:
|
108456 |
| Filed:
|
April 18, 2005 |
Foreign Application Priority Data
| Feb 20, 2003[DE] | 203 02 844 U |
| Jul 11, 2003[DE] | 203 10 761 U |
| Current U.S. Class: |
439/717; 439/594; 439/928; 439/278; 439/281; 439/732 |
| Current Intern'l Class: |
H01R 9/22 (20060101) |
| Field of Search: |
439/715-717,594,928,278,281,732,652,701
|
References Cited [Referenced By]
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| 5070430 | Dec., 1991 | Meusel et al.
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| 5192222 | Mar., 1993 | Krause et al.
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| 5312265 | May., 1994 | Fiori et al.
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| 5897399 | Apr., 1999 | Emery.
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| 5984734 | Nov., 1999 | Piper et al.
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| 6039592 | Mar., 2000 | Shinchi.
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| 6051798 | Apr., 2000 | Mittal.
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| 6053754 | Apr., 2000 | Kano et al.
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| 6081048 | Jun., 2000 | Bergmann et al.
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| 6123585 | Sep., 2000 | Hussong et al.
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| 6254428 | Jul., 2001 | Murakami et al.
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| 6431920 | Aug., 2002 | Endres et al.
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| 6475036 | Nov., 2002 | Morikawa.
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| 6533611 | Mar., 2003 | Morello et al.
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| 6634910 | Oct., 2003 | Lieb et al.
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| 6881101 | Apr., 2005 | Sichner et al.
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| 6916194 | Jul., 2005 | Sichner et al.
| |
| Foreign Patent Documents |
| GM 80 17 060 | Jun., 1980 | DE.
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| 40 32 801 | Apr., 1992 | DE.
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| 36 024 46 | Oct., 1994 | DE.
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| 296 07 525 | Aug., 1996 | DE.
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| 196 38 368 | Apr., 1998 | DE.
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| 197 16 137 | Oct., 1998 | DE.
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| 297 03 367 | Oct., 1998 | DE.
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| 197 48 530 | Feb., 1999 | DE.
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| 198 07 710 | Sep., 1999 | DE.
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| 198 09 879 | Sep., 1999 | DE.
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| 100 11 354 | Jul., 2001 | DE.
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| 100 12 764 | Sep., 2001 | DE.
| |
| 0 914 029 | May., 1989 | EP.
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| 0 481 806 | Apr., 1992 | EP.
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| 0 661 915 | Jul., 1995 | EP.
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| 1 018 788 | Jul., 2000 | EP.
| |
| WO 98/4733/6 | Oct., 1998 | WO.
| |
Primary Examiner: Ta; Tho D.
Attorney, Agent or Firm: Haas; Steven M., Speroff; R. Scott
Parent Case Text
Cross- Reference to Related Application
This application is a continuation of U.S. application Ser. No. 10/716,080 filed
Nov. 17, 2003, U.S. Pat. No. 6,881,101 is hereby expressly incorporated by reference
into this disclosure.
Claims
What is claimed is:
1. An input/output module comprising:
a housing containing input/output electronic circuitry for adapted for industrial
automation input/output functions, wherein said housing comprises an inner housing
and an outer housing inter-fitted with the inner housing to define an interior
space in which said input/output electronic circuitry is contained;
a plurality of input/output electrical connectors operably connected to the input/output
circuitry and projecting outwardly from the housing;
first and second electrical module connectors adapted to mate respectively with
first and second base connectors of an associated backplane;
at least one coupling projection that projects outwardly from the housing and
conformed to mate with and be selectively retained by a coupling device of the
associated backplane,
wherein said plurality of electrical connectors project through and outward from
said outer housing and wherein said plurality of electrical connectors and said
input/output electronic circuitry are potted in said outer housing.
2. The input/output module as set forth in claim 1, wherein the inner housing
is nested within the outer housing, one of the inner and outer housings comprising
a plurality of tabs and the outer of said inner and outer housings comprising a
plurality of recesses, wherein said plurality of tabs are respectively received
in said plurality of recesses with a snap-fit.
3. The input/output module as set forth in claim 2, wherein the inner housing
comprises a continuous wall and said outer housing defines a continuous groove
in which said continuous wall is received.
4. The input/output module as set forth in claim 3, wherein at least one of a
gasket, adhesive and sealant is located in said continuous groove between said
outer housing and said continuous wall of said inner housing.
5. The input/output module as set forth in claim 1, wherein said inner and outer
housings are each defined as a one-piece molded polymeric construction.
6. The input/output module as set forth in claim 5, wherein said inner and outer
housings are each defined as a one-piece molded polymeric construction comprising
glass-filled polyester.
