U.S. patent application number 14/789582 was filed with the patent office on 2017-01-05 for multiple cable disconnect.
The applicant listed for this patent is Tyco Electronics Corporation. Invention is credited to Christopher George Daily, Matthew Edward Mostoller.
Application Number | 20170003010 14/789582 |
Document ID | / |
Family ID | 56204084 |
Filed Date | 2017-01-05 |
United States Patent
Application |
20170003010 |
Kind Code |
A1 |
Mostoller; Matthew Edward ;
et al. |
January 5, 2017 |
MULTIPLE CABLE DISCONNECT
Abstract
A multiple cable disconnect includes a housing having a
separable mating end and a wire terminating end configured to
receive wires of power cables. The housing has a plurality of
terminal chambers with terminals therein. The terminals each have a
base, a mating contact extending from the base and a wire contact
extending from the base. The mating contact has a mating pad
defining a separable mating interface for the terminal for mating
with a corresponding mating terminal of the mating connector. The
wire contact has plural wire interfaces for mating with plural
wires such that plural wires are configured to be terminated to and
commoned with each terminal. Wire retention springs are received in
the housing each having at least one spring arm defining a wire
trap with the corresponding wire contact. The spring arms are
releasable to release the wires from the housing.
Inventors: |
Mostoller; Matthew Edward;
(Hummelstown, PA) ; Daily; Christopher George;
(Harrisburg, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tyco Electronics Corporation |
Berwyn |
PA |
US |
|
|
Family ID: |
56204084 |
Appl. No.: |
14/789582 |
Filed: |
July 1, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F21V 23/003 20130101;
H01R 24/28 20130101; F21V 23/06 20130101; H01R 31/02 20130101; F21Y
2101/00 20130101; H01R 24/20 20130101; H01R 24/84 20130101; H01R
2105/00 20130101; H01R 4/4827 20130101; H01R 13/05 20130101; H01R
13/28 20130101; F21V 23/001 20130101 |
International
Class: |
F21V 23/06 20060101
F21V023/06; F21V 23/00 20060101 F21V023/00; H01R 13/05 20060101
H01R013/05; H01R 24/20 20060101 H01R024/20; H01R 24/28 20060101
H01R024/28 |
Claims
1. A multiple cable disconnect comprising: a housing having a
separable mating end for mating with a mating connector and a wire
terminating end configured to receive wires of power cables, the
housing having a plurality of terminal chambers; terminals received
in corresponding terminal chambers, the terminals each having a
base, a mating contact extending from the base and a wire contact
extending from the base, the mating contact having a mating pad
defining a separable mating interface for the terminal for mating
with a corresponding mating terminal of the mating connector, the
wire contact having plural wire interfaces for mating with plural
wires such that plural wires are configured to be terminated to and
commoned with each terminal; and wire retention springs received in
the housing, each wire retention spring having at least one spring
arm defining a wire trap with the corresponding wire contact, the
spring arms being releasable to release the wires from the
housing.
2. The multiple cable disconnect of claim 1, wherein the terminals
take power in and split the power to multiple power cables.
3. The multiple cable disconnect of claim 1, wherein the separable
mating end of the housing is hermaphroditic and configured to mate
with an identical second housing of a second multiple cable
disconnect defining the mating connector.
4. The multiple cable disconnect of claim 1, wherein the wire
terminating end includes a plurality of wire bores configured to
receive corresponding wires, the wire traps being aligned with
corresponding wire bores to accept the wires.
5. The multiple cable disconnect of claim 4, further comprising
wire release slots associated with corresponding wire bores to
release the wires from the wire traps.
6. The multiple cable disconnect of claim 1, wherein the housing
comprises a front housing at the separable mating end and a wire
holder at the wire terminating end, the wire holder being coupled
to the front housing, the front housing holding the terminals, the
wire holder having wire bores guiding the wires into electrical
connection with the wire contacts when the wires are poked in to
the wire bores.
7. The multiple cable disconnect of claim 1, wherein the terminals
are arranged vertically and stacked within the housing, each
terminal being electrically connected to a different wire of each
power cable poked in to the wire terminating end of the housing,
the wire interfaces being arranged at different vertical heights
along the wire contact for electrical connection to different wires
of different power cables.
8. The multiple cable disconnect of claim 1, wherein each terminal
is configured to electrically common wires from at least three
different power cables.
9. The multiple cable disconnect of claim 1, wherein the spring
arms of the wire retention springs are deflectable toward and away
from the corresponding wire contacts, the spring arms each having
an edge configured to capture the wires at the corresponding wire
interfaces.
