AU2017276337A1

AU2017276337A1 - An electrical connector

Info

Publication number: AU2017276337A1
Application number: AU2017276337A
Authority: AU
Inventors: Paul David Barron; Grant Coe; Dennis Galvin; Dinesh Vijayaraman
Original assignee: Legrand Australia Pty Ltd
Current assignee: Legrand Australia Pty Ltd
Priority date: 2016-12-15
Filing date: 2017-12-15
Publication date: 2018-07-05

Abstract

An electrical connector for making electrical connection to insulated conductors comprising a body having at least one channel for receiving the insulated conductors, and insulation displacement contacts disposed in the at least one 5 channel. The insulation displacement contacts may be staggered laterally and spaced longitudinally in the at least one channel so one at least one of the plurality of insulation displacement contacts makes electrical connection with the conductors. The connector may also comprise at least one guide disposed in the at least one channel to facilitate making the electrical connection between the 10 insulated conductors and the plurality of insulation displacement contacts. 9596924_1 (GHMatters) P104163.AU.1 -- i (Nn L(N Nn 0 N'. *O fr '.

Description

AN ELECTRICAL CONNECTOR Technical Field

This disclosure relates to an electrical connector for making electrical connection to insulated conductors with insulation displacement contacts.

Background Art

Electrical connectors having insulation displacement contacts are typically used to make an electrical connection with insulated conductors (wires) intermediate their ends. Such electrical connectors require the insulation displacement contacts to cut through the insulation of the conductors and make an electrical connection between the contacts and the conductors. This electrical connection is made by relative movement of the insulation displacement contacts and the conductors in a direction that is generally lateral to the longitudinal direction of the conductors. The insulated conductors may be of variable sizes (as measured across their width or diameter), and as such it is desirable that the electrical connector is able to cater for insulated connectors of different sizes and still make an effective electrical connection between the contacts and the conductors.

It is to be understood that, if any prior art is referred to herein, such reference does not constitute an admission that the prior art forms a part of the common general knowledge in the art, in Australia or any other country.

Summary

According to a first aspect, disclosed is an electrical connector for making electrical connection to at least one insulated conductor comprising: a body having at least one channel for receiving the at least one insulated conductor, a terminal; and a first set of insulation displacement contacts electrically connected to the terminal and being staggered laterally and spaced longitudinally in the at least one channel.

Advantageously, conductors of varying dimensions have been found to make an effective electrical connection with the conductors in the channels of the first aspect.

It is understood that staggered may include in alternating or continually overlapping insulation displacement contacts, as well as non-overlapping insulation displacement contacts. In addition, spaced longitudinally includes conductors that are spaced so they are overlapping or adjacent as well as spaced apart or non-overlapping.

In some embodiments, at least one guide disposed in the at least one channel to facilitate making the electrical connection between the insulated conductors and the plurality of insulation displacement contacts. The at least one guide may be disposed in the channel such that the at least one channel is tortuous to define an indirect path for the conductors within the at least one channel. The at least one guide may be positioned proximal to an insulation displacement contact to bend the conductor toward to contact and facilitate an effective electrical connection.

In some forms, the channel is surrounded by a wall, and the at least one guide protrudes from the wall into the channel, and in some forms, the at least one guide protrudes from a bottom surface of the channel.

In some embodiments, the insulation displacement contacts extend longitudinally in the at least one channel. In alternative embodiments, the insulation displacement contacts may extend transverse (at any angle) in the at least one channel or lateral to the longitudinal direction of the at least one channel.

In some forms, the body further comprising first and second first and second parts moveable in relation to each other from an open position where access is provided to locate the at least one conductor in the at least one channel to a closed position where the at least one conductor is captured in the at least one channel. In some embodiments, the body parts pivotable relative to each other and in one form, movably joined via a hinge. In some forms, the electrical connector further comprises a retaining portion for retaining the at least one conductor in the at least one channel. In some forms, in moving the first and second parts to the closed position, an engaging arrangement forces engagement between the at least one conductor with the first set of insulation displacement contacts. In some forms, the retaining portion forms part of the engaging arrangement.

In some embodiments, the connector further comprising a lock to lock the first and second parts in the in the closed position. The lock may comprise a retaining member slideable relative to the first and second parts. In some forms, one of the first and second parts includes the retaining member slideably mounted thereto and a flange, and the other of the first and second parts includes a tab, and in use movement of the retaining member over the tab causes the tab to engage the flange to lock the first and second parts together.

