U.S. patent number 3,585,571 [Application Number 04/818,922] was granted by the patent office on 1971-06-15 for electric wire connector with insulation piercing means.
Invention is credited to Raymond G. Davis, Jacob H. Fonda.
United States Patent |
3,585,571 |
Davis , et al. |
June 15, 1971 |
ELECTRIC WIRE CONNECTOR WITH INSULATION PIERCING MEANS
Abstract
A device for electrically connecting a pair of main supply wires
to a pair of lateral branch wires without stripping insulation from
the main wires. A block of insulating material has two parallel
grooves which receive the main wires and their insulating covering.
Adjacent each main wire is a bore extending radially with respect
to the main wire, the bore containing a sharp pointed metallic
conducting element. The bore containing the pointed metallic
element intersects a lateral bore into which the stripped end of
the branch wire is placed. A screw of insulating material bears
against the stripped end of the lateral wire, presses it tightly
against the butt end of the pointed metallic element and drives the
point thereof through the insulation covering of the main wire, to
make contact with the metallic conductor therein.
Inventors: |
Davis; Raymond G. (Canandaigua,
NY), Fonda; Jacob H. (Canandaigua, NY) |
Family
ID: |
25226763 |
Appl.
No.: |
04/818,922 |
Filed: |
April 24, 1969 |
Current U.S.
Class: |
439/416 |
Current CPC
Class: |
H01R
4/2483 (20130101) |
Current International
Class: |
H01R
4/24 (20060101); H01r 007/12 (); H01r 011/20 () |
Field of
Search: |
;339/97--99,116,272 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Calvert; Ian A.
Claims
What is claimed is:
1. An electric wire connector for connecting a branch wire to an
insulated main wire without requiring insulation to be prestripped
from the main wire, said connector comprising a body having a
groove for receiving the main wire with insulation thereon, a first
bore spaced from and extending crosswise with respect to said
groove, said bore being adapted to receive an end of a branch wire
with insulation stripped from a portion thereof, a second bore
intersecting said first bore and opening externally of said body
and also opening into said groove at a location aligned with a main
wire therein, said second bore having screw threads therein, a
metallic conductor element located in said second bore between said
groove and said first bore, said element having a sharp point at
the end thereof toward said groove, and a screw of insulating
material located in said second bore on the opposite side of said
first bore from said groove, said screw engaging said threads in
said second bore, so that when said screw is screwed into said
second bore with a stripped portion of a branch wire interposed
between said screw and said conductor element, said screw will
press said stripped portion tightly against said element and will
press the point of said element into and through insulation on a
main wire located in said groove to make electric contact with a
conductor within said insulation.
2. A construction as defined in claim 1, wherein said body has two
grooves for receiving two main wires extending parallel to each
other adjacent opposite sides of the body, and wherein there is a
first bore, second bore, conductor element, and screw in separate
cooperative relationship to each groove, respectively.
3. A construction as defined in claim 1, wherein said body is of
insulating material.
4. A construction as defined in claim 1, wherein said body is of
molded plastic.
5. A construction as defined in claim 1, wherein said body is of
transparent material.
6. A construction as defined in claim 1, wherein an outer portion
of said first bore is of sufficient diameter to receive a branch
wire with normal insulation thereon, and an inner portion of said
first bore, in the vicinity of said second bore, is too small to
receive a branch wire with normal insulation thereon but will a
portion of the branch wire from which insulation has been
stripped.
7. A construction as defined in claim 1, wherein said groove has a
depression in which the main wire may become seated so as to resist
accidental lateral displacement of the main wire while the point of
said element is being forced into it.
Description
BACKGROUND OF THE INVENTION
In the installation, for example, of a long series of fluorescent
light fixtures along a ceiling, it is customary to run a pair of
main supply wires along the line of lighting fixtures, and to tap
off of the pair of main wires at each individual fluorescent unit,
with lateral branch wires to supply current to the individual unit.
These lateral branch wires are commonly called ballast wires, since
they usually lead from supply wires to the so-called ballast of the
individual fluorescent lighting unit. In modern large office
buildings, there are frequently thousands of fluorescent lighting
units to be installed. Conventional methods of making the
electrical connections between the main supply wires and the
lateral branches or ballast wires of each unit are fussy, awkward,
and time-consuming, usually involving cutting the main wires,
stripping the ends, and connecting the ends of two main wires and
one ballast wire to each other by means of a "wire nut," on each
side of the circuit at each of the lighting fixtures being
installed. Although various types of special connectors for
connecting a branch wire to a main wire without stripping the main
wire are known in the art, they are difficult or inconvenient to
use for one reason or another, and the known forms of special
connectors have not gone into any widespread use.
