CA1087265A - Butt joint electrical connector - Google Patents
Butt joint electrical connectorInfo
- Publication number
- CA1087265A CA1087265A CA288,748A CA288748A CA1087265A CA 1087265 A CA1087265 A CA 1087265A CA 288748 A CA288748 A CA 288748A CA 1087265 A CA1087265 A CA 1087265A
- Authority
- CA
- Canada
- Prior art keywords
- article
- end portion
- conductor
- contact
- shaped
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
Abstract
Abstract of the Disclosure An article suitable for use in making a butt joint between first and second electrical conductors at least the first of which is a flat conductor. The article comprises an elongate electrically conductive member having two end portions each of which end portions is shaped to contact a respective electrical conductor, and the end portion which is shaped to con-tact the flat conductor having a generally flat surface portion for engagement with the flat conductor. The electrically conductive member is provided with a quantity of solder on at least the surface(s) thereof that will contact the conductors and is substantially infusible at the temperature to which the article is heated to cause fusing of the solder. At least part of the elec-trically conductive member is open in cross-section so that a soldered connection made using the article can be inspected. In use, conductors to be joined can be placed in contact with the article and heat applied to join the conductors to the article.
Description
~ ~72~
This applioation i~ a di~ision of applica~t'~ co-pend~ng Canadian sppli¢ation 8erial No. 173664.
The ln~entio~ rolate~ to article~ ~ultable ior u8e in electrical oonnectors capable oi iorming both an electrical and ph~sical connection between two or more conductore.
~lectrical and physical conneotione between two conductors are commonly mad~ by ~oldering the overlapped end~
of the eonductore together or by crimping a connector over the onde o~ the conduotor~. In man~ applicatione, it ie de~irable to make a traneition ~rom a ~lat conductor (whi¢h may be, ~or e~ample, in a ilat cablo) to a rou~d condu¢tor, but many oi the ¢ommonly u~ed connectors have been iound to b~ un~ati~iaetory ior thisO
One method o~ joinlng a ~lat conductor to a round eonduetor u~e~ a erimp connector ~hich i8 in the ~hape o~ a hollo~ c~lindorO ~he end Or the ~lat conductor i9 bent into a generally U-~haped eoniiguration along it~ longitudinal axi~
eo that thi~ end i~ capable o~ iltting into one end o~ the hollow cylindor~ ~he round conduetor i~ in~erted into the 20 other ond oi the hollow eylinder and the cylinder i8 cri~ped about each ¢onduetor. ~he conneetion i8 then u~uall~ potted ~ithin a re~ilie~t potting material to insulate the connection.
The cri~plng, however, oiten weakens the physical strength of the conductor~ and the connection i~ a relativel~ bulk~ and hea~y oneO
Overlapp~ng and eoldering of the t~o conductor~ has al80 beon u~ed to ~oin a ilat conductor to a round conductor but this method of con~e¢tion has the di~adva~tage o~ using e~txa wire, ae well as requiring a time-con~u~ing and ~kil~ul operatio~. Connection methods which emplo~ male and ~emale member~ con~ected to the re~pective conductors have al~o been , ~
iO87Z65 used but they may require considerable insertion force which must often be transmitted by the conductors them~elves, leading, in many instances, to difficulty in connection, bent conductors or an unsatisfactory connection.
Recently, a new type of heat-recoverable connector for electrical conductors has been developed which has a plurality of interconnected tubular members for receiving, for example, individual conductors of a multi-conductor cable. me connector may have a quantity of solder and flux within each tubular member. When two electrical conductors are to be joined, they are inserted into opposite ends of a tubular member and the connector is heated to cause the ; heat-recoverable material to shrink around the conductors and the solder tG melt and flow around the stripped ends of the conductors. Devices of this nature are described in Belgian Patent Specifications ~os. 110,571 and 110,572.
