U.S. patent number 3,899,236 [Application Number 05/482,149] was granted by the patent office on 1975-08-12 for electrical connector.
This patent grant is currently assigned to Amerace Corporation. Invention is credited to Anthony J. Santos.
United States Patent |
3,899,236 |
Santos |
August 12, 1975 |
Electrical connector
Abstract
A solderless electrically insulated connector has an insulating
body including a base portion and a cover portion. The cover
portion includes a depressible member and a resilient metal contact
element fixedly retained therein for movement with respect thereto.
The base portion is longitudinally grooved to accept insulated
electrically conductive wires therein. Both the base portion and
the cover portion are provided with a first locking means for
locking the base and cover portions together. During installation,
movement of the depressible member causes the contact element to be
forced into the base portion thereby causing the resilient metal
contact element to make a common electrically conductive contact
with each of the wires inserted therein. The contact element is
retained in its depressed position by tangs provided thereon
thereby providing a second locking means between the cover and base
portions.
Inventors: |
Santos; Anthony J. (Edison,
NJ) |
Assignee: |
Amerace Corporation (New York,
NY)
|
Family
ID: |
23914900 |
Appl.
No.: |
05/482,149 |
Filed: |
June 24, 1974 |
Current U.S.
Class: |
439/402 |
Current CPC
Class: |
H01R
4/2433 (20130101) |
Current International
Class: |
H01R
4/24 (20060101); H01r 009/08 () |
Field of
Search: |
;339/95,97-99 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: McGlynn; Joseph H.
Attorney, Agent or Firm: Bender; S. Michael Craig; R. A.
Sachs; Martin
Claims
I claim:
1. Electrical connector apparatus comprising:
a. an insulating body member including a first portion and a second
portion, said first portion including means for receiving a
plurality of insulated electrically conductive wires therein;
and
b. a contact element in said second portion movable between a first
position and a second position relative to said second portion for
providing common electrically conductive engagement with said
plurality of insulated electrically conductive wires positioned
within said receiving means, said contact element including means
for fixedly engaging said first portion upon movement thereof to
said second position thereby providing means for locking said first
portion and said second portion together upon said movement of said
contact element to said second position.
2. Electrical connector apparatus according to claim 1 wherein said
receiving means comprises a plurality of grooves each having means
therein adapted to cooperate with said insulated wires for
retaining said wires within said grooves.
3. Electrical connector apparatus according to claim 1 wherein said
retaining means comprises a pair of opposed obliquely extending
wall portions disposed in a direction resisting longitudinal
withdrawal of said wire engaged thereby.
4. Electrical connector apparatus according to claim 1 wherein said
body member includes separate means for locking said first and
second portions together independent of said last-mentioned
means.
5. Electrical connector apparatus according to claim 4 wherein said
first and second portions are connected together by a
longitudinally extending integral hinge along one side thereof and
said separate locking means comprises cooperating hook-shaped
protrusions provided on said first and second portions along the
side opposite said one side.
6. Electrical connector apparatus according to claim 1 wherein said
second portion includes a depressible member adapted to retain said
contact element therein, and means joining said depressible member
to said second portion for enabling said contact element to be
moved from said first position to said second position.
7. Electrical connector apparatus according to claim 6 wherein said
joining means comprises a flexible web joined between said
depressible member and said second portion.
8. Electrical connector apparatus according to claim 7 wherein said
second portion includes a recess therein defining the path of
movement of said depressible member between said first position and
said second position, said web being joined between said
depressible member and the interior wall of said recess, said
contact element being retained in a groove disposed in the
lowermost portion of said depressible member, whereby in said first
position said uppermost portion of said member is adapted to extend
above the upper surface of said second portion and in said second
position said depressible member is adapted to be seated within
said recess with its said uppermost portion substantially flush
with the upper surface of said second portion.
9. Electrical connector apparatus according to claim 8 wherein said
contact element includes a plurality of tangs for fixedly retaining
at least a portion of said depressible member in said groove.
10. Electrical connector apparatus according to claim 9 wherein
said contact element includes a plurality of slots therein for
engaging the conductive cores of a like plurality of wires
positioned within said receiving means and a second plurality of
tangs provided on said contact element and defining said means for
fixedly engaging said first portion upon movement of said contact
element to said second position.