The lock of this form may be beneficial as it is easy to move between the locked and the unlocked position and it is fixed to one part of the body to prevent loss.

According to a second aspect, disclosed is an electrical connector for making electrical connection to insulated conductors comprising a body having at least one channel for receiving the insulated conductors, and insulation displacement contacts disposed in the at least one channel and at least one guide disposed in the at least one channel to facilitate making the electrical connection between the insulated conductors and the plurality of insulation displacement contacts.

According to a third aspect, disclosed is an electrical connector for making electrical connection to at least one insulated conductor comprising a body having at least one channel for receiving the at least one insulated conductor; a terminal; at least one insulation displacement contact disposed in the at least one channel and electrically connected to the terminal, wherein the body further comprising first and second parts moveable in relation to each other from an open position where access is provided to locate the at least one conductor in the at least one channel to a closed position where the at least one conductor is captured in the at least one channel, and at least one engaging arrangement, wherein in moving the first and second parts to the closed position, the engaging arrangement forces engagement between the at least one conductor with the at least one insulation displacement contact, wherein the at least one engaging arrangement is adjustable to accommodate different sizes of the at least one insulated conductor.

In some embodiments, the engaging arrangement comprises at least one projection extending from an internal surface of one part of the body and is locatable in the at least one channel to force the at least one insulated conductor into engagement with the at least one insulation displacement contact, the engaging arrangement being adjustable to vary the distance between the at least one projection and the at least one insulated conductor in the closed position. The length of the at least one projection may be adjustable. The length of the at least one projection may be adjustable at least in part through having a base portion and removable portion removably mountable on the base portion.

In some forms, the at least one projection is positioned to correspond to the position of the at least one insulation displace contact. In some forms, the at least one projection is dimensioned to fit within the at least one channel.

The electrical connector may further comprise at least one secondary projection which corresponds to the cable to retain the cable in position in relation to the body to facilitate the at least one insulated conductor making electrical connection with the at least one insulation displacement contact.

In some forms, the at least one projection and the at least one secondary projection are integrally formed.

Brief Description of the Drawings

Embodiments will now be described by way of example only, with reference to the accompanying drawings in which

Fig. 1 is a perspective view of an embodiment of an electrical connector in an open position and an embodiment of a cable;

Fig. 2 is a bottom perspective view of the electrical connector of Fig. 1 and an embodiment of a cable in a closed position;

Fig. 3 is a top perspective view of the connector of Fig. 2 in the closed position; Fig. 4 is a perspective view of the connector of Fig. 1 in the open position;

Fig. 5 is a plan view of the connector of Fig. 4;

Fig. 6 is a perspective view of an embodiment of a contact of the connector of Fig. 4;

Fig. 7 is a side view of the connector of Fig. 5;

Fig. 8A is a perspective view of the connector of Fig. 4 and an embodiment of a cable;

Fig. 8B is a perspective view of the connector of Fig. 8A in use in an open position;

Fig. 8C is a bottom perspective view of the connector of Fig. 8B in use in the closed position;

Fig. 8D is a perspective view of the connector of Fig. 8C in use in the closed position and the unlocked position;

Fig. 8E is a close-up side view of an embodiment of a retaining member of Fig. 8D in a locked position;

Fig. 9 is a perspective view of a further embodiment of an electrical connector in an open position and an embodiment of a cable;

Fig. 10A is perspective view of the electrical connector of Fig. 9 and an embodiment of at least one engaging arrangement;

Fig. 1 OB is a close-up perspective view of the extension shown in the circle A in Fig. 10 A;

Fig. 11A is a cross-sectional view of the electrical connector of Fig. 9 in a closed position;

Fig. 1 IB is a close-up cross-sectional view of the electrical connector of Fig. 1 IB; and

Fig. 12 is a perspective view of the electrical connector of Fig. 9 with the embodiment of the at least one engaging arrangement shown in Fig. 10A removed.

Detailed Description

In the following detailed description, reference is made to accompanying drawings which form a part of the detailed description. The illustrative embodiments described in the detailed description, depicted in the drawings and defined in the claims, are not intended to be limiting. Other embodiments may be utilised and other changes may be made without departing from the spirit or scope of the subject matter presented. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the drawings can be arranged, substituted, combined, separated and designed in a wide variety of different configurations, all of which are contemplated in this disclosure.