The present invention provides an article suitable for use in a connector suitable for making a butt joint between a round electrical conductor and a flat electrical conductor, which article comprises an elongate electrically conductive member having two end portions, one of which end portions is shaped to contact the round conductor and the other of which end portions is shaped to contact the flat conductor, and the end portion which is shaped to contact the flat conductor having a generally flat surface portion for engagement with the flat conductor, the electrically conductive member being provided with a quantity of solder on at least the surface(s) thereof that will contact the conductors and being substantially in-fusible at the temperature to which the article is heated to cause fusing of the solder, and at least part of the electrically conductive member being of open form so that at least one of the soldered connections made, in use~ to the article can be inspected.
As indicated above, at least part of the electrically conductive member in the article of the in-vention is of open form so that a soldered connection ~ade using the article can be inspected. The said part may be, for example, a part (for example an end portion) of the electrically conductive member which has a generally flat shape. Alternatively, the said part may be, for example, a hollow portion of the electrically conductive member having an aperture or slot therein. Preferably, at least a part of each end portion of the electrically conductive member is of open form.
In the article of the invention, the solder is preferably provided on at least those surfaces of the end portions of the electrically conductive member that will contact the conductors. The solder is advantageously in the form of a coating layer on the electrically conductive member and this coating may be on only a portion of one surface, on the whole of one surface, or on every surface of the member. The solder need not, however, be in the form of a coating, but could be, for example, in the form of a ring. The solder should be placed in such a way that it does not prevent the correct positioning of the conductors relative to the electrically conductive member.
The electrically conductive member preferably comprises a metal, and may, if desired, comprise a heat-~87265 recoverable metal. The metal should preferably be a goodelectrical conductor and should readily accept solder.
The metal i~ advantageously copper or an alloy thereof, preferably oxygen-free copper, electro tough pitch copper or beryllium copper. The electrically conductive member is preferably formed from a single sheet of electrically con-ductive material. Any of the methods known in the art for forming a shaped article from a flat sheet of material may be used in making the article of the invention. When the solder is in the form of a coating on the electrically conductive member, the sheet from which the member is made may be coated with a layer of solder (and, if desired, flux) either before or after it (the sheet~ has been formed into its final shape.
One of the end portions of the electrically con-ductive member~ is shaped to contact a round conductor and the other end portion is shaped to contact a flat conductor.
The end portion that is shaped ~)contact a round conductor may, for example, be U-shaped in cross-section or, alter-natively, may be cylindrical. A cylindrical end portion may have one or more apertures therein for viewing a con-ductor inserted in the end portion. This aperture may, for example, be round, or square and could if desired, be replaced by a uniform slot or other opening which permits inspection of a conductor inserted in the end portion.
A cylindrical end portion of the electrically con-ductive member may, if desired, be flared to facilitate the insertion of a conductor into that end portion. Flared ends help to eliminate a potential source of w~akness which might otherwise result from contact between the connector ends and the conductors. A cylindrical end portion may also, or alternatively, be ~rovided with pin-retaining means which may comprise, for example, one or more longitudinal slits ~n the end portion.
me end portion that is shaped to contact a flat conductor may have, for example, the shape of a flattened oval or a generally flat shape.
The article of the invention may be positioned within a hollow body of electrically insulating material, the hollow body having two open ends, to form a connector.
The hollow body is advantageously heat-recoverable and may comprise, for example a crosslinked polymeric material. The hollow body is preferably transparent to permit viewing the soldered connection. The hollow body may extend beyond the ends of the article, and may, if desired, be shaped to guide the conductors into contact with the article. A heat-activatable in~ulating material may be provided on the hollow body.
1~7~:65 In one embodiment of the connector, the hollow body may have a sheath portion and a plurality of spaced integrally connected tubular member~ communicating with the sheath portion, at least one, and preferably all, of the tubular members having an article of the invention therein.
Alternatively, the hollow body may have a series of longi-tudinal seam~ which extend from one end of the body to the other, which seams bond opposite walls of the mernber to each other to define and interconnect a plurality of tubular members, at least one, and preferably alL of the tubular members having an article of the invention therein.
