Replaceable tube of conductive gel
This is a division of applicatio Ser. No. 029,340, filed Mar. 23, 1987, now U.S. Pat. No. 4,762,497. 
    
    
     BACKGROUND OF THE INVENTION 
     The invention concerns an electrical connector that can be fastened to a fabric for electrically connecting through the fabric. 
     In the manufacture of integrated circuits and other sensitive electronic components, it is customary for persons to wear wrist straps that are electrically connected to ground to guard against the accumulation of electrostatic charges. When such a person is in a clean room, it may be necessary to wear a garment made from a fabric that completely covers the arms and hands. Although the gloves of the garment may be independent of the sleeves, a wire passing from a wrist strap between a glove and sleeve would introduce an opening that could be a source of contamination. When such an opening has been intolerable, an electrical connector has been permanently attached to the sleeve and fastened to wires leading to the wrist strap to the ground. One such permanently attached connector consists of two metal pieces, one having two sharp prongs which are punched through a garment and then bent over to rivet the two pieces together and thus electrically connect them. While the garment is being worn, the internal and exterior wires can pull at such a permanent connector and thus weaken the fabric, eventually producing openings that could be so minute as to be undetectable and yet could pass contaminants. Such a connector can also be subjected to the same sort of stresses by machinery used to clean the garment, typically after each use. Furthermore, the electrical connector can become slightly corroded by the cleaning materials, thus creating an additional possible source of contamination. Even if the metal of a permanent connector is completely resistant to corrosion, contaminants could be entrapped between the connector and the garment fabric during cleaning and might be released when the garment is worn. 
     SUMMARY OF THE INVENTION 
     The present invention provides an inexpensive, connector that is useful for electrically connecting through a fabric, which may be removable, and yet avoids the aforementioned problems involving prior connectors. The novel connector can quickly and easily be fastened to the fabric, such as a garment sleeve, and, preferably, removed after each use. It then is separately cleaned with no hazard to the garment. 
     An electrical connector is provided which is useful for electrically connecting through a fabric. A first part and a second part are adapted to be interconnected to entrap the fabric from both sides. The first part and the second part interconnect to form a reservoir therebetween. A first electrode is coupled to the first part electrically communicating with the interior of the reservoir. A second electrode is coupled to the second part electrically communicating with the interior of the reservoir. A first interconnection mechanism is coupled to the first part for connecting the first electrode exterior of the reservoir on one side of said fabric. A second interconnection mechanism is coupled to the second part for connecting the second electrode exterior of the reservoir on the other side of the fabric. Constructed in this manner the first part and second part may be interconnected from opposite sides of the fabric and the reservoir may be filled with an electrically conductive gel capable of penetrating the fabric and thus an electrical connection be established through the fabric. 
     For use in a preferred prototype connector of the invention, a tube made of elastic, polymeric foam is formed with a cavity that is open at both ends and is filled with an electrically conductive gel. When the gel-filled open tube is seated in said reservoir, it protrudes beyond the edge of said opening before said first and second parts are interconnected. When the seated tube is compressed by forcing the second electrode against the edge of the reservoir, a squeezing force is transmitted through the foam to the conductive gel, thus forcing a portion of the conductive gel through the exposed open end of the foam tube into the entrapped fabric and against the second electrode. 
     When used with the above-described gel-filled foam tube, the first electrode of the novel connector should be positioned to be contacted by the conductive gel at the end of the foam tube opposite to the entrapped fabric, so that the conductive gel provides a continuous, electrically conductive path between the two electrodes through the fabric. Preferably the periphery of the face of the first electrode is coincident with the periphery of the foam tube, and the polymeric foam is electrically conductive in order to enhance the electrical conductivity of the novel connector. A polymeric foam is easily and economically made electrically conductive by loading it with electrically conductive carbon black. 
     When the foam of the tube is electrically conductive, the cavity formed in the tube need not be open at the base of the reservoir, because the conductive foam can complete the electrical connection between the gel and the first electrode. 