The electrical connector of the disclosure is arranged to electrically connect to insulated conductors Typically, the electrical connector is used in fixed wiring in residential and industrial applications to connect electrical devices (such as lighting and the like) to the wiring. The electrical connector uses insulation displacement contacts and is arranged to be installed intermediate the ends of the insulated conductors and to make an effective electrical connection between the contacts and the conductors. The connector provides a terminal connection for electrical appliances which is typically in the form of a socket outlet, but may take the other form, such as a screw terminal or the like.

Typically the conductors are provided as thermoplastic-sheathed cable (TPS). TPS is commonly used in the building industry in fixed wiring applications. It includes an outer PVC sheath of insulation covering one or more insulated conductors (typically formed of copper). The TPS may be flat or round and the one or more insulated conductors may vary in diameter size. A feature of at least one form of the connector of the disclosure is that it allows rapid connection to the insulated conductors and is able to accommodate conductors of different sizes (typically in the range of 1mm2 -2.5 mm2 in cross-sectional area). However, it is to be appreciated that the disclosure is not limited to this range and the features of the connector of the disclosure may be modified to accommodate different ranges of conductor sizes.

Referring to Figs. 1, to 3, the connector 10 generally includes a body 11 formed from two parts 14 and 15, which in the illustrated form are hinged together and are movable relative to each other between an open position (shown in Fig. 1) and a closed position (shown in Fig. 2). The connector 10 is arranged to receive and clamp insulated conductors (in the illustrated form being three conductors 12A, 12E, and 12N corresponding to the active, earth and neutral conductors) which form part of a flat TPS 13 when the parts are in the closed position. To allow the conductors to be clamped, the outer sheath of the TPS is stripped along a small length to reveal the inner insulated conductors (12A, 12E, 12N in the illustrated form). For convenience, markings 23 may be provided on the body 11 to indicate the strip length required. The connector 10 incorporates an electrical terminal such as a socket outlet 17 on one part 15 of the body 11, and the connector 10 is arranged to establish electrical contact between the conductors 12A, 12E, 12N and corresponding terminals of the socket outlet 42A, 42E, and 42N (see Fig. 5) on clamping of the insulated conductors.

The connector 10 further includes a snap fit latching arrangement 16 incorporating resilient tangs 18 incorporated on one part 14 of the body 11 that engage in a corresponding slot 20 formed in the other part 15 when the parts are moved to the closed position. The purpose of the latching arrangement 16 is to retain the parts in the closed position and prevent them from being easily opened. In use the snap fit latching arrangement 16 is a one way latch and typically only able to be released using a tool such as a screwdriver which would allow the parts 14, 15 to be moved from the closed position (in clamping engagement with the conductors) to the open position. The illustrated latching arrangement 16 includes two latches but any number of latches may be used. A separate lock 22 may be provided which is actuatable when the parts 14, 15 are in the closed position. The lock 22 holds the parts in tight fitting engagement in the closed position and provides an additional level of security to the connector 10 to maintain the body parts 14, 15 closed. The operation of the lock 22 will be described in more detail below.

An embodiment of the construction of the connector 10 that allows the electrical connection between the terminals 42A, 42E, and 42N of the socket outlet 17 and the conductors 12A, 12E, 12N is described below with reference to Figs 4 to 7.

In the illustrated form, the body 10 incorporates at least one channel for receiving the insulated conductors 12. As discussed above, the connector 10 is designed to make rapid and easy electrical connection to the at least one conductor 12 with only the removal of an outer sheath. The number of channels of the connector may correspond to the number of conductors. Alternatively, one channel may be configured to receive any number of conductors. In the illustrated form, three channels 30, 32, 34 are provided which correspond to each of the three conductors 12 A, 12E, 12N.

In the illustrated form, the channels are open and formed in body part 15 and extend across the part 15 and communicate with openings 35, 36 which allow the TPS 13 to extend through the connector 10.