11. Electrical connector apparatus according to claim 10 wherein
the longitudinally opposed edges of at least one of said slots are
slightly bent out of the plane of the contact element in a
direction resisting longitudinal withdrawal of said wire engaged
thereby.
12. A solderless electrical connector comprising:
a. a unitary insulating body member having a cover portion and a
base portion interconnected by an integral longitudinal hinge along
one side thereof, said body member including a first locking means
for locking said cover portion relative to said base portion, said
base portion having internal longitudinally extending wire
receiving grooves therein, said cover portion including a
depressible member; and
b. a resilient slotted contact element for making electrically
conductive contact with the electrically conductive cores of
insulated wires inserted within said longitudinal grooves, said
contact element being provided with tangs located on the upper and
lower portions of the outer edges thereof, said upper tangs fixedly
retaining said contact element within said depressible member and
said lower tangs fixedly retaining said contact element within said
base portion when said contact element is caused to engage said
insulated wires thereby providing electrical conductive contact
between the cores of said wires and providing a second locking
means between said cover and base portions.
13. The method of making and electrically insulating a solderless
connection between a plurality of insulated electrically conductive
wires using connector apparatus comprising an insulation body
member including first and second portions, said body member
including first means for locking said first and second portions
together, said first portion including means for receiving said
plurality of electrically conductive wires therein, and a contact
element in said second portion movable between a first position and
a second position for providing common electrically conductive
engagement with said plurality of insulated electrically conductive
wires positioned within said receiving means, said contact element
including means for fixedly engaging said first portion upon
movement thereof to said second position to provide a second means
for locking said first portion and said second portion together,
said method comprising:
a. positioning a plurality of insulated electrically conductive
wires within said receiving means;
b. actuating said first locking means to retain said insulated
electrically conductive wires in position with said contact element
in its said first position; and
c. moving said contact element to its said second position to
actuate said second locking means and simultaneously provide said
common electrically conductive engagement among said plurality of
electrically conductive wires.
Description
BACKGROUND OF THE INVENTION
The present invention relates to electrical connectors and, more
particularly, to insulated connectors for interconnecting insulated
electrically conductive wires.
Solderless connectors of which we are aware generally comprise
multiple elements, e.g., an insulating body having a separable
cover and base portion, and a separable contact element; or are of
the clamshell type wherein the cover and base portions are hinged
together with a contact element affixed therein, e.g., molded
within the cover or the base portion. The separable-element
connector relies only upon the insulating base and cover portions
to retain and lock the wires therein and maintain the electrically
conductive contact element in position. In addition, the
separable-element connector suffers from the further disadvantage
of having its separable constituent elements susceptible to being
lost or misplaced thus rendering it inconvenient during
installation thereof.
The clamshell type connector also generally relies upon the
insulating base and cover portions to retain and lock the wires and
the contact element in position. Other known forms of connectors
rely only upon the friction between the base and cover portions of
the insulating body or housing for retaining them together.
In each of these prior connectors the electrical contact element is
generally forced into engagement with the conductive cores of the
wires being connected together by means of a conventional pliers,
for example. The contact element includes means for cutting through
the insulation on the wires to be connected together, and for
forming an electrically conductive path or bridge between the cores
of the wires. Frequently, in the process of cutting through the
insulation, the contact element distorts the base portion of the
housing so that when the cover portion is applied or closed the
single locking means common to the base and cover portion of the
connector unit fails to make a properly secure lock. Thus, although
an electrically conductive connection is made, it may easily come
apart or become exposed, thereby causing a danger to personnel or
providing a low resistance leakage path to ground. In addition, in
the hinged or clamshell type connector, once the hinge is broken by
accident or by re-use, the contact element becomes exposed and the
connector must be scrapped.
SUMMARY OF THE INVENTION
Against the foregoing background, it is an object of the present
invention to provide an improved solderless electrically insulated
connector.
It is a further object of the present invention to provide a
solderless electrically insulated connector which includes means
for simultaneously causing an electrically conductive connection to
be made among a plurality of insulated wires positioned in a
housing and for locking the housing in which the wires are
positioned.
Another object of the present invention is to provide a solderless
electrically insulated connector having a base portion and cover
portion including at least two independent locking means for
securely locking the cover and base portions of the connector
together.
A further object of the present invention is to provide an integral
solderless electrically insulated connector having increased
electrical leakage paths when the connector is closed and securely
locked.