     Preferably only the cavity of the foam tube is initially filled with the electrically conductive gel and its polymeric foam is open-cell so that its cells can provide a haven for excess conductive gel which otherwise might be squeezed laterally through the garment fabric beyond the perimeter of the connector to become a source of contamination. Furthermore, conductive gel which is taken up by the foam can be squeezed through the fabric, thus enlarging the area of conductive gel in contact with the second electrode and providing better electrical conductivity through the fabric. 
     In the preferred prototype connector, each of said first and second parts is made of moldable plastic, both for economy and for lightness in weight. The second of said parts forms a hollow cylindrical shell, and the first of said parts is a disk formed with a projection containing said reservoir, which projection is received by said shell. The interior wall of said hollow shell is substantially cylindrical and is formed with a pair of detents about 180° apart, and the projection of the first part is formed with a pair of pawls which interlock with the detents when the two parts are rotated relative to each other to entrap a garment fabric. In order to minimize fraying of the garment during such rotation, the plastic may be nylon which both has a low coefficient of friction in contact with a garment fabric and is highly resistant to chafing. 
     In the preferred prototype, the aforementioned means for connecting said electrodes comprise a metal stud projecting from the face of each of the two plastic parts opposite to its fabric-contacting face. Each metal stud is formed to make a snap fit with a terminal on a wire leading from the wrist strap or ground. It may be preferred to solder a wire to the electrode of the first plastic part to make it easier to attach the novel removable connector to a wrist strap. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A preferred prototype of the electrical connector of the invention is schematically illustrated in the drawings, of which: 
     FIG. 1 is an isometric view of a portion of the sleeve of a garment to which the prototype is temporarily attached; 
     FIG. 2 is a side elevation of the prototype, partly cut away to a central section, and a tube of polymeric foam containing an electrically conductive gel, which tube has been inserted into a reservoir in one of the prototype&#39;s two plastic parts which are in position to be interconnected through the garment sleeve between a wrist strap and ground; 
     FIG. 3 is a front elevation of the reservoir-containing plastic part; 
     FIG. 4 is a front elevation of the other of the two plastic parts, and 
     FIG. 5 is a cross section through the reservoir-containing plastic part of FIGS. 1-3, somewhat enlarged, which has been modified to permit the foam tube to be eliminated. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The prototype removable connector 10 of FIGS. 1-4 comprises first and second interconnectable plastic parts 12 and 14. The first plastic part 12 comprises a disk with a central projection 15 in which is formed a cylindrical, open reservoir 16. The exterior surface of the projection is substantially right cylinder, and projecting therefrom are a pair of pawls 17 about 180° apart. The second plastic part 14 comprises a hollow shell having a substantially cylindrical inner wall from which project a pair of detents 18. The detents interlock with the pawls 17 when the projection 15 is inserted into the hollow shell and the two plastic parts 12 and 14 are rotated relative to each other to become interconnected to entrap a garment fabric 19, with the circular edge 20 of the reservoir 16 fitting flush against the fabric. The exterior surface of the second plastic part 14 is cylindrical except for two flats 21 which serve as finger holds. 
     Each of the first and second plastic parts 12 and 14 is formed at its periphery with a substantially flat fabric-contacting surface 22 and 24, respectively, between which surfaces the fabric 19 is compressed when the two plastic parts 12 and 14 are interconnected. Two rounded knobs 26, 28 positioned 180° apart along each of the fabric-contacting surfaces 22, 24, respectively, together act as rotational stops after the first and second plastic parts 12 and 14 have been rotated in either direction about 90° with respect to each other. 
     Formed in the outer wall and on the axis of each of the first and second plastic parts 12 and 14 is an opening at which first and second metal electrodes 32 and 34, respectively, are riveted to studs 36 and 38, respectively, each of which projects beyond the wall of the plastic part 12, 14 opposite to its fabric-contacting surface 22, 24, respectively. Each of the studs 36 and 38 is formed to make a snap fit with a terminal 39 and 40, respectively, the terminal 39 being connected by a wire to a wrist strap 42 while the terminal 40 is connected by another wire to a ground 44. 