To provide the electrical connection, contacting devices 40 are disposed in the respective channels. In the illustrated form, respective contact devices 40 are provided and disposed in respective channels 30, 32, and 34. These contact devices are conductive and typically formed from a copper alloy. As best shown in Fig. 5, each contact device 40 incorporates a set of insulation displacement contacts 41 and a contact terminal 42 for the socket outlet 17. The contact devices 40 as illustrated are in slightly different configurations to locate within the respective channels of the body part 15 and to be orientated correctly for the socket outlet 17. For convenience in the description below in some instances the references A, E, and N are used to differentiate between the specific ones of the contact devices 40 and their component parts as required.

Each set of insulation displacement contacts 41 are generally upstanding planar conductive portions having a sharp tip designed to pierce the insulation of the conductors 12. Each set of insulation displacement contacts include a plurality of contacts (43, 44, 45) that are conductive and are staggered laterally and spaced longitudinally apart. In the illustrated embodiment, each set of contacts includes three insulation displacement contacts but it is to be appreciated that the set may include more than three or possibly two. The respective socket terminals which are bifurcated are configured to extend into a socket 17 of the connector and therefore project in the opposite direction (see Fig. 6 which shows contact device 40N).

The contact devices (40A, 40E, and 40N) are disposed in the respective channels 30, 32, 34 so that the contacts (43, 44, 45) of the sets of insulation displacement contacts 41 are staggered laterally and spaced longitudinally along the respective channels. Electrical connection may be made between the insulated conductors 12A, 12E and 12N and the contact device 40A, 40E, and 40N by piercing of one or more of the contacts 43, 44, 45 into each of conductors. The staggering and spacing of contacts allows the conductor to accommodate conductors of different diameters.

In the illustrated embodiment, each channel 30, 32, 34 is approximately 2.5mm wide to receive any size conductor having an area of between 1mm2 and 2.5 mm2. However, it is understood, that larger conductors (e.g. 6 mm2) may be used, in which case the size of each channel, or a respective one of the channels may be increased to accommodate the larger size conductors. If a smaller than 1 mm2 conductor is used, then additional insulation displacement contacts may be included in the channel to facilitate electrical contact.

As best shown in Figs. 5 and 7, the position of the insulation displacement contacts 43, 44, 45 in its respective channel is advantageous for making electrical contact with a conductor of different sizes. The insulation displacement contacts 43, 44, 45 are staggered laterally in their respective channel (see Fig. 5). For example, if a 1 mm conductor is received in a 2.5mm wide channel, then at least one of the insulation displacement contacts will make electrical connection with the 1.0 mm2 conductor despite the width of the conductor being smaller than the width of the channel. The insulation displacement contacts 43, 44, 45 are able to make electrical contact with the conductor 12 because at least one is offset from another across the width of the channel 30, 32, 34. Advantageously, no matter where the conductor 12 lies in a respective channel 30, 32, 34, it will inevitably make contact with at least one of the insulation displacement contacts 43, 44, 45. The conductor may be, but is not required to be, centred and aligned in the channel and may be misaligned in the channel. This also facilitates electrical connection if the conductor is not placed in a straight line in the channel.

In the illustrated form, the insulation displacement contacts 43, 44, 45 are offset 1 mm in total from each other across the width of the respective channel. In alternative embodiments, the insulation displacement contacts may be offset across the entire width of the channel, and offset any distance from another insulation displacement contact. In another form, only one contact is offset whereas at least two are aligned.

Further, the insulation displacement contacts 43, 44, 45 are spaced longitudinally in the respective channel. In the illustrated embodiment, the insulation displacement contacts 43, 44, 45 also extend longitudinally in the channel 30, 32, 34. This embodiment is advantageous as it enables the contacts 40 to pierce the insulation and make an electrical connection rather than cutting the insulation and severing the core of the conductor 12. In alternative embodiments, the contacts may be spaced longitudinally and overlapping or spaced apart longitudinally.

To further assist in the orientation of the conductors in the channels, at least one guide is disposed in the at least one of the channels 30, 32, 34. In the illustrated embodiment, a plurality of guides 46, 48, 50 is shown in each channel. The guides 46, 48, 50 facilitate the electrical connection between the insulated conductors and the at least one insulation displacement contact by assisting in positioning of the conductors. The guides 46, 48, 50 project in the respective channels 30, 32, 34 so as to form constrictions in the channel width such that thicker conductors (in the order of 2.5 mm2) are required to lie in a tortuous path within the respective channel 30, 32, 34. For small conductors (in the order of 1 mm2) the conductors arranged to remain in a straight path in the channel substantially central within the channel.

