AU2002301093B2

AU2002301093B2 - System for Electrical Connection and Insulation Displacement Contact Therefor

Info

Publication number: AU2002301093B2
Application number: AU2002301093A
Authority: AU
Inventors: Rafik Munshi
Original assignee: ADC GmbH
Current assignee: TE Connectivity Germany GmbH
Priority date: 1997-12-02
Filing date: 2002-09-19
Publication date: 2004-11-04
Anticipated expiration: 2018-10-30

Description

AUSTRALIA

PATENTS ACT 1990 COMPLETE APPLICATION NAME OF APPLICANT: Krone GmbH ADDRESS FOR SERVICE: DAVIES COLLISON CAVE Patent Attorneys 1 Little Collins Street Melbourne, 3000.

INVENTION TITLE: "System for Electrical Connection and Insulation Displacement Contact Therefor" The following statement is a full description of this invention, including the best method of performing it known to us: P:\OPER\JCM\749119DIV.DOC 19/9/02 -2- System for Electrical Connection and Insulation Displacement Contact Therefor This invention relates to a system for making electrical connection with an insulated electrical wire or cable, and insulation displacement contacts therefor.

Electrical power outlet sockets are used extensively in domestic and commercial buildings for providing outlets from which electrical apparatus can be supplied with mains electrical power.

For example, in Australia, an electrical power outlet socket may typically be installed in a lower region of a wall, and have socket receptacles for three plug pins corresponding to an active, a neutral and an earthing connection. Connecting wires are installed within the building wall to connect the respective contacts of the socket receptacles to the mains electrical power source at, for example, the electrical switching or fuse box of the building, and to other electrical power outlets in the same region of the building. Traditionally, in order to provide a secure electrical connection between the connecting wires in the wall and the electrical contacts of the power outlet socket, screw contacts have been utilised. A screw contact requires that insulation from an end of the connecting wire be removed, and the exposed conductor of the wire inserted in a contact opening and then engaged into secure electrical contact by screwing a contact screw into the contact opening to physically and electrically engage the exposed conductor portion.

Although this is not a particularly difficult operation, if many electrical power outlets are to be installed, it would be desirable to reduce the number and complexity of operations required to make electrical connections to each electrical power outlet.

In accordance with the present invention, there is provided an electrical connector element for making electrical connection with a plurality of conductors in the form of insulated wires or cables, comprising a generally planar conductive member having a plurality of conductor receiving apertures therethrough, the conductive member being further formed with respective conductor engaging slots associated with the conductor receiving apertures, wherein each conductor engaging slot is open at one end thereof to the respective conductor receiving aperture with inner edges of the conductive member defining the conductor engaging slot being adapted to cut through an insulating layer of an insulated wire or cable, wherein the end portion of a plurality of conductors may be inserted to project through respective ones of the conductor receiving apertures and laterally displaced with respect to the conductive member toward the P:\OPER\JCM\7491 I9DIV.DOC- 19/9/02 -3respective conductor engaging slots so as to cause said inner edges of the conductive member to cut through the respective outer insulative layers thereof and form an electrical and mechanical connection between the conductive member and said conductors.

The present invention also provides an electrical connection system comprising a base member supporting an electrical connector element as disclosed above, and a slide member that is supported for slidable movement relative to said electrical connector element between a receiving position and an engaging position, the slide member having at least one aperture therethrough which aligns with a conductor receiving aperture of the electrical connector element in said receiving position and aligns with the associated conductor engaging slot in said engaging position.

The slide member aperture is preferably constructed to guide the end portion of the conductor in the form of an insulated wire or cable through the corresponding conductor receiving aperture of the electrical connector element whilst the slide member is in the receiving position. This enables the slide member to force the conductor end portion into the associated conductor engaging slot of the electrical connector element, and form said electrical and mechanical connection, upon movement of the slide member from the receiving position to the engaging position. The slide member may be also effective to electrically and mechanically disengage the conductor end portion from the electrical connector element upon movement of the slide member from the engaging position back to the receiving position.

Preferably, the slide member, base member and electrical connector element are structured to enable a user to effect movement of the slide member between the receiving and engaging positions by use of a levering action of a screwdriver or the like between surfaces of the slide member and base member.

Preferably the electrical connector element and slide member are mounted in relation to each other in such a way that the axis of the slide member aperture is angled with respect to a perpendicular of the electrical connector element plane.