10. The multiple cable disconnect of claim 1, wherein the housing,
at the separable mating end, includes plural contact holders and
plural hoods associated with corresponding contact holders and
covering such contact holders, the contact holders holding mating
contacts of corresponding terminals, the mating pads of the mating
contacts being exposed along the contact holders for mating with
the mating terminals of the mating connector.
11. The multiple cable disconnect of claim 10, wherein the contact
holders are separated by gaps, the hoods having side walls
surrounding a pocket, the side walls being aligned with the gaps,
the pockets being aligned with the contact holders.
12. The multiple cable disconnect of claim 11, wherein the pockets
have a volume slightly larger than a volume of the contact
holders.
13. The multiple cable disconnect of claim 1, wherein the housing
includes a latch extending from a first end at or near the
separable mating end and the housing includes a catch extending
from a second end opposite the first end at or near the separable
mating end.
14. The multiple cable disconnect of claim 1, wherein the separable
mating end of the housing includes hermaphroditic keying
features.
15. The multiple cable disconnect of claim 1, wherein each wire
retention spring includes a plurality of spring arms corresponding
to the plural wire interfaces.
16. The multiple cable disconnect of claim 1, wherein the wire
retentions springs are integral with the corresponding
terminals.
17. The multiple cable disconnect of claim 1, wherein the housing
includes overstress features adjacent the spring arms to limit
release of the spring arms.
18. A cable connector assembly comprising: first and second
multiple cable disconnects electrically connected together, the
first and second multiple cable disconnects being identical and
hermaphroditic, the first and second multiple cable disconnects
being inverted 180.degree. relative to each other when coupled
together, each of the first and second multiple cable disconnects
comprising: a housing having a separable mating end and a wire
terminating end configured to receive wires of power cables, the
housing having a plurality of terminal chambers; terminals received
in corresponding terminal chambers, the terminals each having a
base, a mating contact extending from the base and a wire contact
extending from the base, the mating contact having a mating pad
defining a separable mating interface for the terminal for mating,
the wire contact having plural wire interfaces for mating with
plural wires such that plural wires are configured to be terminated
to and commoned with each terminal; and wire retention springs
received in the housing, each wire retention spring having at least
one spring arm defining a wire trap with the corresponding wire
contact, the spring arms being releasable to release the wires from
the housing.
19. The cable connector assembly of claim 18, wherein the housing,
at the separable mating end, includes plural contact holders and
plural hoods associated with corresponding contact holders and
covering such contact holders, the contact holders holding mating
contacts of corresponding terminals, the mating pads of the mating
contacts being exposed along the contact holders for mating with
the mating terminals of the mating connector, the contact holders
being separated by gaps, the hoods having side walls surrounding a
pocket, the side walls being aligned with the gaps, the pockets
being aligned with the contact holders; wherein the contact holders
of the first multiple cable disconnect are received in pockets of
the hoods of the second multiple cable disconnect; and wherein the
contact holders of the second multiple cable disconnect are
received in pockets of the hoods of the first multiple cable
disconnect.
20. A lighting system comprising: a lamp assembly having plural LED
arrays, each LED array being powered by a corresponding LED driver,
each LED driver having an associated power cable extending
therefrom; a cable connector assembly supplying power to the power
cables, the cable connector assembly comprising a first multiple
cable disconnect, wherein a plurality of the power cables are
terminated to the first multiple cable disconnect, the first
multiple cable disconnect comprising: a housing having a separable
mating end and a wire terminating end configured to receive wires
of the plurality of power cables, the housing having a plurality of
terminal chambers; terminals received in corresponding terminal
chambers, the terminals each having a base, a mating contact
extending from the base and a wire contact extending from the base,
the mating contact having a mating pad defining a separable mating
interface for the terminal for mating, the wire contact having
plural wire interfaces for mating with corresponding wires of
different power cables to electrically common corresponding wires
of the different power cables with the corresponding terminals; and
wire retention springs received in the housing, each wire retention
spring having at least one spring arm defining a wire trap with the
corresponding wire contact, the spring arms being releasable to
release the wires from the housing; wherein the cable connector
assembly comprises a second multiple cable disconnect identical to
the first multiple cable disconnect, the second multiple cable
disconnect being coupled to the first multiple cable disconnect,
the second multiple cable disconnect being configured to have a
power supply cable supply power to terminals of the second multiple
cable disconnect to electrically power the terminals of the first
multiple cable disconnect at separable interfaces between the
terminals of the second multiple cable disconnect and the terminals
of the first multiple cable disconnect.