These guides are disposed adjacent respective ones of the contacts so that regardless of whether the a thicker conductor aligned in a tortuous path in the channel or a smaller cable in a straight path in the channel, the conductor is presented to the contacts in a manner that at least one contact will pierce and make contact with the conductor core by a glancing cut (i.e., is offset from the centre of the core) that will not sever the core.

The conductors 12 are flexible and able to bend within each channel 30, 32, 34 to follow the indirect path formed by the guides 46, 48, 50. Together, the guides 46, 48, 50 and the lateral and longitudinal position of the insulation displacement contacts 43, 44, 45 in the channels 30, 32, 34 are configured to facilitate an effective electrical connection is made between the contacts 43, 44, 45 and the conductors 12. In the illustrated embodiment, guides are positioned adjacent the insulation displacement contacts. Additional guides may be disposed in the channel along its length to ensure a snug fit for the conductors in the channels. In an alternative embodiment, the guides may be disposed to define a tortuous path for each conductor without having specifically placed insulation displacement contacts. In a further alternative embodiment, the channel may be configured to define a tortuous path without the use of guide or specifically placed insulation displacement contacts.

In an example, a 1.0 mm conductor is received in the illustrated 2.5 mm channel 32. In the illustrated embodiment, the lateral distance between the guides is about 1 mm, and the insulation displacement contacts are offset laterally about 1.0mm. Because of the guides 46, 48, 50, the conductor 12E will be centred within the respective channel 32 and directly overlying the insulation displacement contacts 43, 44, 45 such that, when the conductor 12E is received in the channel an effective electrical connection is achieved between at least one of the insulation displacement contacts 43, 44, 45 and the conductor 12.

Each channel 30, 32, 34 includes surrounding walls and a bottom surface. The walls are more or less parallel to one another and perpendicular the bottom surface. The guides 46, 48, 50 protrude from the walls 24 toward the centre of each channel 30, 32, 64. In alternative embodiments, the guides may protrude from the bottom surface to force the conductor to one side or the other. In particular, if one large channel was used, then the guides protruding from the bottom surface may be beneficial to facilitate electrical connection between the contacts and the conductors by forming less defined channels without surrounding walls.

In a further example, a 2.0 mm2 conductor is received in the illustrated 2.5mm channel. The position of the guides 46, 48, 50 in each channel 30, 32, 34, and the lateral distance of 1.0mm between the guides 46, 48, 50 relative to the size of the conductor, urge the conductor to wind and bend about the guides 46, 48, 50 and follow the tortuous path defined by the guides 46, 48, 50. In this way, an effective electrical connection is made between at least one contact 43, 44, 45 and the conductor.

In yet a further example, a 2.5 mm2 conductor is received in the illustrated 2.5mm channel. In this case, the conductors snugly fits within each channel 30, 32, 34, and the guides 46, 48, 50 will indent (and slightly bend) the conductor. Again, the position of the guides 46, 48, 50 and the insulation displacement contacts 43, 44, 45 will ensure an effective electrical connection is made.

The electrical connector 10 includes a retaining portion 35 for retaining the conductors 12 in the channels. Further, when the first 14 and second 15 parts are moved to the closed position, an engaging arrangement 36 forces engagement between the at least one conductor with the at least one insulation displacement contact. The retaining portion 35 forms part of the engaging arrangement 36. The retaining portion 35 includes at least one projection extending from an internal surface of the first part 14 towards the second part 15 and corresponding to the at least one channel. In the illustrated embodiment, the first part 14 includes three projections 37, 38, 39 which correspond to each of the three channels 30, 32, 34, and more specifically correspond to the position of the insulation displacement contacts 43, 44, 45 in the channels 30, 32, 34. In the illustrated embodiment, the projections 37, 38, 39 are rectangular and extend longitudinally corresponding to the length of the set of insulation displacement contacts 41 and dimensioned to fit within the respective channel 30, 32, 34. In the closed position, the projections 37, 38, 39 overlie the insulation displacement contacts 43, 44, 45 and engage the conductors 12 to press down on the conductors 12 in the channels 30, 32, 34 and thus retain the conductors 12 in the channels and maintain the electrical connection between the contacts 43, 44, 45 and the conductors 12.

The engaging arrangement 36 also includes secondary projections 50 which press down on the cable 13 to retain the cable 13 in position when the connector is in the closed position.