The present invention substantially overcomes the disadvantages of the prior art devices and makes it possible to form a reliable electrical and mechanical connection between two or more conductors. This may be accornplished by, for example, the use of an article comprising a unitary conductive metallic member having two open ends which contain a coating of solder alloy and flux adjacent to at least a portion of the inner surface of the insert. At least part of the article is of open form to permit the viewing of the connection after completion. An article having one round end and one flat open end is particularly useful for joining a round conductor to a flat conductor. One end of the article rnay be in the form of a socket contact which can plug into a wire wrap pin.
~0~7265 One of the adYantage~ o~ a connector which in¢lude~
one or more articl~ of the in~ention is that it can have a small overall thicknes~ and thus can be u~ed, ~or e~ample, for the direct co~nection o~ a ilat cable with conductors whoee centres are ~paoed 0.100 inches apart and wire plns in a printed circult boardO ~he iact that the conne¢tor can be thin (ior e~ample approIimately 0.070 inchee) allow~ stacking on rowe Or 0.100 inch ~pacing. In some circumstancee, the de~ice may be only 0.030 inche~ thlck and, with ~uch a devics, conductor~
Nhose centre~ are spaced 0.050 inches apart mag be connected.
In the in~tallation oi the connectoriwhlch mag be made u81ng the article o~ the invention, the conductor end~, stripped if neces~ary, are in~erted into the connector a~d the a~embly i~ heated thu~ cau~ing the hollow body (1~ this ie heat-~hrinkable) to ~hrink about the conductor and to hold the etrippea ends a~ainst the article(s). Th0 heat ~urther cau~e~ the solder tand ilux, if used) to melt and electrically to connect a pair oi conductore to each article thereby electrically Joining the pair oi conductors~ When the connector compri~ee a plurality of articles held within the hollow body in a parallel and ~paced relation~hip, a parti-cularly u~eiul devioe re~ulto.
A paxticularly ~imple and yet e~ective electri¢al connection can re~ult ~rom the combinatio~ o~ an article oi the invention and a heat-recoverable member. The article ma~
have a completely open, ilat, end and yet may give an exoellent electrical oonta¢tO ~hi~ escellen¢e oi connection i~ a result o~ the iact that the conductor is held tightly again~t the article while the solder i~ heated to a temperature su~icient ~0 to cau~e it to melt and then cooled to allow it to ~olidi~y.
The invention will now be ds~cribed, by way oi 10~7265 example only, with reference to the accompanying drawings, in which:
Figure 1 is a perspective view of an article con3tructed in accordance with the pre-sent invention together with the strip-ped ends of two in3ulated conductors;
Figure 2 i~ a perspective view of a connector containing an article constructed in accordance with the present invention, Figure 3 i8 a perspective view of the connector of Figure 2 installed in the ends o two in~ulated conductors, the plastic sleeve which forms part of the connector being shown in phantom lines;
: 15 Figure 4 is a section taken along line 4-4 of Figure 1;
Figure 5 is a perspective view of a second em-bodiment o~ the present invention, Figure 6 is an end view taken along line 6-6 of Figure 5;
Figure 7 i~ a section taken along line 7-7 of Figure 5:
Figure 8 is a perspective view of a connector containing a plurality of artid es of ; 25 the present invention, . Figure 9 i-Y a perspective view of a third em-; bodiment of the present invention; and Figure 10 is a perspective view of the s~ipped end of a cable which comprises a 1i;)~7265 plurality of flat conductorq.
Referring now to the drawings, Figure 1 shows a unitary conductive metallic member 10. The member 10 has a generally U-shaped oval end 11, which i8 shaped to contact a round conductor, and a flattened oval end 12, which i9 shaped to ~ontact a flat conductor. The transition between these ends is indicated by the reference numeral 18. A
round insulated conductor 13 has a stripped end 14 which will fit within the U-shaped end 11 of the member 10, and a flat inRulated conductor 15 has a stripped end 16 which is capable of fitting w~thin the flattened oval end 12. The round oval end 11 i8 not closed in cross-section but has an opening 11a so that it is of open form and the completed soldered joint may thus be inspected. Similarly, the flattened oval end 12 is provided with an inspection slot 12a (see Figure 4~, and is thus of open form.