Another object of the present invention is to provide a solderless
electrically insulated connector in which the electrical connection
between wires inserted therein is made after the insulating housing
of the connector has been securely locked in a closed position.
A still further object of the present invention is to provide a
solderless electrically insulated connector having a base portion
and a cover portion including a depressible electrical contact
element therein in which the electrical contact element is provided
with means for independently locking the base and cover portions
together.
To the accomplishment of the foregoing objects and advantages the
solderless electrical connector of the present invention comprises,
in brief, an insulating body member having first and second
portions, the body member including first means for locking the
first and second portions together. The first portion includes
means for receiving a plurality of insulated electrically
conductive wires therein. The second portion includes a contact
element movable between a first position and a second position for
providing common electrically conductive engagement with a
plurality of insulated electrically conductive wires positioned
within the receiving means, the contact element including means for
fixedly engaging the first portion upon movement thereof to said
second position after said first and second portions have been
locked together by the first locking means, thereby providing a
second means for locking the first portion and the second portion
together.
Still other objects and advantages as well as a more complete
understanding of the present invention will be more apparent from a
study of the following detailed description of the invention with
reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an exploded perspective view of the electrical connector
of the present invention shown in an open condition;
FIG. 2 is an enlarged top view of the connector depicted in FIG.
1;
FIG. 3 is a cross-sectional view of the connector taken
substantially along line 3--3 of FIG. 2;
FIG. 4 is a cross-sectional view of the connector in a closed
condition with the depressible cover member in a first or extended
position, taken substantially along line 4--4 of FIG. 2; and
FIG. 5 is a cross-sectional view of the connector in a closed
condition with the depressible cover member in a second or
depressed position, taken substantially along the line 5--5 of FIG.
2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIG. 1, there is shown the electrical connector of
the present invention generally indicated by reference numeral 10.
Connector 10 includes a slotted, relatively thin, resilient flat
metallic contact element 12 and an insulating body member 14. In
the preferred embodiment the body member 14 is a unitary structure
and includes a cover portion 16 and a base portion 18 integrally
joined together by a contiguous longitudinally extending hinge 20
along the full length of one side of the connector. The insulating
body member is preferably molded in a known manner from a synthetic
polymeric material, e.g., high-impact polypropylene, although other
suitable materials having adequate insulating and strength
characteristics upon being molded or otherwise formed, may be
employed as will occur to those skilled in the art. The hinge 20 of
the preferred embodiment may be formed with reduced thickness as
shown in FIG. 3 so as to provide increased flexibility facilitating
repeated opening and closing of the cover portion 16 relative to
the base portion 18.
The upper surface of the base portion 18, as best viewed in FIGS. 1
and 2, includes two parallel, longitudinally extending
wire-receiving grooves or channels 22 and 24 adapted to receive
therein a pair of insulated wires 26 and 28, having therein
electrically conductive cores 25 and 27, respectively. The grooves
22, 24 are spaced from one another to define a dividing wall
portions 25 extending the full length of the base portion 18.
Groove 22 as shown in FIG. 1, also extends the full length of the
base portion 18. Groove 24, however, is provided with a wire-stop
wall or abutment 30 proximate one end thereof which functions to
insulate and provide a stop for the terminal end of wire 28
inserted therein. The grooves 22 and 24 include thin partitions 32,
34 and 36 which are adapted to grasp the insulation of the wires 26
and 28 inserted therein, thereby retaining them in position within
their respective grooves. A transverse slot 38 is provided in the
base portion 18 and is preferably centrally disposed with respect
to the opposed longitudinal extremities of the base portion. The
transverse slot 38 extends through each of the grooves 22 and 24 as
well as through the wall portion 23 between the grooves 22 and 24
(see FIGS. 2 and 4) and functions as a guide for the contact
element 12 when the connector is being installed, as will be more
fully explained hereinafter.
Partially circumscribing one lateral end 39 of the transverse slot
38 proximate the non-hinged sidewall 40 of the base portion 18, is
an arcuate U-shaped groove 42. Groove 42 is adapted to receive
therein a complementary U-shaped projection 44 provided on the
cover portion 16 when the cover portion 16 is closed relative to
the base portion thereby functioning to increase the length of the
leakage path between the contact element 12 and the exterior of the
connector when the contact element 12 is depressed into the
transverse slot 38 during installation of the connector as will be
explained below.