As discussed above, the connector includes a lock 22 (Fig. 8E in a close-up view). In the closed position, the part 14 is locked to the part 15 by the lock 22. In the illustrated embodiment, the lock 22 is slideable relative to the connector 10 between a locked (Fig. 8D) and an unlocked position (Fig. 8C). When the lock 22 is in the locked position a positive connection is established. The lock 22 is beneficial as it allows users to confidently lock the connector 10 rapidly and there are no loose parts to be misplaced or inadvertently fall off. The lock 22 has an internal groove and a flange which extend longitudinally (not shown).

The part 15 includes a rail 52 which is configured to fit within the internal groove of the lock 22 such that the lock 22 slides back and forth along the rail 52 of the part 15. The rail 52 is formed along the outer edge of the part 15 opposite the hinge.

The part 14 includes a tab 54 which is configured to engage with the flange of the lock 22 to lock the part 14 in relation to the part 15. The tab 54 is positioned along the outer edge of the lock 22 aligned with the rail 52 and opposite the hinge. It is understood that the lock and the rail may be located on either part of the body, and the tab may be located on the opposite part of the body.

Figs 8 A to 8E illustrate the operation of the connector 10 to clamp the TPS 13, and are arranged sequentially.

First, referring to Fig. 8A, the part 14 of the body 11 is moved to an open position in relation to the part 15. A section of the outer sheath 19 of the cable 13 is removed that equivalent to approximately the length of the channels (e.g. markings 23 may assist to measure this length). Only the outer sheath 19 is removed.

Referring to Fig. 8B, once the outer sheath 19 is removed, the conductors 12 are inserted into the respective channels 30, 32, 34.

Referring to Fig. 8C, the part 14 is closed until it ‘clicks’. The audible ‘click’ indicates a successful snap-fit connection 16 between the part 14 and the part 15. After closing the lock 22 is moved from the unlocked position to the locked position as shown in Fig 8c by sliding it across the body to the position as shown in Fig. 8D where it engages the tab 54. A further embodiment of an electrical connector is shown in Figs. 9 to 12. Like numerals are used for like features. The primary difference between the second embodiment of the connector and the first embodiment of the connector is the engaging arrangement 136 is adjustable to accommodate different sizes of the insulated conductors that are arranged to be received in the at least one channel.

In this way, when the first and second parts are in the closed position, the engaging arrangement 136 forces the at least one conductor into engagement with the at least one insulation displacement contact regardless of the size of the at least one insulated conductor.

In the illustrated embodiment and best shown in Figs. 9, 10A and 10B, the engaging arrangement 136 includes at least one base projection in the form of three projections 137, 138, 139 positioned in the at least one channel. In one form, the three projections 137, 138, 139 correspond to the number of channels 30, 32, 34. It is understood, for example, that one channel may accommodate all three conductors. The engaging arrangement 136 also includes at least one secondary projection 150, which is in the form of two secondary projections 150.

As discussed above, Fig. 9 illustrates the body 11 of the electrical connector 10 that is formed from the two parts 14 and 15, which are hinged together and movable relative to each other between the open position (Figs, 9, 10A) and the closed position (Fig. 11 A). The first part 14 includes the three channels 30, 32, 34 for receiving the conductors 12. The connector 10 is arranged to receive and clamp the insulated conductors 12A, 12E, 12N when in the closed position.

The projections 137, 138, 139 extend from the first part 14 towards the second part 15. The three projections 137, 138, 139 correspond to the position of the insulation displacement contacts 43, 44, 45 in the channels 30, 32, 34. The projections 137, 138, 139 are rectangular and dimensioned to fit within the respective channels 30, 32, 34, and extend longitudinally in the channels 30, 32, 34. In the closed position, the projections 137, 138, 139 force the conductors 12 into engagement with the insulation displacement contacts 43, 44, 45 in each channel 30, 32, 34 to effectively make the electrical connection. In the illustrated embodiment, the projections 137, 138, 139 overlie the insulation displacement contacts 43, 44, 45 to press down on the conductors 12 at the position where electrical contact is made.

The secondary projections 150 extend laterally across the cable 13 and at either end of the channels 30, 32, 34 to press down on the cable 13 to retain the cable 13 in position when the connector 10 is in the closed position. The secondary projections 150 complement the function of the projections 137, 138, 139.