7. An input/output module comprising:
a housing containing input/output electronic circuitry for adapted for industrial
automation input/output functions;
a plurality of input/output electrical connectors operably connected to the input/output
circuitry and projecting outwardly from the housing;
first and second electrical module connectors defined respectively as first and
second female sockets adapted to mate respectively with first and second base connectors
of an associated backplane;
first and second resilient polymeric seals fixedly secured respectively in said
first and second female sockets;
at least one coupling projection that projects outwardly from the housing and
conformed to mate with and be selectively retained by a coupling device of the
associated backplane,
wherein said first and second female sockets are defined in said housing and
comprise respective inner walls, and wherein said first and second seals are mechanically
anchored to and interlocked with said housing with portions of said first and second
seals molded and cured into flow passages that are defined in an said respective
inner walls of said first and second sockets.
8. An input/output module comprising:
a housing containing input/output electronic circuitry for adapted for industrial
automation input/output functions;
a plurality of input/output electrical connectors operably connected to the input/output
circuitry and projecting outwardly from the housing;
first and second electrical module connectors adapted to mate respectively with
first and second base connectors of an associated backplane, wherein said first
and second electrical module connectors comprise respective first and second female
socket connectors;
first and second resilient polymeric seals located respectively in said first
and second female socket connectors;
first and second spaced-apart hook-shaped projections that project outwardly
from the housing and that are conformed to mate with and be selectively retained
by a coupling device of the associated backplane,
wherein said first and second seals are each defined as a one-piece construction
and wherein each of said first and second seals comprises:
a cylindrical peripheral wall;
an end wall connected to and arranged transverse to said cylindrical peripheral wall;
a radial sealing lip that projects radially inward from said cylindrical peripheral
wall; and,
an axial sealing lip that projects axially outward from said end wall.
9. The input/output module as set forth in claim 8, wherein said housing comprises:
an inner housing and an outer housing inter-fitted with each other to define
an interior space in which said input/output electronic circuitry is contained.
10. The input/output module as set forth in claim 8, wherein said first and second
seals are defined together as part of a single one-piece molded polymeric construction
comprising a polymeric web that extends between said first and second female socket
connectors and that interconnects said first and second seals.
11. The input/output module as set forth in claim
8, wherein said first
and second hook-shaped projections comprises respective ejection surfaces adapted
to receive ejection force from the coupling device of the associated backplane
when the coupling device is moved to a release position.
Description
BACKGROUND
The present development relates to a modular electrical device and, more particularly,
to a modular electrical device that is highly resistant to ingress of water, oil,
debris, dirt and other contaminants encountered in manufacturing and other environments
without use of a separate enclosure. As described herein, one application for a
device formed in accordance with the present development is as a modular distributed
input/output (I/O) assembly that forms a part of or is connected to an industrial
automation control system. Those of ordinary skill in the art will recognize that
the device has other applications, and it is not intended that the device be limited
to use for any particular application.
In connection with industrial automation control systems and other electrical
systems, it has been deemed desirable to provide electrical devices for transmission/input/output
of data signals and/or power voltages that are distributed throughout a manufacturing,
distribution or other facility and located directly on or adjacent machines performing
manufacturing, distribution, inspection and/or other processes. It has also been
found that, in certain cases, these electrical devices should be modular to allow
for customization, re-configuration and repair/replacement as needed during installation
or later. This modularity improves usability but can lead to ingress of water,
oil, dirt, debris, and/or other contaminants into the device, with highly undesirable
consequences. Furthermore, modular components can undesirably separate owing to
vibration, impact, cable stresses or other external forces.
Certain modular electrical devices are housed within an enclosure that provides
secure mounting and also protects the device from environmental contamination.
Use of an enclosure is often not practicable due to space constraints, ease of
installation/re-configuration/repair and/or other concerns.
Contamination-resistant modular electrical devices are known.
One example is a distributed input/output (I/O) assembly available commercially
from Rockwell Automation under the trademark 1798 FLEX Armor™. I/O circuitry
is packaged in I/O modules, and the I/O modules of an assembly plug into a common
baseplate. The baseplates is available in sizes of 2, 4, 6, and 8 I/O module slots.
An I/O adapter module and a field termination module plug into two slots of the
baseplate. The baseplate holds the modules in place and provides the backplane
for the assembly. No enclosure is required because each module is packaged in a
sealed housing rated for IP65/67 and NEMA 4 X (indoor/outdoor) and 6 P. While the
FLEX Armor™ I/O system has enjoyed widespread commercial success, certain
modifications have been deemed desirable, at least for particular applications.
For example, with the FLEX Armor™ system, the baseplates are available in
units of 2, 4, 6 and 8 I/O modules. Also, to maintain the environmental ratings,
all slots on the baseplate must be filled with either a live I/O module or a filler module.