Description
BACKGROUND OF THE INVENTION
[0001] The subject matter herein relates generally to multiple
cable disconnects.
[0002] Electrical systems, such as lighting systems, use power
cables to interconnect various electrical components of the system,
such as to connect a power supply to an LED driver. Some systems
require powering of multiple components, such as multiple LED
drivers. For example, in a street light fixture, multiple LED
arrays are provided to supply the required lighting. Each LED array
is controlled by a corresponding LED driver. Each LED driver needs
to be separately connected to the power supply. Typically, the line
input from the power supply is split from the 3 wire cable and
branched out to each of the LED drivers using a wire splice
component such as a wire nut. When connecting multiple branch
cables to the line input cable using the wire nut, difficulties
arise. For example, one or more of the wires may be improperly
terminated, leading to failure of the LED driver associated with
such wire. Termination using the wire nut may be time consuming and
bulky. Additionally, when one of the LED drivers fails and needs to
be replaced, it is not possible to simply remove the one LED driver
and associated cable. Rather, all of the wires are uncoupled from
the wire nut.
[0003] A need remains for a multiple cable disconnect solution that
allows wires of multiple power cables to be commoned and that
allows the wires to be releasable therefrom for rework.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In one embodiment, a multiple cable disconnect is provided
including a housing having a separable mating end for mating with a
mating connector and a wire terminating end configured to receive
wires of power cables. The housing has a plurality of terminal
chambers. Terminals are received in corresponding terminal
chambers. The terminals each have a base, a mating contact
extending from the base and a wire contact extending from the base.
The mating contact has a mating pad defining a separable mating
interface for the terminal for mating with a corresponding mating
terminal of the mating connector. The wire contact has plural wire
interfaces for mating with plural wires such that plural wires are
configured to be terminated to and commoned with each terminal.
Wire retention springs are received in the housing each having at
least one spring arm defining a wire trap with the corresponding
wire contact. The spring arms are releasable to release the wires
from the housing.
[0005] In another embodiment, a cable connector assembly is
provided having first and second multiple cable disconnects
electrically connected together. The first and second multiple
cable disconnects are identical and hermaphroditic and are inverted
180.degree. relative to each other when coupled together. Each of
the first and second multiple cable disconnects include a housing
having a separable mating end for mating with a mating connector
and a wire terminating end configured to receive wires of power
cables. The housing has a plurality of terminal chambers. Terminals
are received in corresponding terminal chambers. The terminals each
have a base, a mating contact extending from the base and a wire
contact extending from the base. The mating contact has a mating
pad defining a separable mating interface for the terminal for
mating with a corresponding mating terminal of the mating
connector. The wire contact has plural wire interfaces for mating
with plural wires such that plural wires are configured to be
terminated to and commoned with each terminal. Wire retention
springs are received in the housing each having at least one spring
arm defining a wire trap with the corresponding wire contact. The
spring arms are releasable to release the wires from the
housing.
[0006] In a further embodiment, a lighting system is provided
including a lamp assembly having plural LED arrays each being
powered by a corresponding LED driver having an associated power
cable extending therefrom. The lighting system includes a cable
connector assembly supplying power to the power cables. The cable
connector assembly includes first and second multiple cable
disconnects. A plurality of the power cables are terminated to the
first multiple cable disconnect. The first multiple cable
disconnect includes a housing having a separable mating end for
mating with a mating connector and a wire terminating end
configured to receive wires of power cables. The housing has a
plurality of terminal chambers. Terminals are received in
corresponding terminal chambers. The terminals each have a base, a
mating contact extending from the base and a wire contact extending
from the base. The mating contact has a mating pad defining a
separable mating interface for the terminal for mating with a
corresponding mating terminal of the mating connector. The wire
contact has plural wire interfaces for mating with plural wires
such that plural wires are configured to be terminated to and
commoned with each terminal. Wire retention springs are received in
the housing each having at least one spring arm defining a wire
trap with the corresponding wire contact. The spring arms are
releasable to release the wires from the housing. The second
multiple cable disconnect is identical to the first multiple cable
disconnect. The second multiple cable disconnect is coupled to the
first multiple cable disconnect. The second multiple cable
disconnect is configured to have a power supply cable supply power
to terminals of the second multiple cable disconnect to
electrically power the terminals of the first multiple cable
disconnect at separable interfaces between the terminals of the
second multiple cable disconnect and the terminals of the first
multiple cable disconnect.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates an electrical system formed in accordance
with an exemplary embodiment.