The length of the projections 137, 138, 139 is adjustable to accommodate different size conductors. Likewise, the length of the secondary projections 150 is adjustable to accommodate different size conductors. In the illustrated embodiment, the length of the projections 137, 138, 139 and the secondary projections 150 is adjustable in that they are interconnected to form a removable engaging arrangement in the form of a packing 100. The packing 100 accommodates insulated conductors to vary the distance between the projections 137, 138, 139 and the conductors 12 in the closed position. The removable engagement arrangement 136 in the form of the packing 100 overlies the projections 37, 38, 39 and the secondary projections 50 of the first embodiment and respectively, the projections 137, 138, 139 extend the length of the projections 37, 38, 39, and likewise, the secondary projections 150 extend the length of the secondary projections 50. As a result, a smaller size conductor may be effectively electrically connected to the electrical connector. The projections 137, 138, 139 of the packing 100 fills otherwise empty space in the channels 30, 32, 34 to facilitate this electrical connection between the conductors 12 and the contacts 43, 44, 45. In the closed position, the packing 100 presses down on the conductors 12 forcing the conductors to make the electrical connection with the contacts 43, 44, 45.

The packing 100 is removable from the first part 14 to facilitate rapid connection of different size insulated conductors 12. In the illustrated embodiment, the packing 100 is engaged with the first part 14 by snap fit engagement. The packing 100 is formed from a resilient material and an internal surface (not shown) of the projections 137, 138, 139 include small lugs designed to fit within dimples 52 formed on the projections 37, 38, 39 to snap fit together. In addition, the secondary projections 50 on the first part include lugs 54 which are designed to fit within dimples formed on an internal surface of the secondary projections 150 (not shown) to snap fit together.

For example, in Figs. 9 to 1 IB, 1mm2 conductors are arranged to be received in the channels 30, 32, 34 of the second part 15. The packing 100 snap fits onto the first part 14. A portion of the outer sheath of the cable 13 is removed to allow the inner insulated conductors 12A, 12E, 12N to be revealed. The conductors 12 are arranged in the channels 30, 32, 34 and pressed down by hand on the contacts 43, 44, 45. The guides 48, 48, 50 discussed in relation to the first embodiment may be included in the channels of the second embodiment to facilitate the electrical connection between the conductors 12 and the contacts 43, 44, 45.

As shown in Figs. 11A and 1 IB, 1.0mm2 size conductors are shown in use with the connector 10 and the packing 100. The electrical connector 10 is moved to the closed position by closing the first part 14 in relation to the first part 15. The packing 100 presses down on the 1.0mm2 conductors 12 in the channels in the channels 30, 32, 34. The secondary projections 150 press down on the cable 13 to also retain the cable in position within the electrical connector 10.

In alternative embodiments, the retaining arrangement may be adjusted by moving the projections into position pressing on the conductors through a slidable or rotatable actuator or a ratchet mechanism. In each case, the projections would be contained within the body (either the first or the second part), and then moved into a position where they are pressing on the conductors to reinforce the electrical connection. The projections may or may not be required to move back into position within the body.

Further, the packing may be used with 1.5 mm2 conductors. A different size packing with projections of different dimensions may be suitable with 1.5 mm2 conductors. Alternatively, the packing may be used with any size conductor by employing different size projections.

Lastly, Fig. 12 shows removal of the packing 100 from the first part 14 of the body 11 so the connector 10 may be used with 2.5mm2 conductors. The packing 100 is easily removed through manual force from the first part 14 as it is engaged by snap fit.

Variations and modifications may be made to the parts previously described without departing from the spirit or ambit of the disclosure.