Other modular electrical devices that are resistant to environmental contamination
are known and available commercially from other sources. Some of these devices
rely on conventional O-ring seals or other types of seals that provide only a single
sealing dynamic at each sealing location, i.e., only radial/lateral sealing or
only axial/compressive sealing. In certain cases, these seals are susceptible to
leakage, especially when the modular components are subjected to vibration or other
external forces such as lateral and/or axial separation forces. Other known devices
utilize conventional O-rings seals or other seals that are positioned in a manner
where they can be damaged or dislodged during handling, installation or during
repair/replacement operations. Another drawback associated with some of these conventional
modular electrical devices is that the seal is connected to or forms a part of
the permanent components of the system, instead of the replaceable components.
As such, use of a replacement component does not automatically result in use of
a new seal. Known modular electrical devices have also been found to be sub-optimal
insofar as operative mating of the components is concerned. Some require use of
separate fasteners such as screws or the like which can be inconvenient and can
lead to component damage if the fasteners are over-torqued. Other systems rely
on a simple friction fit between components, and this can lead to unintended separation
of the components such as when the components are mounted in an inverted position
and/or in response to cable strain. Known systems have also not provided base components
that are conveniently and securely mechanically with each other to ensure proper
definition of the module mounting locations and to minimize undesired movement
between base components. Examples of known modular electrical devices can be found
in the following documents: U.S. Pat. No. 6,475,036; U.S. patent application Publication
No. 2002/0182942; U.S. Pat. No. 4,707,043; German Utility Model No. DE29703367U1;
and, German Utility Model No. DE29607525U1.
In light of the foregoing, it has been deemed desirable to provide a new and
improved
modular base for an electrical device, and/or an electrical device including the
modular base and removable modules with improved operative mating of components
so as to facilitate use and improve ingress protection.
SUMMARY
In accordance with one aspect of the present development, a modular electrical
device comprises a modular base comprising a plurality of base components adapted
to be arranged relative to each other so as to define a backplane comprising at
least one module mounting location, wherein the at least one mounting location
comprises a first electrical base connector of one base component and a second
electrical base connector of another base component. At least one removable module
is adapted to be respectively removably connected to the backplane in the at least
one mounting location. The module comprises: (i) a first module connector adapted
to be mated with the first electrical base connector to form a mated pair of first
connectors; and, (ii) a second module connector adapted to be mated with the second
electrical base connector to form a mated pair of second connectors. The module
is adapted to electrically interconnect said first and second electrical base connectors
of the mounting location. A coupling device is connected to the backplane and is
located in the mounting location. The coupling device is adapted to releasably
secure the module to the backplane.
In accordance with another aspect of the present development, a modular base
for
an electrical device comprises at least two separate base components adapted for
selective mechanical mating via corresponding male and female portions so as to
define a backplane that comprises at least one module mounting location. Each of
the at least two base components comprises at least one electrical connector. The
at least one mounting location comprises first and second electrical connectors
that form a part of respective first and second ones of said at least two base components.
BRIEF DESCRIPTION OF THE DRAWINGS
The development comprises components and arrangements of components, preferred
embodiments of which are disclosed herein and shown in the drawings that form a
part hereof, wherein:
FIG. 1 is an isometric view of a modular electrical device formed in accordance
with the present development;
FIG. 2 is similar to FIG. 1, with all removable modules thereof not shown to
reveal the underlying base assembly;
FIGS. 3, 4 and 5 are isometric views of an adapter base component,
an intermediate base component, and an end base component, respectively;
FIGS. 6, 7 and 8 are top plan, bottom plan and isometric views,
respectively, of one example of a removable module component formed in accordance
with the present development;
FIG. 9 is a sectional view as taken along line 9—9 of FIG. 6;
FIG. 10 is a side view showing a removable module separated from a portion of
the base assembly to which it is adapted to be operatively mated;
FIG. 11 is an isometric view that shows the removable module and portion of
the base assembly of FIG. 10;
FIG. 12 is similar to FIG. 4, but shows the intermediate base component with
an upper surface thereof partially removed to reveal a coupling device formed in
accordance with the present development;
FIG. 13 is a bottom plan view of the intermediate base component shown in FIG. 12;
FIG. 14 is a side view of a removable module mated with the coupling device
of an intermediate or end base component, with portions in the foreground not shown
and portions of the base component broken away for clarity;
FIG. 15 is an isometric view of a sliding lock member component that forms a
part of the coupling device;
FIGS. 16A and 16B diagrammatically illustrate use of the coupling device to
eject a removable module in accordance with the present invention;
FIG. 17A is an isometric view of the inner housing portion of a removable module;
FIG. 17B is a sectional view as taken along line B—B of FIG. 17A;
FIG. 17C is similar to FIG. 17B but shows an isometric sectional view;
FIG. 18A is a top plan view of an alternative seal formed in accordance with
the present development as operatively mounted to a base component;
FIG. 18B is a sectional view as taken along line B—B of FIG. 18A; and,
FIGS. 19A and 19B show a modular electrical device formed in accordance with
an alternative embodiment of the present development.