[0008] FIG. 2 illustrates the electrical system showing multiple
cable disconnects coupled together.
[0009] FIG. 3 illustrates the electrical system showing multiple
cable disconnects poised for mating.
[0010] FIG. 4 is an exploded view of one of the multiple cable
disconnects in accordance with an exemplary embodiment.
[0011] FIG. 5 is cross-sectional view of a portion of a cable
connector assembly of the electrical system showing multiple cable
disconnects coupled together.
[0012] FIG. 6 is a rear perspective view of the multiple cable
disconnect in an assembled stated.
[0013] FIG. 7 is a partial cross-sectional view of a portion of the
multiple cable disconnect showing a wire being poked in to the
multiple cable disconnect.
[0014] FIG. 8 is a partial cross-sectional view of a portion of the
multiple cable disconnect showing the wire terminated to the
multiple cable disconnect.
[0015] FIG. 9 is a partial cross-sectional view of a portion of the
multiple cable disconnect showing the wire being released from the
multiple cable disconnect.
[0016] FIG. 10 illustrates an electrical system formed in
accordance with an exemplary embodiment showing components thereof
poised for mating.
[0017] FIG. 11 illustrates the electrical system shown in FIG. 10
showing the components mated.
DETAILED DESCRIPTION OF THE INVENTION
[0018] FIG. 1 illustrates an electrical system 100 formed in
accordance with an exemplary embodiment. The electrical system 100
includes a cable connector assembly 102 used to electrically
connect one or more electrical components 104, 106. In an exemplary
embodiment, the cable connector assembly 102 is used to connect one
or more electrical components 104 with one or more electrical
components 106 using power cables 110, 112. The cable connector
assembly 102 includes multiple cable disconnects 120, 122 to
electrically connect the power cables 110 and the power cables 112.
In an exemplary embodiment, each power cable 110 includes a
plurality of wires 114, such as a hot wire, a neutral wire and a
ground wire. The power cables 110, 112 may include any number of
wires 114 and are not limited to 3 wire power cables as shown in
the illustrated embodiment. In the illustrated embodiment, one
power cable 110 is coupled to the multiple cable disconnect 120
while multiple power cables 112 are coupled to the multiple cable
disconnect 122. Any number of power cables 110, 112 may be coupled
to the multiple cable disconnects 120, 122. The multiple cable
disconnects 120, 122 are used to splice and/or common various power
cables 110, 112. In an exemplary embodiment, the multiple cable
disconnects 120, 122 are identical and hermaphroditic.
[0019] The electrical system 100 may be used in various
applications. For example, in an exemplary embodiment, the
electrical system 100 is a lighting system and may be referred to
hereinafter as lighting system 100. The lighting system 100
includes a lamp assembly 130 used as part of a lighting
application. For example, the lamp assembly 130 may be a street
light fixture or another type of lighting fixture. The electrical
system 100 is not limited to a lighting system. For example, the
electrical system 100 may be an HVAC unit where AC power enters the
unit and may be split by the multiple cable disconnect 120 to run
multiple devices of the unit, such as a fan, a control board, a
humidifier, and the like. The electrical system may be another
device, such as an appliance where AC power enters the appliance
(for example, a washing machine) and is then split by the multiple
cable disconnect to power other components, such as a motor, a
control board, and the like.
[0020] The lamp assembly 130 may include one or more lighting
devices, such as LED arrays 132. The LED arrays 132 are controlled
by LED drivers 134. The LED arrays 132 and LED drivers 134 define
various electrical components 106 of the electrical system 100 in
the illustrated embodiment. The power cables 112 are electrically
connected between the multiple cable disconnect 122 and the LED
drivers 134. The LED drivers 134 may include circuit boards or
other components. Optionally, the LED arrays 132 and LED drivers
134 may be part of a common circuit board. Alternatively, other
cables or wires may extend between the LED drivers 134 and the LED
arrays 132.
[0021] The lighting system 100 may be powered by a power supply
136. For example, the power cable 110 may be electrically connected
between the power supply 136 and the multiple cable disconnect 120.
The power supply 136 may be an AC power supply, such as from a
circuit breaker. The power supply 136 may define one of the
electrical components 104. The multiple cable disconnects 120, 122
may splice the power from the power supply 136 into multiple lines
to multiple LED drivers 134.