In the context of an electrical power outlet as introduced above, each of the input electrical contacts for supplying electricity to the power outlet may comprise a generally flat contact P:\OPER\JCM\749II 9D1V.DOC- 19/9/02 -4portion with a slot formed therein, the slot having a narrow holding portion with generally parallel contact edges adjacent to a widened insertion portion. The contact edges of the holding portion are spaced so that a wire/cable inserted therein will have its insulation cut by the edges so that the edges make electrical connection with the wire/cable conductor. The insertion portion is dimensioned so that an end of the wire/cable can be inserted therein transversely of the plane of the flat contact portion for subsequent movement parallel to the slot into the holding portion. In this form of the invention it is preferred that a slidable member be provided and supported by the power outlet socket adjacent one flat side of the flat contact portion of the input electrical contact. The slidable member has an aperture therethrough and is slidable so that the aperture can moved from alignment with the insertion portion to alignment with the holding portion. In operation, the insulated end of the wire/cable to which contact is to be made is inserted through the aperture in the slidable member and into the insertion portion of the slot.

The slidable member is then moved to alignment with the holding portion of the slot, which in turn forces the wire/cable between the contact edges of the holding portion, cutting through the insulation and making electrical connection between the edges and the wire/cable conductor.

The invention is described in greater detail hereinafter, by way of example only, with reference to an embodiment thereof illustrated in the accompanying drawings, wherein: Figure 1 is a front isometric view of an electrical power outlet having two sockets and corresponding power switches; Figure 2 is a rear view of an electrical power outlet base portion constructed in accordance with an embodiment of the invention; Figure 3 is a front view of the electrical power outlet base portion; Figure 4 is a front view of a set of electrical contacts adapted for use in the electrical power outlet; Figures 5A, 5B and 5C are separate views of the earthing, active and neutral electrical contacts of Figure 4; and Figure 6 is a perspective view of another form of electrical contact element according to an embodiment of the invention.

An embodiment of the invention is described hereinafter in the context of an electrical power P:\OPERUCM\7491 I9DIV.DOC 19/9/02 outlet, of the type shown at 2 in Figure 1. It is to be understood that the invention is not limited such structure or application, however, and those skilled in the art will readily recognise the various possible configurations and applications that the present invention is capable of from the following description.

An electrical power outlet 2 is illustrated in front view in Figure 1, in this case adapted to make separate electrical connection to two standard domestic three pin electrical plugs. A face plate 6 and base portion cover 4 cover the electrical power outlet from the front. For each socket the base portion cover has three pin apertures and a corresponding switch 8 which protrudes through the base portion cover.

Figure 2 illustrates a base portion 60 of an electrical power outlet according to an embodiment of the present invention from a rear view, and Figure 3 is a front view of the base portion with base portion cover removed. As can be seen in Figure 3, two sets of active, neutral and earth output contacts 76, 86 and 96, respectively, are arranged on the base portion 60, seated in respective recesses of the base portion. When the base portion cover 4 (Figure 1) is fitted over the base portion 60, the apertures for the sockets 10 align with respective output contacts, to enable plug pins to be inserted through the apertures to be engaged in the output contacts.

Three sets of electrical connection elements 70, 80 and 90 are provided for the active, neutral and earth circuit portions, respectively. In the case of the neutral and earth, the connection elements 80, 90 are connected directly to the respective neutral and earth output contacts 86, 96.

In the case of the active connection element 70, however, the active output contacts 76 are formed separately, so that switches 8 can control electrical connection between the respective active output contacts 76 and the active connection element which includes input electrical contacts. Figure 4 illustrates the layout of the connection elements and output contacts separately from the base portion 12.

The base portion 60 is constructed with parallel transversely extending contact recesses 62 formed in the rear structure thereof as seen in Figure 2. For each of the active, neutral and earth, the rear of base portion 60 is provided with two elongate contact recesses 62 arranged end to P:\OPERUCM\74911 9DIV.DOC 19/9/02 -6end. The contact recesses for the active, earth and neutral are arranged side by side so as to form two sets of three parallel contact recesses 62 positioned at the rear of the base portion between the positions of the sockets 10 on the front of the electrical power outlet.

Within each contact recess 62 there is mounted a carrier block or slider 64. The carrier block 64 is shorter in length than the elongate recess, and is slidably movable from one end of the recess to the other. The carrier block 64 has two wire apertures 65 formed therethrough, extending from the rear of the base portion to the input contacts mounted at the front thereof.