DETAILED DESCRIPTION
FIG. 1 illustrates a modular electrical device
10 in accordance with
the present development. The device
10 comprises a modular base assembly
12 and one or more removable modules
14. The modules
14 are
releasably connected to the base assembly
12 and can be selectively removed
to reveal the underlying base assembly
12 as shown in FIG. 2. The device
10 can be electrically configured to perform any of a wide variety of functions,
and it is not intended that the development as described herein be limited to any
particular electrical function. For ease of explaining the development
10,
however, reference is made herein to use of the device
10 as a distributed
modular input/output (I/O) assembly as used, e.g., as part of an industrial automation
control system.
FIG. 2 shows that the base assembly
12 comprises a plurality of modular
base components
12c (i.e., more than one) arranged adjacent each
other, preferably mechanically interconnected with each other, so as to define
a field bus or backplane
20. The backplane
20 defines a plurality
of module mounting locations such as the four mounting locations M
1-M
4
shown in FIG. 2. As is described in full detail below, each mounting location is
adapted to receive and releasably retain one of the removable modules
14.
In a typical installation, the base assembly
12 is defined by a single
adapter base component
12c1, one or more intermediate base
components
12c2 and a single end base component
12c3.
The number of intermediate base components
12c2 is varied
to control the number of mounting locations M
1-M
4 defined by the
backplane
20.
An adapter base component
12c1 is shown separately in FIG.
3 and comprises a body
30 to which network (e.g., data/power) connectors
30a are affixed. The network connectors
30a are conventional
and provide input and/or output of electrical power and data to/from an external
network. The adapter base component
12c1 further comprises
a first base connector
30b1 including one or more contacts
30c which can comprise, e.g., male or female contacts. The base connector
30b1 is shown as a male plug connector with female contacts
30c, but could also be a female socket connector with male pin contacts.
The network connectors
30a and contacts
30c are electrically
connected to electronic circuitry
30d housed within the body
30
as shown by paths
30p. LED's or other visual output devices
30e
are connected to and/or form part of the circuitry and provide visual output
on the status of the circuitry
30d.
The network connectors
30a provide for input and output of power
and/or data between the circuitry
30d and other portions of the modular
electrical device
10 and an external network, as controlled by the electronic
circuitry
30d, while the first base connector
30b1
and contacts
30c thereof provide for input and output of data and/or
power between the adapter base component
12c1 and other portions
of the device
10, such as the intermediate base component(s)
12c2
and end base component
12c3 of the base assembly
12,
and the removable modules
14 connected thereto. In one example, the modular
electrical device
10 is provided as a distributed I/O assembly for an industrial
automation network, and the network connectors
30a and circuitry
30d are configured to connect and communicate with the external automation
network. The electronic circuitry
30d and, except for the accessible
mating portions, the network connectors
30a and contacts
30c,
are sealed within the body by potting compound or other means to protect against
environmental contamination.
The body
30 of the adapter base component
12c1 comprises
a first puzzle-piece connector structure P
1 defined by a first peripheral
edge
30e1. The first puzzle-piece connector structure P
1
comprises one or more male projections P
1a and female recesses P
1b.
The first base connector
30b1 is located on one of the male
projections P
1a.
FIG. 4 illustrates an intermediate base component
12c2.
The intermediate base component comprises a body
32 which includes both
first and second base connectors
30b1,
30b2
each including one or more contacts
30c which can comprise, e.g.,
male or female contacts. The base connectors
30b1,
30b2
can be male (plug) connectors (as shown) or female (socket) connectors. Each contact
30c of the first base connector
30b1 is electrically
coupled to a corresponding contact
30c of the second base connector
30b2 by conductor bars
32d or the like which
are sealed in the body
32 by potting compound or other means.
The body
32 of component
12c2 comprises a first peripheral
edge
32e1 that also defines the first puzzle-piece connector
structure P
1 described above. The body
32 further comprises a second
peripheral edge
32e2, located opposite the first peripheral
edge, that defines a second puzzle-piece connector structure P
2 that includes
one or more male projections P
2a and female recesses P
2b
that are conformed to mate closely with corresponding male/female structures
P
1a,P
1b of the first puzzle-piece structure P
1
in only a single possible position. As such, the second puzzle-piece structure
P
2 of an intermediate base component
12c2 is mated
with the first puzzle-piece structure P
1 of the adapter base component
12c1
or another intermediate base component
12c2 as shown in FIG. 2.
FIG. 5 illustrates an end base component
12c3. The end
base component comprises a body
34 which includes only a second base connector
30b2 having one or more contacts
30c which can
comprise, e.g., male or female contacts. The base connector
30b2
can be male (plug) connector (as shown) or female (socket) connector. In certain
cases, the contacts
30c of the end base module
12c3
can be non-functional (e.g., grounded through one or more resistors or otherwise)
because they are located at the terminal end of the backplane
20.