An object of the present invention is the provision of a connecting
device for connecting a pair of branch or ballast wires to a pair
of main supply wires in such an easy and simple manner as to
overcome the reluctance of electricians to use connectors of the
forms previously available, and to provide a connecting device so
designed that the necessary connections can be made in an extremely
rapid and convenient manner, saving a substantial amount of time in
making each connection as compared with the time previously
required. When perhaps thousands of connections are to be made in a
large installation, the saving of even a fraction of a minute in
making each connection should result in the saving of a large
amount of time and expense for the entire installation.
Another object is the provision of a connector of the type
requiring no stripping of the main supply wires, so designed that
it can be easily and inexpensively manufactured, that the
electrical connection is reliably made from the standpoint of good
conductivity from each main supply wire to the associated lateral
branch or ballast wire, and that all electrically charged parts are
adequately enclosed within insulating material, with no danger of
shock or short circuits.
BRIEF DESCRIPTION OF THE DRAWING
In the accompanying drawing, incorporated herein by reference and
constituting a material part of the disclosure and relating to an
exemplary embodiment of the invention:
FIG. 1 is a top plan view of a connector in accordance with a
preferred embodiment of the invention;
FIG. 2 is a bottom plan view thereof;
FIG. 3 is a section taken approximately on the line 3-3 of FIGS. 1
and 2; and FIG. 4 is a side elevation of the connector.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The main body of the connector comprises a block 11 of insulating
material, having therein two grooves or notches 13 arranged
parallel to each other and running along opposite sides of the
block 11. These grooves 13 receive the main supply wires or
conductors, one of which is shown at 15, and has an insulating
covering 17 surrounding the metallic conductor. The width of the
groove 13, opening out to one side of the block 11, is sufficiently
great to receive the wire 15, 17 in its original state, that is,
without removal of the insulating covering. At the inner edge of
each groove 13, the thickness of the groove is slightly enlarged by
a rounded depression 19 extending longitudinally of the groove, to
form a seat for the main wire, as will be readily understood from
FIG. 3.
Extending inwardly from each of two opposite side faces of the
block 11, is a bore for receiving the end of the ballast wire or
other branch wire which is to be electrically connected to the main
wire. This bore extends in a direction at approximately a right
angle to the direction of the main wire, and has an outer portion
21 of sufficient diameter to receive the branch wire 25 with
insulation thereon, and an inner portion 23 of smaller diameter,
sufficient only to receive an end portion 27 of the branch wire
with the insulation stripped or removed therefrom.
In each lateral half of the block there is still another bore
indicated in general at 31, intersecting the bore 21, 23 and being
perpendicular to this bore 21, 23 as well as perpendicular to the
longitudinal length of the groove 13, and aligned with the hollowed
or rounded part 19 of the groove 13, as readily apparent from FIG.
3. The inner end portion of this bore 31, that is, the end which
opens into the groove 13, is of smaller diameter as shown at 32,
and fits rather snugly around a cylindrical shank portion 33 of a
metalic pin or plunger having a sharp pointed end 34. The pin also
has an enlarged cylindrical head 35 which fits snugly and slidably
in the larger diameter portion of the bore 31.
The outer portion of the length of the bore 31 is tapped to provide
internal screw threads to engage the threads of a screw 41. In the
preferred form of construction, the screw 41 is made of insulating
material, such as a tough strong form of plastic, and has at its
outer end either a screw driver slot, or a polygonal head 42, or
preferably both, so that it may be turned either by a screw driver
or by a small wrench. For some distance inwardly from the head, the
screw is threaded at 43 to fit the threads of the outer portion of
the bore 31. Inwardly of the threads 43, a smooth shank portion 44
is of somewhat smaller diameter than the bore 31, sufficiently
smaller so that there is room for a stripped portion of the branch
wire (ballast wire) between the smooth shank 44 and the surrounding
wall of the bore 31.