[0022] Other electrical components 104, 106 may be provided in the
lighting system 100 in alternative embodiments. Optionally, other
power cables 110 may be electrically connected to the multiple
cable disconnect 120. For example, other power cables 110 may
extend from the multiple cable disconnect 120 to an LED driver or
other electrical component. As such, the multiple cable disconnect
120 may operate as a splicer or pigtail connector.
[0023] FIG. 2 illustrates the lighting system 100 showing the
multiple cable disconnects 120, 122 coupled together. FIG. 3
illustrates the lighting system 100 showing the multiple cable
disconnects 120, 122 poised for mating. The multiple cable
disconnects 120, 122 are coupled together to electrical connect the
power cables 110, 112 and thus the electrical components 104, 106
(shown in FIG. 1).
[0024] In an exemplary embodiment, the multiple cable disconnects
120, 122 are hermaphroditic and oriented 180 degrees relative to
each other for coupling thereto. In the description below,
components or features may be described with respect to the
multiple cable disconnect 120 or the multiple cable disconnect 122,
however such components or features may be applicable to the other
multiple cable disconnect 120, 122.
[0025] The multiple cable disconnect 120 includes a housing 140
having a separable mating end 142 for mating with a mating
connector, such as the multiple cable disconnect 122. The housing
140 has a wire terminating end 144 configured to receive the wires
114 of the one or more power cables 110. Terminals 150 (FIG. 3) are
received in and held by the housing 140. The wires 114 of the power
cables 110 are configured to be electrically connected to the
terminals 150, such as at the wire terminating end 144. The
terminals 150 are configured to be electrically connected to mating
terminals 150 of the multiple cable disconnect 122.
[0026] In an exemplary embodiment, the multiple cable disconnect
120 includes a latch 152 extending from a first end 154 of the
housing 140 at or near the separable mating end 142. The housing
140 includes a catch 156 extending from a second end 158 opposite
the first end 154 at or near the separable mating end 142. In the
illustrated embodiment, the first end 154 defines a bottom end of
the multiple cable disconnect 120 and the second end 158 defines a
top end of the multiple cable disconnect 120, while the first end
154 defines a top end of the second multiple cable disconnect 122
and the second end 158 defines a bottom end of the second multiple
cable disconnect 122. Optionally, the latch 152 may include a latch
release 160 for releasing the latch 152 from the catch 156 of the
multiple cable disconnect 122. The latch 152 is deflectable to
release and uncouple the multiple cable disconnects 120, 122. The
latch 152 may have a ramped lead-in surface to guide mating of the
latch 152 with the catch 156 of the other multiple cable disconnect
122.
[0027] Optionally, the multiple cable disconnect 120 may have
keying features 162, 164 for keyed mating of the multiple cable
disconnect 120 with the multiple cable disconnect 122. For example,
in the illustrated embodiment, the keying feature 162 is a slot and
the keying feature 164 is a tab or protrusion configured to be
received in the keying feature 162. Other types of keying features
may be provided in alternative embodiments. Other multiple cable
disconnects may have keying features in other locations for keyed
mating with the corresponding multiple cable disconnect.
[0028] FIG. 4 is an exploded view of the multiple cable disconnect
120 in accordance with an exemplary embodiment. The multiple cable
disconnect 120 includes the housing 140 holding the terminals 150.
In an exemplary embodiment, the housing 140 is a multi-piece
housing including a front housing 170 at the separable mating end
142 and a wire holder 172 at the wire terminating end 144. The
front housing 170 and the wire holder 172 are separate components
configured to be coupled together. Optionally, the front housing
170 and wire holder 172 may be dielectric components, such as
plastic components, which may be molded, such as by injection
molding.
[0029] The front housing 170 has a plurality of terminal chambers
174 that receive corresponding terminals 150. The terminal chambers
174 may be open at the rear end of the front housing 170 and the
terminals 150 may be loaded into the terminal chambers 174 through
the open rear end. Separating walls 176 separate the terminal
chambers 174. The separating walls 176 may electrically isolate the
terminals 150 from each other. The separating walls 176 may define
a mounting structure for the terminals 150 to mount and secure the
terminals 150 in the front housing 170.
[0030] The wire holder 172 includes a base 180 that may be coupled
to the front housing 170. The wire holder 172 includes a plurality
of wire bores 182 extending therethough. The wire bores 182 are
configured to receive corresponding wires 114 and may guide the
wires 114 into electrical connection with the corresponding
terminals 150 when the wires 114 are poked in to the wire bores
182.
