Subsea electrical connector and method

1. A subsea electrical connector for connecting a first cable and a second cable, comprising:

a first insulator, said first insulator comprising a first insulator outer face and a pin portion transverse to said first insulator outer face;

a second insulator comprising a second insulator outer face and a pin receptacle, said second insulator outer face mating to said first insulator outer face, said pin portion mating to said pin receptacle;

a face seal ring between said first insulator outer face and said second insulator outer face, said face seal ring being molded to one of said first insulator or said second insulator;

at least one pin seal ring between said pin portion and said pin receptacle, said at least one pin seal ring being molded to at least one of said first insulator or said second insulator;

an interference fit between said pin portion and said pin receptacle such that said pin portion comprises an outer diameter of said pin portion other than said at least one pin seal which is greater than an inner diameter of said pin receptacle other than said at least one pin seal prior to a make-up of said pin portion within said pin receptacle;

a seating angle seal comprising an angled surface on said pin portion and a corresponding angled surface within said pin receptacle;

first and second metal electrical connectors mounted within said first insulator and said second insulator, said first and second metal electrical connectors each comprising a socket for receiving said first and second cables;

molding around said first and second insulators operable to seal around said first cable and said second cable; and

a plurality of fasteners for securing said first insulator to said second insulator, said plurality of fasteners extending through said first insulator outer face and said second insulator outer face.

2. A subsea electrical connector for connecting a first cable and a second cable, as claimed in claim 1 further comprising a pin end seal surface positioned at an end of said pin portion, and a mating seal surface in said pin receptacle, said angled surface on said pin portion being positioned between said pin end seal surface and said at least one pin seal ring.

3. A subsea electrical connector for connecting a first cable and a second cable, as claimed in claim 1 further comprising a face seal surface at an end of said pin, which mates to a corresponding seal surface within said pin receptacle, said seating angle surface on said pin portion being positioned between face seal surface and said at least one pin seal ring.

4. A subsea electrical connector for connecting a first cable and a second cable, as claimed in claim 1 further comprising a plurality of receptacles in said first insulator and said second insulator for said plurality of fasteners, and a plurality of stop members, which allow limited relative rotation to a selected rotational orientation between said first insulator and said second insulator, such that in said selected rotational orientation said plurality of receptacles in said first insulator and said second insulator are aligned.

5. A subsea electrical connector for connecting a first cable and a second cable, as claimed in claim 1 further comprising a plurality of receptacles in said first insulator and said second insulator for said plurality of fasteners, a metal ring mounted within at least one of said first insulator or said second insulator that defines a plurality of openings, which are aligned with said plurality of receptacles.

6. A subsea electrical connector for connecting a first cable and a second cable, as claimed in claim 1 further comprising a plurality of receptacles in said first insulator and said second insulator for said plurality of fasteners, and at least one guide member to align said plurality of receptacles in said first insulator and said second insulator.

7. A method for making a subsea electrical connector for connecting a first cable and a second cable comprising the steps of:

forming a first insulator comprising a first insulator outer face and a pin portion transverse to said first insulator outer face;

forming a second insulator comprising a second insulator outer face and a pin receptacle, said second insulator outer face mating to said first insulator outer face, said pin portion mating to said pin receptacle;

providing a molded face seal ring between said first insulator outer face and said second insulator outer face;

providing at least one molded pin seal ring between said pin portion and said pin receptacle;

providing a seating angle seal comprising an angled surface adjacent an end of said pin portion and a corresponding angled surface within said pin receptacle;

mounting first and second metal electrical connectors within said first insulator and said second insulator;

providing that said first and second metal electrical connectors each comprise a socket for receiving said first and second cables;

providing insulator end sockets in said first insulator and said second insulator for receiving said first and second cables;

providing a plurality of fasteners for securing said first insulator to said second insulator that extend through said first insulator outer face and said second insulator outer face; and

molding said first and second insulators around said first and second cables for sealing around said insulator end sockets of said first and second insulators with respect to said first and second cables.