The body
34 comprises a first peripheral edge
34e1
that is non-functional and further comprises a second peripheral edge
32e2,
located opposite the first peripheral edge, that defines the second puzzle-piece
connector structure P
2 as described above, including the one or more male
projections P
2a and female recesses P
2b that are conformed
to mate precisely and in only one possible position with corresponding male/female
structures P
1a,P
1b of the first puzzle-piece structure
P
1. As such, the second puzzle-piece structure P
2 of the end base
component
12c3 is mated with the first puzzle-piece structure
P
1 of the adapter base component
12c1 or an intermediate
base component
12c2 as shown in FIG. 2.
Referring again to FIG. 2, it can be seen that when the backplane
20
is constructed by the adapter base component
12c1, at least
one intermediate base component
12c2 and an end base component
12c3, the mounting locations M
1-M
4 each comprises
a corresponding pair of base connectors
30b1,
30b2,
i.e., a first base connector
30b1 from a first base component
12c and a second base connector
30b2 from a
second, adjacent base component
12c. The backplane
20 can
alternatively comprise only the adapter base component
12c1
and the end base component
12c3 so as to comprise only a single
mounting location. Corresponding pairs of base connectors
30b1,
30b2
defining each mounting location M
1-M
4 are electrically connected
only through the removable modules
14, when the modules are mated to the
backplane
20. The various mating puzzle-piece structures P
1,P
2
mechanically interconnect the base components
12c1,
12c2,
12c3,
and ensure proper spacing and alignment of the corresponding pairs of base connectors
30b1,
30b2 to define the mounting locations
M
1-M
4 to allow for releasable mating of a module
14. Each
base component
12c1,
12c2,
12c3
includes at least one aperture or other fastener-receiving location
12f
adapted to receive a screw, rivet, clip, pin or other fastener or fastening
means for fixedly securing the base component
12c1,
12c2,
12c3
to a support surface.
With reference again to FIG. 2, the base connectors
30b1,
30b2
include outer surfaces
36b1,
36b2 and
transverse end walls
38b1,
38b2, respectively.
As shown, the base connectors
30b1,
30b2
are frusto-conical in shape, with the outer surfaces
36b1,
36b2
converging slightly (e.g., at a 1 degree angle) moving toward the transverse end
walls
38b1,
38b2, but the outer surfaces
36b1,
36b2 can also be purely cylindrical
or otherwise shaped. The frusto-conical shape is thought to facilitate sealing
and unsealing between the connectors
30b1,
30b1
and a module
14 mated therewith as described below. The end walls
38b1,
38b2
define apertures
39, and the contacts
30c are located within
these apertures (for female contacts as shown) or project through these apertures
(for male contacts).
FIGS. 6-9 illustrate one example of a removable module
14 formed in
accordance with the present development. Each module
14 comprises a housing
40 constructed from inner and outer housing members
40a,
40b
that are inter-fitted with each other to define an enclosed interior space
42 (FIG. 9) in which electronic circuitry
44 is located.
A plurality of connectors
46 are operably connected to the circuitry
44
and project through the outer housing member
40b so as to be adapted
for mating with corresponding cable connectors from external devices. The circuitry
and connectors
44,
46 are adapted for any desired electrical application.
In one example, each module
14 performs as an industrial automation I/O
module to which field devices and the like are connected via connectors
46,
and the circuitry
44 is configured for this purpose. FIG. 1 shows a plurality
of differently configured removable modules
14 including different types
and arrangements of circuitry
44 and connectors
46. Regardless of
the configuration, modules
14 typically comprises a visual indicators such
as LED's
48a that provide visual output signals concerning the state
of the circuitry
44 and marker holders
48b used for labeling
connectors
46 or for other purposes.
The housing
40 is sealed against ingress of environmental contaminants.
The circuitry
44 and connectors
46 are potted within the outer housing
member
40b or otherwise sealed in place. The inner housing member
40a is then sealed within the outer housing member, preferably by
both mechanical and adhesive means, to provide the sealed interior space
42.
With reference to the sectional view of FIG. 9, it can be seen that the inner housing
member
40a is adapted for nesting within the outer housing member
40b and comprises a plurality of tabs
50a that are
received in corresponding recesses
50b such as notches, or apertures
defined by the outer housing member
40b so that the housing members
40a,
40b are mechanically interlocked with a close snap-fit.
The tabs
50a can alternatively project from the outer housing
40b
and the recesses
50b can be defined in the inner housing
40a.
Furthermore, the inner housing member
40a comprises a continuous
wall
52a projecting outwardly therefrom that is received within a
corresponding continuously extending groove
52b defined by the outer
housing member
40b. The joint at the junction of the wall
52a
and groove
52b is sealed with a gasket or, preferably, with an
adhesive and/or sealant such as, e.g., epoxy.