Figure 5B shows the active connection element 70 in isolation, without active output contact portions 76. The active connection element 70 comprises an elongate input contact portion 72, with a frame portion 74 extending transversely from one end thereof. As seen best in Figure 4, when viewed from the front of the electrical power outlet, the active input contact portion 72 lies to the left hand side of the base portion structure, with the contact frame 74 arranged toward the top of the structure and extending to each side to adjacent the respective active output contacts 76 for connection with the respective switches 8 (not shown in Figure The input contact portion 72 comprises two (upper and lower) sets of input contacts, each set of input contacts comprising two contact openings 75 and respective contact slots 73. Each contact opening 75 comprises a generally circular hole, and each contact slot extends from one side of the circular hole and has substantially parallel edges. The openings 75 and slots 73 are arranged in alternating fashion in each set, and the sets are disposed to opposite ends of the input contact portion 72. The input contact portion 72 is generally planar, but is angled with respect to the plane of the frame portion 84. For example, the input contact portion 72 may be angled at about degrees to the plane of the frame portion. The frame portion 84 and input contact portion 72 may be integrally formed, or may be formed separately and joined together by welding, soldering, riveting or the like.

Figure 5C illustrates the neutral connection element 80 having an input contact portion 82 which is generally similar in construction to the input contact portion 72 of the active connection element 70. In this case, however, the frame portion 84 extends from the centre of the input contact portion 82, and is integrally formed with output contact portions 86 at the ends thereof remote from the input contact portion. Furthermore, the frame portions 84 are raised slightly P:\OPER\JCM\749119DIV.DOC. 19/9/02 -7with respect to the input contact portion, to enable the frame portion to extend over the active and earth connection elements 70, 90, without electrical connection therebetween, when the neutral connection element 80 is in situ in the base portion of the power outlet, as shown arranged in Figure 4. The neutral input contact portion 82 is disposed to the right hand side of the base portion structure, when viewed from the front, as shown in Figures 3 and 4.

The earth connection element 90, illustrated in Figure 5A, is also generally similar in construction to the neutral and active contacts, although the frame portion 94 thereof extends transversely from the opposite end of the input contact portion 92, as compared to the active connection element 70. The frame portion 94 is integrally formed with output contact portions 96 at the ends thereof remote from the input contact portion.

Referring particularly to Figure 2, as mentioned the carrier blocks 64 are slidably movable within the contact recesses 62. With the carrier block 64 disposed at one end of the respective contact recess 62, the wire apertures 65 align with the contact openings 75 of the respective set of input contacts. Such position of the carrier block can be referred to as the receiving position, where the carrier block is positioned so that the end portion of a wire or cable may be received in the aligned wire apertures and contact openings. When the carrier block 64 is moved to the other end of the contact recess (the engaging position), the wire apertures 65 align with the corresponding contact slots 73 of the respective set of input contacts. With the carrier blocks in the first mentioned configuration, the end of an insulated wire or cable may be inserted into a wire aperture 65 from the rear of the base portion 60, to project through the corresponding input contact opening 75. If the carrier block 64 is then moved within the contact recess to the other end thereof, then the end of the wire or cable which projects thereinto is forced into the angled contact slot 73. This action causes edges of the slot 73 to cut through the insulative sheath of the wire or cable and make electrical connection with the conductor therein.

The movement of the carrier block 64 with wire or wires projecting thereinto can be conveniently achieved by the use of a screw driver or the like with a lever action against an end of the carrier block and an end of the recess 62. For this purpose, the carrier blocks 64 and recesses 62 may be constructed so that a lever opening 66 remains between the recess end and carrier block end, to accommodate a flat projection such as screw driver tip. Once electrical connection has been established to a wire or cable, the corresponding carrier block 64 is left in P:\OPER\JCM\7491 I9DIV.DOC- 19/9/02 -8place at that end of the contact recess. The carrier block 64 and recess 62 may be constructed with interfitting protrusions and recesses or the like which align when the carrier block is in the engaging position to provide a form of positive engagement of the carrier block in the recess and thus reduce the likelihood of unintended movement of the carrier block back into the receiving position. If removal of the wire/cable is desired, a similar lever action may be applied to the carrier block from the other end so as to force the wire/cable back into the corresponding contact opening 75 for extraction of the end of the wire/cable.

In the illustrated embodiment, each of the carrier blocks has two wire apertures 65 which align with corresponding contact openings and slots 75, 73. This allows for connection and disconnection of two wires or cables simultaneously through one movement of the carrier block.

In alternative embodiments, any number of wire apertures and corresponding contact openings/slots may be provided for terminating fewer or greater numbers of wires/cables, as may be desirable in certain applications.

It will be appreciated that it is not essential for the input contact openings and slots to be shaped as illustrated in Figures 2 to 5, and many variations are possible. Another form of input contact portion is illustrated in perspective view in Figure 6, by way of example. In this case, the input contact portion has been formed separately from the frame portion, and is constructed to enable it to be joined to a frame portion at one end thereof by welding, soldering, riveting or the like.