Each end of the unitary conductive metallic member 10 is flared to facilitate the insertion of the stripped ends 14 and 16. The member 10 is coated with a thin layer of a solder alloy 17 and is also provided with a portion of flux.
Although the solder layer is shown in the drawings as a continuous coating on both the inner and outer surface~ of the member, t may, instead, cover only a portion of the member 10. For instance, the layer 17 could cover only the inner surface of the member 10 or it could cover only those parts of the inner surface that will contact the stripped ends 14 and 16.
In operation, the stripped end 14 of conductor 13 is inserted into the U-~qhaped end 11, preferably ~o that it extends to the transition 18 betwéen the round andfLattened portions of the member 10. Similarly, the stripped end 16 _ 10 -~0~7265 of the conductor 15 i9 inserted into the flattened oval end 12, and preferably also extends transition 18. The member 10 and stripped ends are then heated by any suitable means, for example, infrared, hot air or induction heating, in order to melt the flux and solder alloy layer 17 which then flowR
onto stripped ends 14 and 16 thereby creating a secure electrical and mechanical connection. The amount of solder used is preferably sufficient to fill the space~ between the member 10 and the conductors. Although this is not essential, the ends of the conductors may be tinned to facili~ate the soldering step.
Turning now to Figure 2, the unitary member 10 of Figure 1 is shown positioned within a heat-recoverable sleeve 25. T~,e sleeve is preferably formed from an electrically insulating plastics material which has been conver~ed to a heat-recoverable state so that it will tend to shrink when it is heated to its heat-recovery temperature. Such heat-recoverable sleeves, and some of their many uses, are dis-closed in U.S. Patents Nos. 2,027,962 (Currie), 3,086,242 (Cook) and 3,243,211 (Wetmore). The sleeve 25 extends beyond the ends of the member 10 so that it can cover the stripped portions of the conductors which will be in~erted within member 10.
Figure 3 shows the connector of Figure 2 after it has been installed on the insulated conductors 13 and 15. The heat-recov~rable sleeve 25, which is shown in phantom lines, shrinks around the insulated conductors 13 and 15 and the con-ductive member 10. Although the member 10 and the heat-recoverable sleeve 25 are preferably installed simultaneously (that i~, in the form of the connector device of Figure 2), the sleeve 25 could be shrunk around an assembly made as ~L~8726~i described with re~pect to Figure 1. In the latter case, the sleeve 25 must, of course, be ~lipped over one of the con-ductor~ 13 and 15 before the latter are joined by the member 1O, and after such joining is moved into position around the mem~er 10 to form the complete connector.
A ~econd embodiment of the present invention i5 shown in Figure 5. This Figure shows an article 30 which comprises an outer layer 31 of a conductive material, for example copper or beryllium/copper alloy, and an inner layer 32 of a solder alloy. The article 30 ha~ a flat end 33 (that i9, an end with a generally flat shape) for contacting a flat conductor and a rounded end 34 for contacting a round conductor, and the solder layer 32 extends from the flat end to the rounded end. An opening 35 i8 located midway along the rounded portion of article 30. The opening 35 makes it pos~ible to inspect the interior of article 30 when a trans-parent heat-recoverable member is used around the article 30, thus allowing visual confirmation that a satisfactory soldered joint has been made.
The article 30 is shown in end view in Figure 6 and in longitudinal section in Figure 7. The flat end 33 of the article 30 i~ adapted for electrical connection with a flat conductor. A stripped end portion of a cable having a plurality of flat conductors 70, 71 and 72 which may be electrically connected to the flat end 33 is shown in Figure 10, the flat conductors 70, 71, and 72 are insulated from one another by electrically insulating material 73. The round end 34 of the artic]e 30 is adapted for electrical connection to a round conductor, for example that identified by reference numeral 14 in Figure 1 of the drawings.