The housings
30,
32,
34 of the base components
12c1,
12c2,
12c3
and the inner and outer housing members
40a,
40b of
the removable modules
14 are preferably defined as molded polymeric constructions
utilizing any of a wide variety of polymeric materials in an injection molding
process. One suitable material is glass-filled polyester, although it is not intended
that the development be limited to such material or any other material.
As noted above, each module
14 is adapted for releasable connection to
the backplane
20 of the base assembly
12. To this end, each releasable
module
14 comprises first and second module connectors
60b1,
60b2
(see e.g., FIGS.
7,
8) that are adapted to mate respectively with
a corresponding pair of first and second base connectors
30b1,
30b2
of the backplane
20 at each mounting location M
1-M
4. In the
illustrated embodiment, the first and second module connectors
60b1,
60b2
are female or socket connectors comprising a plurality of male (as shown) or female
contacts
60c, wherein the contacts
60c are electrically
coupled to the module circuitry
44 and/or to other contacts
60c
by paths
44p as shown in FIG. 7. Each base connector
60b1,
60b2
is dimensioned and conformed for mating with a base connector
30b1,
30b2
of the backplane
20, so that the contacts
60c mate with corresponding
contacts
30c of the base connectors
30b1,
30b2
to establish electrical connection between the backplane
20 and the modules
14. In this manner, the modules
14 act as and provide electrical
links by which the individual base components
12c are electrically
interconnected to each other through their base connectors
30b1,
30b2
so that data and/or power can flow from each module
14 to each other module
14, from each base component
12c to each other base component
12c, and/or from each module
14 to each base component
12c,
including the adapter base component
12c1 and circuitry
30d
thereof as required for use of the device
10.
FIGS. 10 and 11 are provided to show the relationship of a removable module
14 to the backplane
20 of base components
12c as the
removable module is about to be connected to the backplane. There, it can be seen
that the mounting location M
2 of the backplane
20 is defined by base
connectors
30b1,
30b2 of interlocked base
components
12c2. The connectors
60b1,
60b2
of removable module
14 are adapted to mate with the base connectors
30b1,
30b2,
respectively, so that module spans the base connectors
30b1,
30b2.
Of course, the electrical conductors
32d of each base component
12c2
interconnect each of the base connectors
30b1,
30b2
of the mounting location M
2 to the other base connector
30b2,
30b1
on the same base component.
When a removable module
14 is operatively mated to the backplane
20
as shown in FIG. 1, it is releasably interlocked to one of the base components
12c to prevent unintended separation of the module
14 from
the backplane
20 by gravity, vibration, impact, vandalism, cable stresses
and/or other external forces. FIGS. 2,
4 and
5 illustrate that each
intermediate base component
12c2 and the end base component
12c3 comprises a coupling device
70 adapted to receive
and retain a portion of a removable module
14 to connect the module to the
base component
12c2,
12c3 to prevent unintended
disconnection. FIGS. 7,
8 and
10 clearly show that each module
14
comprises at least one and, preferably, at least two coupling projections such
as spaced-apart hooks
82a,
82b that project outwardly
from an inner surface
14s thereof (the inner surface
14s
is defined as the surface of module
14 that contacts and/or is located
adjacent the backplane
20 when the module
14 is mated to the backplane).
These first and second hooks
82a,
82b are received into
first and second slots
72a,
72b (FIGS.
4,
5)
of the base component housing
32,
34 and are retained by the coupling
device
70 when the module
14 is operatively connected to the backplane
20.
The structure and operation of the coupling device
70 and use of same
to operably couple a module
14 to the backplane
20 is explained further
with reference to FIGS. 12-16B, using an intermediate base component
12c2
as an example. Those of ordinary skill in the art will recognize that the coupling
device
70 of an end base module
12c3 is structured
and functions identically. In FIG. 12, portions of the housing
32 are broken
away to reveal the coupling device
70. The coupling device
70 comprises
a lock member
74 that is slidably connected to the housing
32 and
adapted for reciprocating sliding movement between a first or "locked" position
(FIGS.
12,
16A) and a second or "release" position (FIG. 16B). The
lock member
74 is preferably spring-biased into the first position.
FIG. 15 shows the lock member
74 by itself. In the illustrated embodiment,
the lock member comprises a one-piece molded polymeric construction comprising
first and second ends
74a,
74b separated from each other
by a spring portion
74c. The spring-biasing can be supplied by a
separate spring or other resilient element but, in the illustrated embodiment,
the biasing is provided by the spring portion
74c that is defined
as a part of the one-piece molded plastic lock member. One suitable polymeric material
for molding the lock member is acetal, although other materials are contemplated
and can be used. It is not intended that the development be limited to a one-piece
molded polymeric lock member, and the lock member can be defined from other materials
and/or fabricated from multiple pieces, and the term "member" as used herein is
not intended to be limited to a one-piece structure.