[0031] The terminals 150 each have a base 200, a mating contact 202
extending from the base 200 and a wire contact 204 extending from
the base 200 opposite the mating contact 202. In the illustrated
embodiment, the mating contact 202 is oriented generally
horizontally extending forward of the base 200. The mating contact
202 has a mating pad 206 defining a separable mating interface 208
for the terminal 150 for mating with the corresponding mating
terminal 150 of the multiple cable disconnect 122 (shown in FIG.
3). The mating contact 202 includes a spring arm 210 for supporting
and spring biasing the mating pad 206 against the mating terminal
150 of the second multiple cable disconnect 122 when mated thereto.
The spring arm 210 may be provided at a distal end of the mating
contact 202. Optionally, the mating pad 206 may be generally
planar. Alternatively, the mating pad 206 may be curved or
arched.
[0032] The wire contact 204 has plural wire interfaces 212 for
mating with plural wires 114 of different power cables 110, 112
such that plural wires 114 are configured to be terminated to and
commoned with each terminal 150. Optionally, the wire contact 204
may include one or more tabs 214, each defining one or more wire
interfaces 212. Optionally, the tabs 214 may be bent in different
directions. In the illustrated embodiment, the tabs 214 of the wire
contacts 204 are oriented vertically and are configured to be
loaded into corresponding terminal chambers 174 for mating with the
wires 114. As such, the wire contacts 204 of the terminals 150 are
arranged vertically and are stacked within the housing 140. Each
terminal 150 is configured to be electrically connected to a
different wire 114 of each of the power cables 110 (or 112) poked
in to the wire terminating end 144 of the housing 140. The wire
interfaces 212 are arranged at different vertical heights along the
wire contact 204 for electrical connection to different wires 114
of different power cables 110 (or 112). For example, the wire
interfaces 212 may be aligned with corresponding wire bores 182 at
different vertical heights along the wire contact 204.
[0033] In an exemplary embodiment, the multiple cable disconnect
120 includes wire retention springs 220 configured to be received
in the front housing 170. The wire retention spring 220 are used in
association with corresponding terminals 150. The wire retention
springs 220 and the terminals 150 define wire traps for trapping
corresponding wires 114 in the multiple cable disconnect 120. For
example, the wires 114 may be poked in to corresponding wire bores
182 and pinched or sandwiched between the wire retention spring 220
and the corresponding terminal 150 to create an electrical
connection between the wire 114 and the terminal 150.
[0034] In the illustrated embodiment, the wire retention spring 220
is a separate component from the terminal 150 and includes a base
222 and one or more spring arms 224. Alternatively, the wire
retention spring 220 may be integral with the terminal 150, such as
being stamped and formed from the terminal 150. In the illustrated
embodiment, each wire retention spring 220 includes a plurality of
spring arms 224, with each spring arm 224 being associated with a
corresponding wire bore 182 and configured to receive a different
wire 114. Alternatively, multiple wire retention springs may be
provided and associated with each terminal 150, where each wire
retention spring includes a single spring arm. Having the wire
retentions springs 220 separate from the terminal 150 allows the
wire retention spring 220 to be manufactured from a different type
of material as compared to the terminal 150. For example, the
terminal 150 may be manufactured from a material having
characteristics of good electrical conductivity, such as copper,
whereas the wire retention spring 220 may be manufactured from a
material having a characteristic of good mechanical integrity or
spring force, such as stainless steel. The spring arms 224 include
edges 226 that are used to pinch the wire 114 and hold the wire 114
in the multiple cable disconnect 120. A wire trap may be defined
between the edge 226 of the spring arm 224 and the wire interface
212 of the wire contact 204.
[0035] With additional reference back to FIG. 3, the housing 140,
at the separable mating end 142, includes plural contact holders
240 and plural hoods 242 associated with corresponding contacts
holders 240. The contact holders 240 and the hoods 242 define a
hermaphroditic mating interface of the multiple cable disconnect
120. The hoods 242 cover the contact holders 240. The contact
holders 240 hold mating contacts 202 of corresponding terminals 150
such that the mating pads 206 are exposed along a portion of the
contact holder 240 for mating with the mating terminals 150 of the
second multiple cable disconnect 122.
[0036] The contact holders 240 each have a front end 244, sides
246, 248 extending rearward from the front end 244, an outer end
250 extending rearward from the front end 244 between the sides
246, 248 and an inner end 252 opposite the outer end 250. The inner
end 252 faces the corresponding hood 242. The inner end 252 may
have an opening and the mating pad 206 may be exposed within the
opening at the inner end 252. Gaps 254 are provided between
adjacent contact holders 240. The sides 246, 248 face each other
across the gaps 254.