The contact openings and respective contact slots shown in Figure 6 are also shaped differently than those previously discussed, wherein the contact openings are generally rectangular with tapered portions leading into the respective contact slots. Also, the individual contact openings and slots are formed separately on the input contact portion illustrated in Figure 6, which may be desirable for improved structural rigidity of the contact portion, particularly if it is made from relatively thin sheet material or the like. Furthermore, the contact slots as shown in Figure 6 may have chamfers on opposite sides of the slot edges to aid in insulation displacement and notching of the wire conductor when inserted therein. All of the slot and aperture features may be arranged in the same direction, or one pair may be arranged in the opposite direction to the other, for example.

From the foregoing description, it will be readily apparent to those of ordinary skill in the art that the electrical power outlets disclosed herein and the construction and arrangement of the input contacts in particular allow for simple and fast connection to electrical wires/cables which P:\OPERVCM\7491 I9DIV.DOC 19/9/02 -9was not possible using conventional connectors. It is not necessary to remove insulation from the wire/cable before making the connection, and the connecting procedure is particularly simple, and requires only a simple tool.

The foregoing detailed description of the present invention has been presented by way of example only, and is not intended to be considered limiting to the present invention as defined in the claims appended hereto.

Throughout this specification and the claims that follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that that prior art forms part of the common general knowledge in Australia.

Claims

1. An electrical connector element for making electrical connection with a plurality of conductors in the form of insulated wires or cables, comprising a generally planar conductive member having a plurality of conductor receiving apertures therethrough, the conductive member being further formed with respective conductor engaging slots associated with the conductor receiving apertures, wherein each conductor engaging slot is open at one end thereof to the respective conductor receiving aperture with inner edges of the conductive member defining the conductor engaging slot being adapted to cut through an insulating layer of an insulated wire or cable, wherein the end portion of a plurality of conductors may be inserted to project through respective ones of the conductor receiving apertures and laterally displaced with respect to the conductive member toward the respective conductor engaging slots so as to cause said inner edges of the conductive member to cut through the respective outer insulative layers thereof and form an electrical and mechanical connection between the conductive member and said conductors.

2. An electrical connector element as claimed in claim 1, wherein the conductive member is elongate with said conductor receiving apertures and associated conductor engaging slots being distributed longitudinally in the conductive member.

3. An electrical connector element as claimed in claim 1 or 2, wherein the disposition of each conductor receiving aperture and associated conductor engaging slot provided in the conductive member is substantially the same.

4. An electrical connection system comprising a base member supporting an electrical connector element as claimed in any one of claims 1 to 3, and a slide member that is supported for slidable movement relative to said electrical connector element between a receiving position and an engaging position, the slide member having at least one aperture therethrough which aligns with a conductor receiving aperture of the electrical cQnnector element in said receiving position and aligns with the associated conductor engaging slot in said engaging position. An electrical connection system as claimed in claim 4, wherein the slide member has a plurality of apertures, one for each conductor receiving aperture in the electrical connector element.

P:\OPERJCM\749119DIV.DOC 19/9/02 -11-

6. An electrical connection system as claimed in claim 4, including a plurality of said slide members.

7. An electrical connection system as claimed in claim 4, wherein the slide member aperture is constructed to guide the end portion of a said conductor in the form of an insulated wire or cable through the corresponding conductor receiving aperture of the electrical connector element whilst the slide member is in the receiving position.

8. An electrical connection system as claimed in claim 7, wherein the slide member is effective to force said conductor end portion into the associated conductor engaging slot of the electrical connector element, and form said electrical and mechanical connection, upon movement of the slide member from the receiving position to the engaging position.

9. An electrical connection system as claimed in claim 8, wherein the slide member is further effective to electrically and mechanically disengage the conductor end portion from the electrical connector element upon movement of the slide member from the engaging position back to the receiving position.

An electrical connection system as claimed in any one of claims 4 to 9, wherein the slide member, base member and electrical connector element are structured to enable a user to effect movement of the slide member between the receiving and engaging positions by use of a levering action of a screwdriver or the like between surfaces of the slide member and base member.

11. An electrical connection system as claimed in any one of claims 4 to 10, wherein the electrical connector element and slide member are mounted in relation to each other in such a way that the axis of the slide member aperture is angled with respect to a perpendicular of the electrical connector element plane.

12. An electrical connector element substantially as hereinbefore described with reference to the accompanying drawings. P:\OPERCM\749119DIV.DOC 19/9/02 12-

13. An electrical connection system as substantially as hereinbefore described with reference to the accompanying drawings. DATED this 19th day of September, 2002 KRONE GMBH By its Patent Attorneys DAVIES COLLISON CAVE