A pair of spaced, hook-shaped protrusions 46 are formed within
sidewall 40 of base portion 18 to function as one portion of a
first locking means, the other portion of which comprises a pair of
spaced, complementary, hook-shaped protrusions 48 extending from
the inner surface 49 of the depending sidewall 51 of cover portion
16. Hook-shaped portions 48 are adapted to cooperate with the
hook-shaped protrusion 46 to securely lock the cover portion to the
base portion when the former is in a closed condition with respect
to the latter.
In accordance with the invention, and with reference to FIGS. 2-5,
the cover portion 16 is provided with an elongated, transversely
oriented depressible member 50. The member 50 is integral with
respect to the cover portion 16 by virtue of it being joined to the
cover portion by a continuous encircling membrane or flexible web
52, extending between the member 50 and the interior wall surface
53 of a central recess 55 disposed within the cover portion 16. The
flexible web 52 has a reduced thickness relative to that of the
remaining cover portion 16 so as to facilitate displacement of the
depressible member 50 relative to the cover portion 16, that is,
between a first non-depressed position as shown in FIG. 4, and a
second depressed position as shown in FIG. 5. It will be noted that
in the second or depressed position of member 50 as shown in FIG.
5, the flexible web 52 assumes a taut condition and the depressible
member 50 is seated substantially within the central recess 55 such
that its upper surface 70 does not extend beyond the upper surface
of the cover portion.
The depressible member 50 preferably is provided with a narrow
transverse groove 54, which is adapted to receive and retain the
contact element 12 therein.
The contact element 12 which preferably is fabricated from a
suitable resilient metallic material such as, for example,
phosphorbronze, brass, or copper so as to provide good electrical
conductivity, is provided with slots 56 and 58 thereby forming leg
portions 60, 62 and 64. The transverse or lateral width dimension
of each slot 56, 58 is chosen to be slightly less than the diameter
of the electrically conductive cores 25, 27 in each of the wires
26, 28 to be received within grooves 22 and 24 and for this reason,
leg portions 60 and 64 are adapted to flex slightly in an outwardly
or lateral direction when the contact element is forced into
engagement with the wire cores 25, 27 as will be more fully
explained. It will be appreciated that the slots 56 and 58 are in
alignment with grooves 22 and 24, respectively, when the cover
portion 16 is closed relative to base portion 18. The leg portions
60, 62 and 64 are generally parallel to one another and are
provided with sharpened edges along the length of the slots 56 and
58 to facilitate cutting into the insulation on the wires 26 and 28
during the installation of the connector as will be more fully
explained below. It will be observed further that the edges of slot
58 are slightly bent out of the plane of the contact element toward
the wire-stop wall 30, as shown in FIG. 2, thereby providing means
for axially retaining the insulated wire 28 received within groove
24, i.e., for resisting pullout forces exerted on the wire in a
direction parallel to the longitudinal axis of the wire. As best
seen in FIGS. 1, and 3 through 5, the contact element 12 preferably
is provided with a first pair of tangs 66 adjacent the upper edge
thereof, and a second pair of tangs 58 located on the outer edges
of leg portions 60 and 64. The first pair of tangs 66 is adapted to
fixedly retain the contact element 12 within the transverse groove
54; hence, within the depressible member 50. It is contemplated
that the contact element 12 will be inserted in groove 54 when the
connector is manufactured and that the cover portion 16 and the
base portion 18 will be integrally molded as a unitary structure so
that a mechanical installing the connector will not have to be
concerned with missing or loose elements at the time of the
installation thereof.
It will be noted that the upper surface 70 of depressible member 50
is preferably curved slightly to conveniently mate with the jaws of
a conventional pliers, which latter may be used to depress the
member 50 during the installation of the connector.
When the cover portion 16 of the connector is closed upon the wires
26 and 28 received within grooves 22 and 24 of the base portion 18
and locked relative to the base portion by engagement of the
cooperating protrusions 46 and 48, depressible movement of the
member 50 and its contact element 12 from its first position (FIG.