8. A method for making a subsea electrical connector for connecting a first cable and a second cable as claimed in claim 7 further comprising providing an interference fit between said pin portion and said pin receptacle whereby an outer diameter of said pin portion at a position other than at said at least one molded pin seal ring is greater than a corresponding inner diameter of said pin receptacle prior to make-up of said subsea electrical connector.

9. A method for making a subsea electrical connector for connecting a first cable and a second cable as claimed in claim 7 further comprising mounting at least one metal ring within at least one of said first insulator or said second insulator, said at least one metal ring defining a plurality of openings therein, said plurality of openings being positioned so as to be operable for receiving said plurality of fasteners.

10. A method for making a subsea electrical connector for connecting a first cable and a second cable as claimed in claim 7 further comprising providing a plurality of rotation stop members to limit relative rotation between said first insulator and said second insulator and to align said first insulator and said second insulator for securing said plurality of fasteners.

11. A method for making a subsea electrical connector for connecting a first cable and a second cable as claimed in claim 7 further comprising providing a pin end seal surface positioned at an end of said pin portion, and a mating seal surface in said pin receptacle, and providing that said angled surface on said pin portion is positioned between said pin end seal surface and said at least one pin seal ring.

12. A method for making a subsea electrical connector for connecting a first cable and a second cable as claimed in claim 7 further comprising providing a plurality of molded pin seal rings between said pin portion and said pin receptacle.

13. A method for making a subsea electrical connector for connecting a first cable and a second cable as claimed in claim 7 further comprising providing that said plurality of fasteners comprise a plurality of enlarged head portions, forming a plurality of pockets which are enlarged to receive said plurality of head portions with at least one of said first insulator or said second insulator, providing that said plurality of pockets are each sized to permit limited axial movement of a respective head portion.

14. A subsea electrical connector for connecting a first cable and a second cable, comprising:

a first insulator comprising a first insulator outer face and a pin portion transverse to said first insulator outer face;

a second insulator comprising a second insulator outer face and a pin receptacle, said second insulator outer face mating to said first insulator outer face, said pin portion mating to said pin receptacle;

a face seal ring between said first insulator outer face and said second insulator outer face;

first and second metal electrical connectors molded within said first insulator and said second insulator, said first and second metal electrical connectors each comprising a socket for receiving said first and second cables, said first and second metal electrical connectors being sized such that when said first insulator outer face engages said second insulator outer face then said first and second metal electrical connectors define a clearance therebetween to allow said first insulator outer face and said second insulator outer face to engage;

at least one pin seal ring between said pin portion and said pin receptacle, said at least one pin seal ring being molded to at least one of said first insulator or said second insulator;

a plurality of fasteners, said first insulator and said second insulator defining a plurality of receptacles for said plurality of fasteners, said plurality of receptacles extending through said first insulator outer face and said second insulator outer face.

15. A subsea electrical connector for connecting a first cable and a second cable, as claimed in claim 14 further comprising an interference fit between said pin portion and said pin receptacle such that said pin portion comprises an outer diameter greater than an inner diameter of said pin receptacle prior to a make-up of said pin portion within said pin receptacle.

16. A subsea electrical connector for connecting a first cable and a second cable as claimed in claim 14 further comprising at least one metal member positioned in at least one of said first insulator or said second insulator, said at least one metal member defining a plurality of openings which are aligned with said plurality of receptacles.

17. A subsea electrical connector for connecting a first cable and a second cable as claimed in claim 14 further comprising molding around said first and second insulators operable to seal around said first cable and said second cable.

18. A subsea electrical connector for connecting a first cable and a second cable, as claimed in claim 14 further comprising a seating angle seal comprising an angled surface on said pin portion and a mating angled surface within said pin receptacle.

19. A subsea electrical connector for connecting a first cable and a second cable, as claimed in claim 18 further comprising a pin end seal surface positioned at an end of said pin portion, and a mating seal surface in said pin receptacle, said angled surface on said pin portion being positioned between said pin end seal surface and said at least one pin seal ring.