     Shown in FIG. 2 is a cylindrical tube 45 of elastic, polymeric, electrically conductive, open-cell foam which is formed with a cavity that is open at both ends and filled with an electrically conductive gel 47. When the gel-filled open tube 45 is seated in the reservoir 16 as shown in FIG. 2, it and the conductive gel 47 rest against the flat face of the first metal electrode 32 at the bottom of the reservoir, and protrude a short distance beyond the circular edge 20 of the reservoir. When the garment fabric 19 is entrapped as shown in FIG. 1, the foam tube 45 is compressed by the flat face of the second metal electrode 34 and transmits a squeezing force against the conductive gel 47, thus forcing it to flow into the interstices of the fabric 19 and into contact with the second electrode 34. This forms an electrical path though the conductive gel 47 between the first and second electrodes 32, 34 and thus permits the wrist strap 42 to be electrically connected through the garment to the ground 44. 
     As shown in FIG. 5, the gel-filled tube 45 can be replaced by other means for squeezing the electrically conductive gel into an entrapped fabric. Soldered to the first electrode 32 is an electrically conductive metal coil spring 50, the other end of which is soldered to a disk-shaped electrically conductive metal plate 52. Adhesively bonded to the perimeter of the metal plate 52 is a flexible rubber cup 54 which is corrugated to be collapsible. The plate thus forms the base of the cup, the lip of which is adhesively bonded to one end of a plastic sleeve 56. The length of the coil spring 50 is selected so that with the plastic sleeve 56 slidably positioned in the reservoir 16, the cup 54 extends beyond the edge 20 of the reservoir, as illustrated in FIG. 5. The rubber cup 54 is filled with an electrically conductive gel 57. When the first plastic part 12, fitted as shown in FIG. 5, is connected to the second plastic part 14 to entrap a garment fabric, the plastic sleeve 56 is forced into the reservoir 16 by the flat face of the second metal electrode 34, thus compressing the coil spring 50 which transmits a squeezing force against the conductive gel 57. This forces the gel to flow through the fabric and into electrical contact with the second electrode 34, thus completing an electrical path between the two electrodes 32 and 34. 
     Example 
     The prototype shown in the drawing has been constructed using &#34;Delrin&#34; acetal resin from E. I. duPont for the first and second plastic parts 12 and 14, because this plastic is easy to machine. Nylon would be preferred when the plastic parts are molded. The metal electrodes 32, 34 were stainless steel #304. The tube 45 was an open-cell polyurethane foam having a density of 3 lbs/ft 3   and filled with electrically conductive carbon black to provide a electrical resistivity of 1×10 5  ohm-cm. 
     An electrically conductive gel 47 was prepared as follows: 
     A mixture of 52 grams of ethylene glycol, 16 grams of glycerol, and 2 grams of methyl vinyl ether/maleic anhydride copolymer was heated to 85° C. with stirring until gelling had started. This temperature was maintained for 3 hours to provide a gel which then was allowed to cool to room temperature. The pH of the gel was about 6. Its electrical conductivity was surprisingly good in view of it being water-free and salt-free. By being water-free, there is no hazard of evaporation. The absence of salt avoids corrosion problems. 
     
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Significant dimensions of the                                             
prototype were:      in inches in cm                                      
______________________________________                                    
Outside diameters of plastic parts                                        
                     1.120     2.87                                       
12 and 14                                                                 
Spacing between fabric-contacting                                         
                     .010      0.025                                      
surfaces 22 and 24 when parts                                             
12 and 14 are interlocked                                                 
Diameter of reservoir 16                                                  
                     .400      1.02                                       
Depth of reservoir 16                                                     
                     .200      0.51                                       
Height of rounded knobs 26, 28                                            
                     .025      0.064                                      
Circumferential thickness of                                              
                     .050      0.13                                       
knobs 26, 28                                                              
Diameters of electrodes 32 and 34                                         
                     .4        1.0                                        
Height of uncompressed foam tube 45                                       
                     .375      0.96                                       
Inside diameter of foam tube 45                                           
                     .125      0.32                                       
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     Using a syringe, the electrically conductive gel 47 was squirted into the cavity of the foam tube 45, and the filled tube was seated in the reservoir 16. The two plastic parts 12, 14 were then interconnected to entrap a piece of cleanroom garment fabric (polyester) which had a thickness of about 0.125 mm. The electrical resistance between the studs 36 and 38 was then measured to be 200,000  ohms. In order to bleed off static charges, the electrical resistance should be about one megohm or less. 
