Connector With Lining For Guiding Conductor Into Same

Abstract

There is provided a connector for insulated electrical conductors formed of a plurality of coaxially telescopically disposed sleeves. An inner sleeve formed of electrically conductive material has spaced apart inwardly extending perforations on its inner surface defining insulating piercing and wire engaging protuberances or tines. An outer jacket or sleeve of electrically insulating material is provided. An inner lining is provided within the inner sleeve for guiding insulated electrical conductors past the protuberances of the sleeve. Deformation of the inner sleeve by pressure applied to the outside of the jacket forces the protuberances through the lining and through the insulation on the conductors so as to engage the metallic portion of the conductor and to make electrical contact therewith.

Parent Case Text

This application is a continuation of my application Ser. No. 230,566, filed Mar. 1, 1972, now abandoned which application Ser. No. 230,566 is a continuation-in-part of my application Ser. No. 114,954, filed Feb. 12, 1971, now abandoned.

Description

This invention relates to the assembly and joining of electrical conductors or wires and more particularly to the assembly and joining of electrical conductors with a solderless insulated connector without removing the insulation therefrom.

Solderless electrical connectors for insulated electrical conductors are known wherein there is provided a plurality of coaxially telescopically disposed sleeves including an inner sleeve of electrically conductive material and an outer jacket of electrically insulating material. The inner sleeve is provided on its inner surface with spaced apart perforations defining inwardly extending insulating piercing and wire engaging tines or protuberances. In one particular embodiment thereof the inner liner is formed of relatively hard spring-like material encased within an intermediate sleeve of relatively soft material. A plurality of insulated electrical conductors or wires may be inserted within the inner sleeve portioned in the central bore thereof and having their end portions confined and embraced by the protuberances on the inner sleeve and establishing electrical contact with the metallic portion of the wires when the connector is deformed by pressure applied by the outside thereof. A crushing action is thereby exerted on the inner sleeve forcing the protuberances through the insulation on the wires and causing the protuberances to engage the metallic conducting portion of the wire with sliding or biting action. One such connector is more fully described and illustrated in U.S. Pat. No. 3,064,072 granted Nov. 13, 1962 to Graff et al.

Connectors of this type are used by the millions and automatic machinery has been provided for feeding and deforming the connectors in an assembly operation. However, heretofore difficulty has been experienced in that upon insertion of the wires into the inner sleeve, the wires may hang-up on the inwardly projected protuberances, and although an operator may play the wires free of the protuberances during assembly thereof, there is no assurance that the wires have bottomed, or been fully received within the connector, and moreover such playing of the wires past the protuberances is time consuming.

Accordingly an object of the present invention is the provision of an improved connector which overcomes the above mentioned difficulties.

Another object of the present invention is the provision of an improved electrical connector of the type described including an inner sleeve having inwardly projecting protuberances wherein wires inserted in the sleeve will not hang-up on the protuberances.

Yet another object of the present invention is the provision of a new and improved electrical connector.

Another object of the present invention is the provision of a new and improved method of joining a plurality of insulated electrical conductors.

Still another object of the present invention is the provision of a new and improved method of assembling a plurality of insulated electrical conductors into a connector of the type having inwardly projecting protuberances.

Still another object of the present invention is the provision of a new and improved method of assembling an electrical connector.

In accordance with these and other objects there is provided an improvement in an electrical connector of the type described above wherein an inner lining is provided within an inner sleeve of the connector for guiding the wires past the protuberances. Deformation of the inner sleeve by pressure applied to the outside of the connector forces the protuberances through the lining and through the insulation of the wires so as to engage a metallic portion of the wires to make electrical contact therewith.

Advantageously, the inner lining may be formed of a strip or ribbon of film of any suitable material such as of thermoplastic resin, for example, polypropylene or polyester, vinyl resins, and the like. One suitable strip has been found to be a film of polypropylene 0.001 inches thick and 0.170 inches wide. When such film is folded through the open end of the connector in a generally U-shape, the edges of the ribbon of film will generally overlap forming a substantially closed receptacle for receiving and guiding the wires past the protuberances of the sleeve. The ends of the film strip may be secured adjacent the open end of the connector in any suitable manner, such as, fusing therewith by ultrosonic vibrations; suitable adhesive such as, silicone adhesive; or by bringing the ends of the film strip out of the connector, folding them over the edge of the connector, and securing them in place by a ring, band or other suitable means.