A connector containing a plurality of conductive articles is shown in Figure 8. A heat-recoverable member 40 : ` ' of electrically in~ulating material has an open end 41 adapted to receive a plurality of flat conductors, the ends of which have been stripped (see, for example Figure 13). The member 40 has a second open end 42 which is adapted to receive a plurality of round conductors or a plurality of wire-wrapped conductor~ or the like, the ends of which have also been stripped. The open end 41 communicates with a sheath por-tion of the member 40 and the open end 42 communicates with a plurality of parallel tubular members. The extent to which the conductors are stripped should be auch that the conductor in~ulator i8 received within member 40 but does not extend into conductive articles, ~or example articles 43, 44 and 45, with which the member 40 is provided. The member 40 may be provided with a heat-activatable adhesive or oth~r softenable material which serves to insulate and seal a conductor from the adjacent conductors. This provides maximum voltage break down and insulating resi3tance values after the member 40 has been heated.
In operation, a plurality of flat conductors are stripped and inserted into open end 41. One conductor is in-serted against each of the conductive articles 43, 44, 45 etc., each of which article~ has one end which has a generally flat shape. Similarly, a stripped end of a round insulated conductor is inserted into the other end of each of the insert~, this second end being cylindrical in each case. The ~tripped ends of the conductors may be tinned to facilitate the soldering step. The member 40 is then heated by any con-ventional means, for example infrared, hot air or induction heating, in order to cause the heat-recoverable member 40 to recover against the inserted conductor~ and to cause the flux and solder layers of the conductive articles to melt and electrically connect the conductors to the inserts.
A third embodiment of the invention i~ shown in Figure 9. The conductive article 65 ~hown in Figure 9 ha~
a ~ocket end 66 and an end 67 having a generally flat shape.
At least the flat end 67 is coated with older. The flat end 67 functions in a manner analogous to the flat end 33 of insert 30 in Figure 5. The socket end 66 i~ flared outwardly to facilitate the insertion of a conductive pin therein. A
pair of slits 68 and 69 are provided in the side wall of the socket end 66 to give a spring action which tends to retain a pin of an appropriate diameter which has been inserted into end 66. The article 65 is preferably made from a metal having good resiliency and strength, for example beryllium copper.
.. ~ .. ~, .
This applioation i~ a di~ision of applica~t'~ co-pend~ng Canadian sppli¢ation 8erial No. 173664.
The ln~entio~ rolate~ to article~ ~ultable ior u8e in electrical oonnectors capable oi iorming both an electrical and ph~sical connection between two or more conductore.
~lectrical and physical conneotione between two conductors are commonly mad~ by ~oldering the overlapped end~
of the eonductore together or by crimping a connector over the onde o~ the conduotor~. In man~ applicatione, it ie de~irable to make a traneition ~rom a ~lat conductor (whi¢h may be, ~or e~ample, in a ilat cablo) to a rou~d condu¢tor, but many oi the ¢ommonly u~ed connectors have been iound to b~ un~ati~iaetory ior thisO
One method o~ joinlng a ~lat conductor to a round eonduetor u~e~ a erimp connector ~hich i8 in the ~hape o~ a hollo~ c~lindorO ~he end Or the ~lat conductor i9 bent into a generally U-~haped eoniiguration along it~ longitudinal axi~
eo that thi~ end i~ capable o~ iltting into one end o~ the hollow cylindor~ ~he round conduetor i~ in~erted into the 20 other ond oi the hollow eylinder and the cylinder i8 cri~ped about each ¢onduetor. ~he conneetion i8 then u~uall~ potted ~ithin a re~ilie~t potting material to insulate the connection.