4) to its second position (FIG. 5) will cause the sharpened edges
along the length of slots 56, 58 to cut through the electrical
insulation of the wires 26 and 28 and come into intimate engaging
contact with the electrically conductive cores 25 and 27 thereof,
thereby completing an electrically conductive path between the
cores 25 and 27. Simultaneously, the lower pair of tangs 68 of
resilient contact element 12 will be forced respectively into
embedding engagement with the opposed walls 39, 41 of transverse
slot 38 by the action of the electrically conductive cores 25 and
27 of wires 26 and 28, causing the outer leg portions 60, 64 to
flex laterally thus fixedly retaining the contact element 12
relative to the base portion 18. Since the flexible web 52 is made
taut when the member 50 is depressed to its second position as
explained above and as shown in FIG. 5, the action of the second
pair of tangs 68 engaging the base portion 18 serves to define a
second locking means securely locking the cover portion 16 to the
base portion 18. That is, the cover portion 16 will be fixedly
retained relative to the base portion 18 through the first pair of
tangs 66 embedded within the member 50, the second pair of tangs 68
embedded within the base portion 18, and the taut connection
provided by the flexible web 52 between the member 50 and the cover
portion 16.
In addition to bending the cutting edges along slot 58 slightly out
of the plane of the element 12, as described above, further means
for restraining the wire 28 received within groove 24 may be
provided. These may include a pair of obliquely extending wall
portions 72 extending toward the wire stop-wall 30 which are
adapted to grasp the insulation of the wire 28 inserted into groove
24; and a protrusion 74 which may be provided on the inside surface
of cover portion 16 as shown in FIG. 2 and which is adapted to
exert holding pressure on the wire 28 inserted into groove 24 when
the cover portion 16 is closed and locked relative to the base
portion 18.
It will be noted by those skilled in the molding art that the
rectangular shaped through-apertures 76 and 78 depicted in FIGS. 1,
3, and 5 are caused by suitable inserts placed in the mold for the
purpose of facilitating the formation of the hooked-shaped
protrusions 48 in the cover portion 16 during manufacture of the
connector 10.
The connector of the present invention may be employed to form an
electrically conductive connection between the two electrically
conductive cores 25 and 27 of wires 26 and 28, respectively, as
follows. At the time of installation the connector 10 is normally
in the completely opened condition, as shown in FIGS. 1, 2, and 3
and the contact member 12 is retained within transverse groove 54,
as mentioned earlier. The wire 26, having an electrically
conductive core 25, to which a connection is to be made, is
inserted into groove 22. A second wire 28, having an electrically
conductive core 27, is inserted into groove 24 and pushed forward
until its free or terminal end abuts against stop-wall 30. The
insulation need not be removed from the wires 26, 28. The cover
portion 16 of the connector 10 is then closed relative to the base
portion 18 and locked together via the first locking means
comprising the cooperatively engaging hook-shaped protrusions 46
and 48. Next, a downwardly directed force is applied against the
depressible member 50 sufficient to cause it to be movably
displaced from its first extended or non-depressed position (FIG.
4) to its second, depressed position as shown in FIG. 5. As
explained above, such movement causes the sharpened edges of slots
56 and 58 of contact element 12 to cut through the electrical
insulation of the wires 26 and 28 and make intimate electrically
conductive contact with the electrically conductive cores 25 and 27
thereof whereas substantially simultaneously, resilient leg
portions 60 and 64 of contact element 12 are caused to flex in an
outward or lateral direction firmly embedding the tangs 68 within
the oppposed end walls 39 and 41 of transverse slot 38 thereby
fixedly retaining the contact element 12 within the base portion 18
and providing a second independent locking means between the cover
portion 16 and the base portion 18 of body member 14.
From the foregoing, it will now be appreciated that the present
invention discloses a relatively inexpensive, solderless,
electrically insulated connector of relatively simple, but rugged
construction. Although a preferred embodiment has been described
above, it will be understood that many variations and modifications
hereof may occur to those skilled in the art without departing from
the principles of the invention. For example, the preferred
embodiment described above is useful for making a tap connection
between an insulated wire extending completely through the housing
and at least one other insulated wire terminating within the
housing. The connector 10 of the present invention may obviously be
modified by eliminating the abutment or wire stopwall 30 located
within groove 24, thus providing an electrical connector suitable
for interconnecting at least a pair of electrically conductive
wires extending completely through the body member 14. Other
modifications or variations will occur to those of ordinary skill
in the art. Accordingly, it is desired that the subject invention
be limited only by the spirit and scope of the appended claims.
* * * * *