The invention will be more clearly understood from the following detailed description when read in connection with the accompanying drawings, in which:

FIG. 1 is an exploded perspective view of the new and improved connector according to the present invention;

FIG. 2 is a cross-sectional view of the connector of FIG. 1, taken along line 2--2 of FIG. 1;

FIG. 3 is a cross-sectional view of the connector of FIG. 1, taken along line 3--3 of FIG. 1;

FIG. 4 is a cross-sectional view of the connector of FIG. 1, taken along line 4--4 of FIG. 2;

FIG. 5 is a cross-sectional view of the connector of FIG. 1, illustrated in its squeezed position making contact with electrical wires;

FIG. 6 is an exploded perspective view of another embodiment of the new and improved connector according to the present invention.

FIG. 7 is a cross-sectional view of the connector of FIG. 6, taken along line 7--7 of FIG. 6;

FIG. 8 is a cross-sectional view of the connector of FIG. 6, taken along line 8--8 of FIG. 6, illustrating the guiding of the insulated electrical conductors past the protuberances;

FIG. 9 is a cross-sectional view of the connector of FIG. 6, taken along line 10--10 of FIG. 7; and

FIG. 10 is an exploded perspective view of the connector of FIG. 6, illustrating assembly thereof.

Referring now to the drawings and particularly to the embodiment of FIGS. 1 through 5 there is illustrated a connector 10 according to the present invention and including a plurality of coaxially telescopically disposed sleeves, including an inner sleeve 11 of relatively hard spring-like electrically conductive material, an intermediate sleeve 12 of soft deformable material, and an outer jacket or sleeve 13 of suitable electrically insulating material.

The inner sleeve 11 is comparatively thin with respect to the intermediate sleeve 12, and is constructed of hard spring-like electrically conductive material such as, spring-tempered phosphor bronze and is provided on its inner surface with a plurality of inturned perforations 16 which provide protuberances or tines 17. These protuberances may be spaced on the inner sleeve in any suitable manner. The configuration of the perforations 16 and the resulting protuberances 17 is such that a plurality of curved upstanding knife-like edges are provided for each perforation. The intermediate sleeve 12 is formed of a soft, permanently deformable material, such as, annealed brass, and closed at its lower end.

The outer jacket 13 is formed of a suitable electrically insulating material, such as, a heat shrinkable thermoplastic material, and is heat shrunk at one end 13a during the heat curing process of the jacket to form a reduced neck. The other end of the outer jacket 13 is open, as at 13b, to provide for the insertion of insulated electrical wires 20, 21 as illustrated in FIG. 5.

In accordance with the present invention there is provided an inner lining 25 within the cavity formed by the inner sleeve which serves to guide wires past the protuberances. In the illustrated embodiment the inner lining 25 consists of a strip or ribbon of film of suitable material, such as polypropylene which, in a particular embodiment, was 0.001 inches thick and 0.170 inches wide. The upper loose ends 25a of the strip 25 may be secured adjacent the open end of the connector 10 in any suitable manner, as by adhesive. It will be understood that other suitable means may be used, such as, fusion with ultrasonic vibrations, or folding over the tape edges and securement thereof to the outside of the connector.

In a known commercial connector of generally oval shape with major and minor diameter of 0.112 and 0.052 inches respectively, a ribbon or strip 25 of 0.170 inches in width will overlap along the longitudinal edges, as best illustrated in FIG. 4, to form a pocket for receiving the wires 20 and 21. Moreover, the ribbon 25 will fold into a generally U-shape configuration (FIGS. 2, 3 and 5), but has sufficient stiffness so that the bottom portion thereof will bulge outwardly to lock below the lower edge of the inner sleeve 11.