[0037] The hoods 242 have a plurality of walls defining pockets
260. The pockets 260 are sized, shaped, and positioned to receive
the contact holders 240 of the second multiple cable disconnect 122
when the multiple cable disconnects 120, 122 are coupled together.
For example, the pockets 260 may have a volume slightly larger than
a volume of the contact holders 240 (e.g. height, length, width).
The pocket 260 is defined by side walls 262 extending rearward from
a front end 264 of the hood 242. The hood 242 has an outer end 266
extending between the side walls 262 opposite the contact holder
240. The hood 242 is open along the inner end to expose the mating
contact 202. In an exemplary embodiment, the side walls 262 are
aligned with the gaps 254 and the contact holder 240 are aligned
with the pockets 260. For example, in the illustrated embodiment,
the contact holders 240 are positioned below the pockets 260 of the
corresponding hoods 242.
[0038] The second multiple cable disconnect 122 is inverted 180
degrees such that the contact holders 240 of the second multiple
cable disconnect 122 are positioned above the hoods 242 and
corresponding pockets 260. When the second multiple cable
disconnect 122 is coupled to the first multiple cable disconnect
120, the pockets 260 of the hoods 242 receive corresponding contact
holders 240 and the mating contacts 202 of the terminals 150 are
electrically connected together.
[0039] The multiple cable disconnects 120, 122 have a
hermaphroditic mating interface defined by the contact holders 240
and the hoods 242. Optionally, the contact holders 240 and the
hoods 242 at the front ends 244, 264 may be chamfered or have
lead-in surfaces for guiding mating of the multiple cable
disconnects 120, 122. The keying features 162, 164 are provided on
the hoods 242 and contact holder 240 respectively.
[0040] FIG. 5 is cross-sectional view of a portion of the cable
connector assembly 102 showing the multiple cable disconnects 120,
122 coupled together. The terminals 150 are received in
corresponding terminal chambers 174. The terminal chambers 174
extend at least partially through the contact holders 240 and the
mating contacts 202 are exposed at front ends of the terminal
chambers 174. The front ends 244 of the contact holders 240 are
positioned forward of the mating contacts 202.
[0041] The spring arms 210 of the mating contacts 202 engage the
contact holders 240 to spring bias the mating pads 206 outward
toward each other to spring bias the terminals 150 of the multiple
cable disconnects 120, 122 into electrical engagement with each
other. Optionally, the spring arms 210 may be at least partially
compressed or deflected when mated to ensure that the mating pads
206 are spring biased against each other.
[0042] FIG. 6 is a rear perspective view of the multiple cable
disconnect 120 in an assembled stated. The wire holder 172 is
coupled to the front housing 170 and the wire bores 182 are
configured to receive corresponding wires 114 (shown in FIG. 2). In
the illustrated embodiment, the wire bores 182 are arranged in rows
and columns. Each row of wire bores 182 is configured to receive
the wires 114 of a corresponding power cable 110 (or 112).
Optionally, the wire bores 182 may be color coded to indicate which
wire 114 is supposed to be plugged into which wire bore 182. For
example, the left wire bore 182 of each row may be configured to
receive a neutral wire, the middle wire bore 182 of each row may be
configured to receive a ground wire and the right wire bore 182 of
each row may be configured to receive a hot or power wire. The wire
bores 182 in each column are all configured to receive the same
type of wire, such that the same types of wires are each commoned
to the same terminal 150. For example, all of the grounding wires
are all commoned to the same terminal, all neutral wires are all
commoned to the same terminal and all hot wires are commoned to the
same terminal. Any number of rows of wire bores 182 may be provided
depending on the number of power cables that the multiple cable
disconnect 120 is used to electrically common. In the illustrated
embodiment, the multiple cable disconnect 120 is used to common up
to three power cables.
[0043] In an exemplary embodiment, the wires 114 are releasable
from the multiple cable disconnect 120, such as to rework or rewire
the multiple cable disconnect 120. In an exemplary embodiment, the
wire holder 172 includes wire release slots 270 that may receive a
tool to release the wires 114 from the wire bores 182 and the wire
traps inside the multiple cable disconnect 120. Optionally, each
wire 114 may be individually released, and as such, some of the
wires 114 may be unreleased while other wires 114 are released for
rework or rewiring.