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

Claims

Claims

1. An electrical connector for making electrical connection to at least one insulated conductor comprising: a body having: at least one channel for receiving the at least one insulated conductor, a terminal; and a first set of insulation displacement contacts electrically connected to the terminal and being staggered laterally and spaced longitudinally in the at least one channel.
2. An electrical connector according to claim 1, further comprising at least one guide that projects into the at least one channel to facilitate making the electrical connection between the at least one insulated conductor and at least one of the insulation displacement contacts.
3. An electrical connector according to claim 2, wherein the at least one guide is disposed in the at least one channel to form a tortuous path for a conductor disposed in said channel.
4. An electrical connector according to any one of the preceding claims, wherein the insulation displacement contacts extend longitudinally in the at least one channel.
5. An electrical connector according to any one of the preceding claims further comprising a retaining portion for retaining the at least one conductor in the at least one channel.
6. An electrical connector according to any preceding claim, wherein the body further comprising first and second first and second parts moveable in relation to each other from an open position where access is provided to locate the at least one conductor in the at least one channel to a closed position where the at least one conductor is captured in the at least one channel.
7. An electrical connector according to claim 6, wherein in moving the first and second parts to the closed position, an engaging arrangement forces engagement between the at least one conductor with the first set of insulation displacement contacts.
8. An electrical connector according to claim 7, when dependent on claim 5, wherein the retaining portion forms part of the engaging arrangement.
9. An electrical connector according to any one of claims 6 to 8, further comprising a lock to lock the first and second parts in the in the closed position.
10. An electrical connector according to claim 9, wherein the lock comprises a retaining member slideable relative to the first and second parts.
11. An electrical connector according to claim 10, wherein one of the first and second parts includes the retaining member slideably mounted thereto and a flange, and the other of the first and second parts includes a tab, and in use movement of the retaining member over the tab causes the tab to engage the flange to lock the first and second parts together.
12. An electrical connector according to any preceding claim comprising at least one further terminal each having a further set of insulation displacement contacts electrically connected to that further terminal, the further set(s) of insulation displacement contacts being staggered laterally and spaced longitudinally in the or a respective one of the at least one channel.
13. An electrical connector according to claim 12, comprising a plurality of channels each incorporating a said set of insulation displacement contacts, each channel being arranged to receive a respective one of a plurality of insulated conductors.
14. An electrical connector according to claim 12 or 13, wherein the body includes a socket outlet incorporating the terminals.
15. An electrical connector for making electrical connection to at least one insulated conductor comprising a body having at least one channel for receiving the at least one insulated conductor, at least one insulation displacement contact disposed in the at least one channel, and at least one guide disposed in the at least one channel to facilitate positioning of the at least one insulated conductor to make electrical connection with the at least one insulation displacement contact.
16. An electrical connector according to claim 15, wherein the at least one guide is disposed in the at least one channel to form a tortuous path for a conductor disposed in said channel.
17. An electrical connector according to claim 15 or 16, wherein the at least one guide projects into the said channel so as to form a constriction in said channel.
18. An electrical connector for making electrical connection to at least one insulated conductor comprising: a body having at least one channel for receiving the at least one insulated conductor; a terminal; at least one insulation displacement contact disposed in the at least one channel and electrically connected to the terminal, wherein the body further comprising first and second parts moveable in relation to each other from an open position where access is provided to locate the at least one conductor in the at least one channel to a closed position where the at least one conductor is captured in the at least one channel, and at least one engaging arrangement, wherein in moving the first and second parts to the closed position, the engaging arrangement forces engagement between the at least one conductor with the at least one insulation displacement contact, wherein the at least one engaging arrangement is adjustable to accommodate different sizes of the at least one insulated conductor.
19. An electrical connector according to claim 18, wherein the engaging arrangement comprises at least one projection extending from an internal surface of one part of the body and is locatable in the at least one channel to force the at least one insulated conductor into engagement with the at least one insulation displacement contact, the engaging arrangement being adjustable to vary the distance between the at least one projection and the at least one insulated conductor in the closed position.
20. An electrical connector according to claim 19, wherein the length of the at least one projection is adjustable.
21. An electrical connection according to claim 20, wherein the length of the at least one projection is adjustable at least in part through having a base portion and a removable portion removably mountable on the base portion.
22. An electrical connector according to any one of claims 19 to 21, wherein the at least one projection is positioned to correspond to the position of the at least one insulation displacement contact.
23. An electrical connector according to any one of claims 19 to 22, wherein the at least one projection is dimensioned to fit within the at least one channel.
24. An electrical connector according to any one of claims 18 to 23, wherein the engaging arrangement further comprises at least one secondary projection which aligns with the cable to retain the cable in position in relation to the body in moving the parts to the closed position to facilitate the at least one insulated conductor making electrical connection with the at least one insulation displacement contact.
25. An electrical connector according to claim 24, when dependant on claim 21, wherein the at least one secondary projection also includes a base portion and a removable portion removably mountable on the base portion, and the removable portion of at least one projection and the at least one secondary projection are integrally formed as a packaging.