It will be understood that in the use of the connector 10, electrical wires 20 and 21 may be readily inserted through the open end of the connector 10, and the wires will slide past the protuberances 17 without holding up so as to completely bottom within the connector 10. Pressure applied to the outside of the connector will exert a crushing action on the inner sleeve forcing the protuberances 17 thereof through the inner lining 25 and through the insulation of the wires 20 and 21 causing the protuberances to engage the metallic conductor portion of the wires with a sliding, biting action to provide good electrical contact therewith.

Further in accordance with the present invention, there is illustrated the improved method of joining a plurality of insulated electrical conductors and the like, and more specifically the improved method includes the step of initially assembling the inner lining 25 within the inner sleeve 11 for guiding the insulated electrical conductors past the protuberances 17 of the inner sleeve. The wires 20 and 21 are then inserted into the inner sleeve, being guided past the protuberances 17 along the inner liner 25. Thereafter applying pressure to the outside of the connector so as to crimp the same will exert a crushing action on the inner sleeve forcing the protuberances thereof through the lining and through the insulation on the wires 20, 21 so as to engage the metallic conductor portions of the wires, 20, 21 and providing good electrical contact therewith.

Electrical connectors for joining small insulated electrical wires are used by the millions, and may be fed automatically to a work station on a production job. Advantageously, an operator may readily insert the wires into the connectors with assurance that the wires will fully bottom within the connector and that good electrical contact will be made when the connector is deformed.

FIGS. 6 through 10 illustrate a preferred embodiment of the invention wherein the upper end portions of the inner lining or guiding film strip of the connector are folded outwardly over the open end of the outer jacket, along the outer surface thereof, and are retained by a suitable retaining band such as an elastic band. More specifically, and referring to FIGS. 6-10 there is illustrated a connector 30 according to another embodiment of the present invention. The connector 30 is similar to the connector 10 heretofore described except for the arrangement and securement of the film strip in the connector. Specifically, the connector 30 includes an inner sleeve 31 of relatively hard spring-like electrically conductive material, an intermediate sleeve 32 of soft deformable material, and an outer jacket or sleeve 33 of suitably electrically insulating material.

The inner sleeve 31 is comparatively thin with respect to the intermediate sleeve 32, and is constructed of hard spring-like electrically conductive material such as spring-tempered phosphor bronze and is provided on its inner surface with a plurality of inturned perforations 36, FIGS. 7 and 8, and the resulting protuberances 37 are such that a plurality of curved upstanding knife-like edges are provided for each perforation. The intermediate sleeve 32 is formed of a soft, permanently deformable material, such as annealed brass, and is closed at its lower end.

The outer jacket 33 is formed of a suitable electrically insulating material, such as a heat shrinkable thermo-plastic material, and is heat shrunk at one end 33a during the heat curing process of the jacket to form a reduced neck. The other end of the outer jacket 33 is open, as at 33b, to provide for the insertion of insulated electrical wires 40, 41 as illustrated in FIG. 8.

In accordance with the present invention, there is provided an inner lining 45 within the cavity formed by the inner sleeve which serves to guide the wires past the perforation. In the illustrated embodiment, the inner lining 45 comprises a strip or ribbon of film, as heretofore described, and is inserted within the inner sleeve 31 in a generally U-shape configuration with the loose upper ends 45a, FIG. 10, thereof initially projecting outwardly from the upper open end 33b of the connector, and thereafter folded down as shown in FIGS. 6 through 8 over the open end of the connector along the outer surface thereof. An elastic band 46 is snapped over the folded over ends of the inner lining 45 securing the inner lining 45 in place.

As best illustrated in FIGS. 8 and 10, the improved method of joining a plurality of insulated electrical connectors or wires 40, 41 includes the step of lining the inner sleeve 31 with an inner lining 45, which may consist of a strip or ribbon of film or other suitable material, for guiding the insulated electrical conductors or wires 40, 41 past the protuberances 46. The wires 40, 41 are inserted into the inner sleeve 33, being guided past the protuberances 37 by the inner lining 45 thereof. Deformation or crimping of the inner sleeve by pressure applied to the outside of the connector 30 is effective to drive the protuberances through the inner lining 45, and through the insulation on the conductors so as to engage the metallic portion of the conductors and to make electrical contact therewith as heretofore described.