In the example shown herein, the spring portion
74c comprises a
frame
74d that defines an open space
74e. At least
one and, preferably, a plurality of fingers
74f project from the
frame
74d into the space and terminate in free distal ends comprising
feet
74g defined in the form of a post or other structure. With reference
now to FIGS. 12 and 13, the feet
74g are engaged with bosses
74i
or other portions of the body
32 of the base component
12c
so as to be restrained against sliding movement with other portions of the
lock member
74. Except for the feet
74g, the lock member
74
is slidably movable relative to the body
32 of the base component
12c
between the first and second positions as indicated by the arrow
74j,
by exertion of force on the actuator portion
74k of the lock member
that projects outwardly away from the housing
32. Thus, when the actuator
74k is pulled outwardly away from the housing (FIG. 16B), the lock
member
74 slides from its normal first position to its second "release"
position, while the fingers
74f resiliently deflect owing to the
immovable engagement of the feet
74g with the body
32 of the
base component
12c. Upon release of the actuator
74k,
the natural resilience of the fingers
74f returns them to their original
shape or "home" position as shown in FIGS. 12 and 13 so as to move the lock member
74 back to its first "locked" position.
The lock member
74 comprises first and second latch portions
74p1,
74p2
that are conformed and dimensioned and otherwise adapted to receive and retain
the respective first and second hooks or other projections
82a,
82b
of the module
14. The first and second latch portions
74p1,
74p2
are located respectively in the slots
72a,
72b of the
base component housings
32,
34.
FIG. 14 shows a module
14 operatively mated to the backplane
20
in a mounting location M
1-M
4, with the coupling projections
82a,
82b
thereof mated with and retained by the first and second latch portions
74p1,
74p2,
respectively. The first and second latch portions are adapted to mate with the
first and second hooks
82a,
82b and thus comprise hook-like
structures oriented oppositely relative to the hooks
82a,
82b
of the modules
14. The first and second latch portions
74p1,
74p2
are each defined with a sloped outer surface
76k1,
76k2
oriented and located so that, during installation of a module
14 to the
backplane
20, the projections
82a,
82b of the
module engage the sloped surfaces
76k1,
76k2
and urge the lock member
74 out of its natural first position toward its
second position until the module
14 is fully seated against the backplane
20, at which time the spring portion
74c of the lock member
74 biases the lock member back to its first position so that the latch members
74p1,
74p2 engage the hooks
82a,
82b,
respectively, with a snap-fit so that a user received tactile feedback of full
and proper installation of the module
14 to the backplane
20.
As shown in FIG. 14, when a removable module
14 is fully operatively seated
against a component
12c of the backplane
20, the first and
second hooks
82a,
82b thereof are engaged with the first
and second latch members
74p1,
74p2. The
lock member
74 also functions as a module ejector and, thus, comprises one
or more ejection surfaces such as the first and second ejection ramps
74r1,
74r2
(see also FIGS.
4,
5) conformed and arranged to engage the first and
second hooks
82a,
82b or another part of the module
14 when the lock member
74 is moved toward and into its second operative
position. In the illustrated embodiment, the module coupling hooks
82a,
82b
comprise respective ejection surfaces
84a,
84b (see
FIGS.
10,
14) that lie adjacent the ejection ramps
74r1,
74r2.
It is preferred that the ejection surfaces
84a,
84b and
ejection ramps
74r1,
74r2 be conformed
as smooth mating sloped ramp surfaces.
With reference now to FIG. 14 and also FIGS. 16A and 16B, when the lock member
is moved from its first or "locked" position (FIGS.
14,
16A) to its
second or "release" position (FIG. 16B), the latch portions
74p1,
74p2
disengage from hooks
82a,
82b to allow for separation
of the module
14 from the backplane. At the same time, the first and second
ramp surfaces
74r1,
74r2 of the lock member
74 slidably bear against the ejection surfaces
84a,
84b
of the module
14 and displace the module outwardly away from the backplane
20 to a position where it will be freely separable from the backplane (even
if the lock member
74 is again released and allowed to return to its normal
locked position before the module is lifted away from the backplane). The actuator
portion
74k of the lock member
74 is preferably defined with
a recess
74s that is adapted to receive a screw-driver blade or other
tool T as shown in FIGS. 16A and 16B to facilitate movement of the lock member
74 from its locked position to its unlocked position as shown.
The device
10 comprises a seal associated with each mated pair of a base
connector
30b1,
30b2 with a module connector
60b1,
60b2 to sealingly engage these connectors
and prevent contamination of the contacts
30c,
60c.
