IP Library › Granted Patent US 11,069,995
Granted Patent B1
US 11,069,995 · App. 16/784,518 · Granted Jul 20, 2021

Single self-insulating contact for wet electrical connector

Inventors: Harvey P. Hack (Arnold, MD); James R. Windgassen (Chester, MD)
Assignee: Northrop Grumman Systems Corporation
H01R13/03H01R13/523
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Quick Facts
Patent No.
US 11,069,995
App. No.
16/784,518
Granted
Jul 20, 2021
Kind
B1
Abstract

An electrical connector includes an electrically insulating body and a self-passivating contact held at a higher voltage than a non-passivating contact. The self-passivating contact includes a first electrically conductive material that forms an electrically insulating passivation layer when exposed to water or other aggressive environment. The non-passivating contact includes a second electrically conductive material that is unreactive when exposed to water or other aggressive environment. The passivation layer on the self-passivating contact prevents electric current from flowing between the self-passivating contact and the non-passivating contact through the water or other aggressive environment.

Claims (36)

1. An electrical connector connected to a power source, the electrical connector comprising:

an electrically insulating body;

a self-passivating contact comprising a first electrically conductive material that forms an electrically insulating passivation layer when exposed to water; and

a non-passivating contact comprising a second electrically conductive material that is unreactive when exposed to water,

wherein the self-passivating contact is held at a higher voltage than the non-passivating contact by the power source.

2. The electrical connector of claim 1 , wherein the first electrically conductive material includes a transition metal, and the electrically insulating passivation layer is an oxide formed from the transition metal.

3. The electrical connector of claim 2 , wherein the first electrically conductive material is an outer layer of the self-passivating contact.

4. The electrical connector of claim 2 , wherein the transition metal is selected from a group containing niobium, tantalum, titanium, zirconium, molybdenum, ruthenium, rhodium, palladium, hafnium, tungsten, rhenium, osmium, and iridium.

5. The electrical connector of claim 1 , wherein the second electrically conductive material is resistant to corrosion in an aqueous environment.

6. The electrical connector of claim 5 , wherein the second electrically conductive material includes copper, silver, gold, platinum, graphite, or aluminum.

7. The electrical connector of claim 1 , wherein the electrically insulating passivation layer prevents electrical current from flowing from the self-passivating contact to the non-passivating contact when exposed to water.

8. A system comprising:

a first electrical connector comprising:

a first self-passivating contact formed with a self-passivating electrically conductive material that forms an electrically insulating passivation layer when exposed to water; and

a first non-passivating contact formed with a non-passivating, electrically conductive material that is unreactive when exposed to water;

a second electrical connector comprising:

a second self-passivating contact configured to mate with the first self-passivating contact, the second self-passivating contact formed with the self-passivating electrically conductive material; and

a second non-passivating contact configured to mate with the first non-passivating contact, the second non-passivating contact formed with the non-passivating, electrically conductive material; and

a power source configured to hold the first self-passivating contact at a higher voltage than the first non-passivating electrode.

9. The system of claim 8 , wherein the self-passivating, electrically conductive material includes a transition metal, and the electrically insulating passivation layer is an oxide formed from the transition metal.

10. The system of claim 9 , wherein the transition metal is selected from a group containing niobium, tantalum, titanium, zirconium, molybdenum, ruthenium, rhodium, palladium, hafnium, tungsten, rhenium, osmium, and iridium.

11. The system of claim 8 , wherein the non-passivating, electrically conductive material is resistant to corrosion in an aqueous environment.

12. The system of claim 11 , wherein the non-passivating, electrically conductive material includes copper, silver, gold, platinum, graphite, or aluminum.

13. The system of claim 8 , wherein the electrically insulating passivation layer prevents electrical current from flowing from the first self-passivating contact to the first non-passivating contact when exposed to water.

14. The system of claim 8 , wherein the second self-passivating contact is configured to scrape at least a portion of the electrically insulating passivation layer when mating with the first self-passivating contact, enabling current to flow between the first self-passivating contact and the second self-passivating contact.

15. A method comprising:

forming a connector body from an electrically insulating material;

forming a self-passivating anode comprising a first electrically conductive material that forms an electrically insulating passivation layer when exposed to water; and

forming a non-passivating cathode comprising a second electrically conductive material that is unreactive when exposed to water; and

installing the self-passivating anode and the non-passivating cathode in the connector body,

wherein the electrically insulating passivation layer prevents electrical current from flowing from the self-passivating anode to the non-passivating cathode when exposed to water.

16. The method of claim 15 , wherein forming the self-passivating anode comprises forming a transition metal as the first electrically conductive material, and wherein the electrically insulating passivation layer is an oxide formed from the transition metal.

17. The method of claim 16 , wherein forming the self-passivating anode comprises selecting the transition metal from a group containing niobium, tantalum, titanium, zirconium, molybdenum, ruthenium, rhodium, palladium, hafnium, tungsten, rhenium, osmium, and iridium.

18. The method of claim 15 , wherein forming the self-passivating anode comprises coating an anode formed from the second electrically conductive material with a layer of the first electrically conductive material.

19. The method of claim 15 , wherein forming the non-passivating cathode comprises forming a metal that is resistant to corrosion in an aqueous environment as the second electrically conductive material.

20. The method of claim 19 , wherein forming the non-passivating cathode comprises selecting the second electrically conductive material to include copper, silver, gold, platinum, graphite, or aluminum.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Feb 7, 2020
From: HACK, HARVEY P.; WINDGASSEN, JAMES R.
To: NORTHROP GRUMMAN SYSTEMS CORPORATION
Reel/Frame 051753/0001 →
Cited By (2)
US 12,195,153 US 12,261,386