[0044] FIG. 7-9 are partial cross-sectional views of a portion of
the multiple cable disconnect 120. FIG. 7 illustrates the wires 114
being poked into the multiple cable disconnect 120. FIG. 8
illustrates the wire 114 terminated to the multiple cable
disconnect 120. FIG. 9 illustrates the wire 114 being released from
the multiple cable disconnect 120.
[0045] The wire 114 is prepared for connection to the multiple
cable disconnect 120 by stripping the end of the wire and removing
a portion of a jacket 280 of the wire 114 to expose a conductor 282
of the wire 114. The conductor 282 may be a solid conductor or may
be a stranded conductor. The wire bore 182 is sized to receive the
conductor 282 and may be sized to receive the jacket 280. The wire
bore 182 may include a wire guide 290 for guiding the wire 114 into
the multiple cable disconnect 120.
[0046] The wire 114 is loaded into the wire bore 182 (FIG. 7) such
that the conductor 282 is poked into a wire trap 292 defined
between the wire retention spring 220 and the wire contact 204. The
wire retention spring 220 is held in the front housing 170, such as
in a slot 294 and the spring arm 224 extends toward the wire
interface 212 of the wire contact 204. When the wire 114 is poked
into the wire trap 292, (FIG. 8) the spring arm 210 may be at least
partially deflected away from the wire contact 204. The edge 226 of
the spring arm 224 engages and presses against the conductor 282 to
hold the wire 114 in the multiple cable disconnect 120. The
conductor 282 is forced against the wire interface 212 of the wire
contact 204 by the spring arm 210 to create an electrical
connection between the conductor 282 and the terminal 150.
[0047] The wire 114 may be released (FIG. 9) from the multiple
cable disconnect 120 by releasing the spring arm 210 from the
conductor 282. A tool 296 is used to release the spring arm 210.
The tool 296 is loaded through the wire release slot 270 and
engages the spring arm 210 to force the spring arm 210 away from
the conductor 282. In an exemplary embodiment, the front housing
170 includes an overstress feature 298 adjacent the spring arm 210
to limit release of the spring arm 210 and thus prevent overstress
of the spring arm 210 (e.g. plastic deformation). After the wire
114 is removed from the multiple cable disconnect 120, the spring
arm 210 may be released and returned to the normal position (shown
in FIG. 7).
[0048] FIG. 10 illustrates an electrical system 300 formed in
accordance with an exemplary embodiment showing the components
thereof poised for mating. FIG. 11 illustrates the electrical
system 300 showing the components mated. The electrical system 300
includes an electrical connector 302 mounted to a circuit board 304
within a chassis 306. The circuit board 304 may be an LED driver or
another electrical component. The multiple cable disconnect 120 is
configured to be electrically connected to the electrical connector
302. The electrical connector 302 includes a mating interface
similar to the multiple cable disconnect 122, including contact
holders 308 and hoods 310. The electrical connector 302 includes
terminals (not shown) configured to be electrically connected to
the circuit board 304, such as by soldering, through-hole mounting,
or by other processes. Power may be supplied to the electrical
connector 302 by the power cable 110. Other power cables may extend
from the multiple cable disconnect 120 to other components, such as
other LED drivers. In other embodiments, power may be supplied to
the multiple cable disconnect 120 from the circuit board through
the electrical connector 302.
[0049] It is to be understood that the above description is
intended to be illustrative, and not restrictive. For example, the
above-described embodiments (and/or aspects thereof) may be used in
combination with each other. In addition, many modifications may be
made to adapt a particular situation or material to the teachings
of the invention without departing from its scope. Dimensions,
types of materials, orientations of the various components, and the
number and positions of the various components described herein are
intended to define parameters of certain embodiments, and are by no
means limiting and are merely exemplary embodiments. Many other
embodiments and modifications within the spirit and scope of the
claims will be apparent to those of skill in the art upon reviewing
the above description. The scope of the invention should,
therefore, be determined with reference to the appended claims,
along with the full scope of equivalents to which such claims are
entitled. In the appended claims, the terms "including" and "in
which" are used as the plain-English equivalents of the respective
terms "comprising" and "wherein." Moreover, in the following
claims, the terms "first," "second," and "third," etc. are used
merely as labels, and are not intended to impose numerical
requirements on their objects. Further, the limitations of the
following claims are not written in means-plus-function format and
are not intended to be interpreted based on 35 U.S.C. .sctn.112(f),
unless and until such claim limitations expressly use the phrase
"means for" followed by a statement of function void of further
structure.
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