FIGS. 7,
8 and
11 illustrate one embodiment of a seal formed in accordance
with the present development, wherein a seal
90 is associated with each
module connector
60b1,
60b2. When the
module connectors
60b1,
60b2 are female
socket-type connectors as shown, the seal
90 is located within the socket
of the connector as shown. In this manner, when a module
14 is removed from
the backplane
20 and replaced with a new module, the new module is supplied
with a new seal
90.
The seal
90 is explained with reference to FIGS. 17A-17C. As noted, a
seal
90 is associated with each connector
60b1,
60b2
of each module
14. FIG. 17A shows an inner housing
40a of
a module
14 and first and second seals
90 connected thereto (the
male pin contacts
60c are not shown). The seals
90 are recessed
within first and second connector sockets
60d1,
60d2
of the housing
40b.
The seals
90 are each preferable defined as a one-piece molded polymeric
construction using any suitable elastomeric or other resilient polymeric material
(as shown the two seals
90 are also defined as a one-piece construction
with each other and are interconnected by a web
90w). In one embodiment,
each seal
90 is defined as a one-piece molded construction from a thermoplastic
elastomer (TPE) such as SANTOPRENE® brand TPE, but it is not intended that
the development be limited to this material. It is possible for the seals
90
to be molded or otherwise constructed separately from the inner housing member
40a, and then installed into the connector sockets
60d1,
60d2
so as to be retained by a friction-fit, adhesive and/or other means. It is deemed
preferable, however, to utilize a two-step injection molding process: (i) a first
step to mold the inner housing
40a, including the sockets
60d1,
60d2;
and, (ii) a second step to mold the seals
90 directly into the sockets
60d1,
60d2.
This method reduces labor costs and is believed to result in a better connection
of the seal
90 to the housing
40a.
FIGS. 17B and 17C are sectional views that show one embodiment for the seal
90 and connection of same to the socket
60d1 (the seal
90 is connected to the socket
60d2 in a corresponding
fashion). The socket
60d1 comprises an inner transverse wall
60e through which a plurality of apertures
60f are
defined to allow for installation of contacts
60c such as the male
pins shown in FIG. 11 and elsewhere. The peripheral wall
60p of socket
60d1 is generally cylindrical, and the seal
90 comprises
a correspondingly generally cylindrical peripheral wall portion
90a that
is closely conformed to the socket
60d1. The seal
90
also comprises an annular inner wall
90b arranged transverse to the
cylindrical portion
90a and abutted with the inner wall
60e
of socket
60d1. The annular inner wall
90b of
seal
90 defines a central opening
90c that is aligned with
the portion of the inner wall
60e in which the apertures
60f
are defined to ensure that the seal
90 does not obstruct the apertures
60f. The result of this structure is that the seal
90 has
a generally L-shaped cross-section. If desired, the inner wall
90b of
seal can completely cover the inner wall
60e of the socket and include
apertures defined therein that are registered with the apertures
60f
of the socket inner wall
60e. The outer end
90d of
seal
90 preferably diverges moving out of the socket
60d1
to facilitate insertion of a base connector
30b1,
30b2.
The inner wall
60e of the socket
60d1 also
defines flow passages
60g and, during the two-step molding operation,
the material from which the seal is defined flows through these passages
60g
and then cures, with the result being that the seal
90 is mechanically
interlocked with the socket
60d1 and anchored therein. Depending
upon the particular materials from which the seal
90 and housing
40a
are molded, the seal
90 can also be adhered to the socket
60d
and/or chemically bonded thereto as a result of the two-step molding operation.
The seal
90 comprises at least one and preferably at least two sealing
elements that provide two different, transverse sealing dynamics. As shown, the
seal comprises a radial sealing element for sealingly engaging radially or laterally
adjacent surfaces and an axial (compressive) sealing element for sealingly engaging
axially adjacent surfaces.
The radial sealing element comprises at least one continuous radial lip
92
that projects radially inward from the peripheral wall portion
90a toward
a central region of the socket
60d1. The one or more radial
lips
92 are adapted to abut and sealingly engage the outer cylindrical or
conical surfaces
36b1,
36b2 (FIG. 2) of
an associated base connector
30b1,
30b2
inserted in the socket
60d1. If the associated base connector
30b1,
30b2 is frusto-conical as described
above, it has been found to facilitate insertion and removal of the base connector
30b1,
30b2 relative to the socket
60d1
without compromising the effectiveness of the radial sealing element
92.
The axial sealing element comprises at least one continuous axial lip
94
that projects axially outward from the inner wall
90b of the seal
90 into the socket
60d1 toward the entrance
60h
of the socket. The one or more the axial lips
94 are adapted to abut
and sealingly engage the transverse end wall
38a,
38b(FIG.
2) of an associated connector
30b1,
30b2
inserted into the socket
60d1.
The combined radial and axial sealing has been found to be