     When the garment fabric is polyester, the electrical resistivity reaches its ultimate value almost immediately. However, cleanroom garment fabrics which are less porous may require a short period of time to allow the electrically conductive gel to penetrate fully. When the cleanroom garment fabric is &#34;Gore-tex&#34;, there is a delay of about 10 minutes before the desired electrical conductivity is achieved. 
     Some cleanroom garment fabrics are electrically conductive by virtue of a grid of electrically conductive fiber woven into the fabric. Because the spacing between adjacent conductive fibers of those fabrics is less than the diameters of the reservoir 16 of the prototype, such garments have inevitably been grounded through the electrically conductive gel of the prototype whenever it has been attached to one of those garments without any concern as to its positioning. 
     The prototype should be useful with cleanroom garment fabrics having thicknesses from about 0.01 to 0.015 inch (0.025 to 0.038 cm). Greater or lesser fabric thicknesses would call for correspondingly increased or decreased spacing between the fabric-contacting surfaces 22; and 24 when the plastic parts 12 and 14 are interlocked. 
     Because some of the conductive gel is lost when the prototype entraps fabric, a fresh foam tube and conductive gel should be used each time the removable connector is attached to a garment. Furthermore, it is necessary to remove the used foam tube and conductive gel in order to clean the connector between each use. The foam tube can be cut from a block but preferably is die-cut from a sheet, the thickness of which equals the desired axial length of the tube. By doing so, the cut edges of the foam tube are mainly within the reservoir, thus minimizing possible contamination from fragments generated during cutting. 
     Although the first plastic part 12 is of more economical manufacture when designed for a gel-filled foam tube 45 than when fitted as shown in FIG. 5, the latter may be more economical to use, requiring only gel refills. 
     While the illustrated prototype uses wire between the first electrode 32 and wrist strap 42, the stud 36 could be snapped directly onto a fitting of the wrist strap. However, a wire permits the wire to emerge anywhere from the garment, although it is assumed that most users will prefer to use a wire no longer than the length of the sleeve. 
     Each of the plastic parts 12, 14 could be entirely metal, but this would add to their cost and weight. Molded plastic parts are inexpensive and lightweight. 
     Another prototype of the novel connector employed screw threads to interconnect two plastic parts, but in use, the two parts had a tendency to work loose. When employing any such connector of the invention which includes means for preventing such loosening, care should be taken that such means do not chafe or fray the garment. 
     In a third prototype of the novel connector, the two interconnecting parts also comprised plastic, and the reservoir of the first plastic part was designed to be filled directly with an electrically conductive gel without using any plastic foam. In this prototype, the second electrode was formed to project into the reservoir to provide a squeezing force, but this force tended to make the two plastic parts work loose. 
     Numerous other variations in details of construction of the novel removable connector can be made within the ambit of the invention. For example, each of the two electrically insulative plastic parts of the removable connector could be formed with a reservoir to receive a foam tube filled with electrically conductive gel which would be forced into the entrapped fabric from both sides. In another variation, first and second plastic parts are formed as shown in the drawing except that the fabric-contacting surfaces 22 and 24 are shallowly inclined planes, thus eliminating the need for the rounded knobs 26 and 28, because rotation is stopped when the garment fabric cannot be further compressed by the force applied by the user&#39;s fingers. 
     Thus, there has been shown and described a novel electrical connector for electrically conducting through a fabric. It is to be recognized and understood, however, that various changes, modifications and improvements in the form and the details of the invention may be made by those skilled in the art without departing from the scope of the following claims.