In using this device, the two main supply wires are placed in the
two grooves 13 on opposite sides of the body 11, and it is not
necessary to take time to strip any insulation from these main
wires. The width of each groove 13 will just snugly receive the
wire 15 with insulation 17 thereon, it being intended to provide a
separate size of connector for each separate size of main wire.
Insulation is stripped from a short length at the extreme end of
each ballast wire or other branch wire which is to be connected to
a main wire, it being necessary to strip only a very short length
of the branch wire, say about a quarter of an inch or three-eights
of an inch, much less length than would be necessary if the branch
wire were to be wrapped around a stripped portion of the main wire,
according to one form of connection commonly used heretofore, and
less than necessary when using wire nuts according to another
commonly used from of connection. In some cases, the ends of the
ballast wires may come from the factory already stripped to the
required extent.
The end of the branch wire is inserted in the lateral bore 21, 23
so that the still insulated part 25 of the branch wire enters the
larger diameter portion 21 of the lateral bore, and the stripped
portion 27 of the branch wire enters the smaller diameter portion
23 of the bore. At this time the screw 41 is in its outer position;
that is, partially unscrewed so that it does not obstruct the
entrance of the branch wire into the bore portion 23, as seen at
the right side of FIG. 3. It is advisable, at this time, to have
the block 11 upside down as compared with the position shown in
FIG. 3, with the screws at the top rather than the bottom, so that
gravity will hold the sharp point 34 of the metal plunger against
the associated main wire, and the butt end or head 35 of the
plunger will not obstruct entrance of the branch wire into its
bore.
The screw 41 is now tightened. The end of the smooth shank portion
44 presses the stripped part 27 of the branch wire tightly against
the butt end or head 35 of the metallic pin, and drives the pointed
end 34 through the insulating covering 17 on the main wire and
makes contact with the conductor 15 within the insulation. During
the travel necessary to penetrate the insulation 17 and drive the
point 34 firmly into the metallic conductor 15, the end of the
shank 44 will advance somewhat beyond the location of the lateral
bores 21, 23, but this is possible because of the somewhat smaller
diameter of the shank 44 as compared with the diameter of the bore
31. As seen at the left side of FIG. 3, where the parts are in the
final "home" or fully connected position, the bare or stripped
portion 27 of the branch wire can extend longitudinally along one
side of the shank 44 and across the end thereof and down the other
side of the shank 44.
This completes the connection of one branch wire to its main wire,
and it can be done in less time than it takes to describe it,
particularly if the ends of the branch wires have previously been
stripped to the required extent, or if they come from the factory
already stripped. Of course two connections are made with each
device, one branch wire to one main wire, and a second branch wire
to the second main wire. Upon tightening the respective screws 41,
the connections are complete, and nothing remains to be done.
Because the screws 41 are of insulating material, the fact that the
outer ends of these screws are exposed does not create any hazard.
The device does not have to be wrapped with insulating tape after
the connections are completed.
It will be noted that this device comes from the manufacturer ready
for use and all parts assembled. It is not necessary to take it
apart in order to insert the wires and make the connections. In
some of the connectors previously proposed, there are two mating
parts which have to be separated from each other, then the wires
(either the main wires or the branch wires or both) have to be
inserted between the two separated parts, and then the parts have
to be fastened together again, by screws or bolts or other means.
This is very time consuming. In the present construction, nothing
has to be taken apart, and there are no separate parts to be lost
or mislaid. Each connector constitutes a single unit, assembled at
the factory and reaching the ultimate user in complete condition
ready for use. The electrician making the connections merely places
the two main wires in the respective grooves 13, inserts the ends
of the branch wires in the bores 21, 23, and tightens the two
screws 41. That is all there is to it.
It has been mentioned above that the main body or block 11 is of
insulating material. It may be molded of porcelain, or hard rubber,
or any other insulating material capable of being molded to the
desired shape. Preferably it is molded from any one of the modern
plastics which have high dielectric strength as well as high
mechanical strength. Several such materials are known.
Conveniently, the plastic used is a transparent plastic, having the
advantage that the user can look through the block to make sure
that the end of the ballast wire is in proper relation to the
screw, before the screw is tightened, but this feature of
transparency is not essential. It will be noted that the depression
19 in the groove 13 holds the main wire against accidental lateral
displacement when the sharp pointed metallic connector element 33
is thrust into the insulation of the main wire.
* * * * *