Moreover, as best illustrated by reference to FIGS. 6 and 10 there is also provided an improved method for assembling the inner lining 45 with the connector, and including the steps of inserting the lining 45 into the inner sleeve in a generally U-shape configuration with the ends 45a thereof initially projecting outwardly from the open end of the connector, and thereafter folding the projecting ends 45a of the lining 45 outwardly over the ends of the connector along the outer surface thereof. The ends 45a are then secured to the connector 30 with a suitable band, such as the illustrated elastic band 46.

While the invention has been shown and described with reference to a single embodiment thereof, it is be understood that various changes and modifications may be made without departing from the spirit of the invention and it is intended by the appended claims to cover all such modifications as fall within the true spirit and scope of the invention.

Claims

What is claimed as new and desired to be secured by Letters Patent of the

1. A connector for insulated electrical conductors and the like including a plurality of coaxially telescopically disposed sleeves including an inner sleeve of electrically conductive material and an outer jacket sleeve of electrically insulating material to provide a pigtail connector open at one end and closed at the other, said inner sleeve having on its inner surface spaced apart perforations and having inwardly extending insulation piercing and wire engaging protuberances, and an inner imperforate lining within said inner sleeve for guiding insulated electrical conductors past said protuberances anchored adjacent said open end, whereby deformation of said inner sleeve by pressure applied to the outside thereof forces the protuberances to pierce through the lining and through the insulation on the conductors so as to engage the metallic portion of the conductors to

2. A connector as set forth in claim 1 wherein said inner lining is formed of a strip of film folded through said open end in general U-shape with

3. A connector as set forth in claim 2 wherein said upper ends of said strip are folded over the end of said outer sleeve along the outer surfaces thereof, and further including a retaining band secured over said

5. A connector for insulated electrical conductors and the like including a plurality of coaxially telescopically disposed sleeves including an inner sleeve of electrically conductive material and an outer jacket sleeve of electrically insulating material to provide a pigtail connector open at one end and closed at the other, said inner sleeve having on its inner surface spaced apart perforations and having inwardly extending insulation piercing and wire engaging protuberances, and an inner lining within said inner sleeve for guiding insulated electrical conductors past said protuberances anchored adjacent said open end, said inner lining being formed of a strip of film folded through said open end in a general U-shape with the edges of the film generally overlapped, whereby deformation of said inner sleeve by pressure applied to the outside thereof forces the protuberances through the lining and through the insulation on the conductors so as to engage the metallic portion of the

6. In combination:

a connector for insulated electrical conductors and the like including a plurality of coaxially telescopically disposed sleeves including an inner sleeve of electrically conductive material and an outer jacket sleeve of electrically insulating material to provide a pigtail connector open at one end and closed at the other, said inner sleeve having on its inner surface spaced apart perforations and having inwardly extending insulation piercing and wire engaging protuberances; and

an inner imperforate lining assembled with said connector within said inner sleeve for guiding insulated electrical conductors past said protuberances anchored adjacent said open end;

whereby deformation of said inner sleeve by pressure applied to the outside thereof forces the protuberances to pierce through the lining and through the insulation on the conductors so as to engage the metallic portion of

7. In combination:

a connector for insulated electrical conductors and the like including a plurality of coaxially telescopically disposed sleeves including an inner sleeve of electrically conductive material and an outer jacket sleeve of electrically insulating material to provide a pigtail connector open at one end and closed at the other, said inner sleeve having on its inner surface spaced apart perforations and having inwardly extending insulation piercing and wire engaging protuberances; and,

an inner lining assembled with said connector within said inner sleeve for guiding insulated electrical conductors past said protuberances anchored adjacent said open end, said inner lining being formed of a strip of film folded through said open end in a general U-shape with the edges of the film generally overlapped;

whereby deformation of said inner sleeve by pressure applied to the outside thereof forces the protuberances through the lining and through the insulation on the conductors so as to engage the metallic portion of the conductors to make electrical contact therewith.