The cri~plng, however, oiten weakens the physical strength of the conductor~ and the connection i~ a relativel~ bulk~ and hea~y oneO
Overlapp~ng and eoldering of the t~o conductor~ has al80 beon u~ed to ~oin a ilat conductor to a round conductor but this method of con~e¢tion has the di~adva~tage o~ using e~txa wire, ae well as requiring a time-con~u~ing and ~kil~ul operatio~. Connection methods which emplo~ male and ~emale member~ con~ected to the re~pective conductors have al~o been , ~
iO87Z65 used but they may require considerable insertion force which must often be transmitted by the conductors them~elves, leading, in many instances, to difficulty in connection, bent conductors or an unsatisfactory connection.
Recently, a new type of heat-recoverable connector for electrical conductors has been developed which has a plurality of interconnected tubular members for receiving, for example, individual conductors of a multi-conductor cable. me connector may have a quantity of solder and flux within each tubular member. When two electrical conductors are to be joined, they are inserted into opposite ends of a tubular member and the connector is heated to cause the ; heat-recoverable material to shrink around the conductors and the solder tG melt and flow around the stripped ends of the conductors. Devices of this nature are described in Belgian Patent Specifications ~os. 110,571 and 110,572.
The present invention provides an article suitable for use in a connector suitable for making a butt joint between a round electrical conductor and a flat electrical conductor, which article comprises an elongate electrically conductive member having two end portions, one of which end portions is shaped to contact the round conductor and the other of which end portions is shaped to contact the flat conductor, and the end portion which is shaped to contact the flat conductor having a generally flat surface portion for engagement with the flat conductor, the electrically conductive member being provided with a quantity of solder on at least the surface(s) thereof that will contact the conductors and being substantially in-fusible at the temperature to which the article is heated to cause fusing of the solder, and at least part of the electrically conductive member being of open form so that at least one of the soldered connections made, in use~ to the article can be inspected.
As indicated above, at least part of the electrically conductive member in the article of the in-vention is of open form so that a soldered connection ~ade using the article can be inspected. The said part may be, for example, a part (for example an end portion) of the electrically conductive member which has a generally flat shape. Alternatively, the said part may be, for example, a hollow portion of the electrically conductive member having an aperture or slot therein. Preferably, at least a part of each end portion of the electrically conductive member is of open form.
In the article of the invention, the solder is preferably provided on at least those surfaces of the end portions of the electrically conductive member that will contact the conductors. The solder is advantageously in the form of a coating layer on the electrically conductive member and this coating may be on only a portion of one surface, on the whole of one surface, or on every surface of the member. The solder need not, however, be in the form of a coating, but could be, for example, in the form of a ring. The solder should be placed in such a way that it does not prevent the correct positioning of the conductors relative to the electrically conductive member.
The electrically conductive member preferably comprises a metal, and may, if desired, comprise a heat-~87265 recoverable metal. The metal should preferably be a goodelectrical conductor and should readily accept solder.
The metal i~ advantageously copper or an alloy thereof, preferably oxygen-free copper, electro tough pitch copper or beryllium copper. The electrically conductive member is preferably formed from a single sheet of electrically con-ductive material. Any of the methods known in the art for forming a shaped article from a flat sheet of material may be used in making the article of the invention. When the solder is in the form of a coating on the electrically conductive member, the sheet from which the member is made may be coated with a layer of solder (and, if desired, flux) either before or after it (the sheet~ has been formed into its final shape.
One of the end portions of the electrically con-ductive member~ is shaped to contact a round conductor and the other end portion is shaped to contact a flat conductor.
The end portion that is shaped ~)contact a round conductor may, for example, be U-shaped in cross-section or, alter-natively, may be cylindrical. A cylindrical end portion may have one or more apertures therein for viewing a con-ductor inserted in the end portion. This aperture may, for example, be round, or square and could if desired, be replaced by a uniform slot or other opening which permits inspection of a conductor inserted in the end portion.
A cylindrical end portion of the electrically con-ductive member may, if desired, be flared to facilitate the insertion of a conductor into that end portion. Flared ends help to eliminate a potential source of w~akness which might otherwise result from contact between the connector ends and the conductors. A cylindrical end portion may also, or alternatively, be ~rovided with pin-retaining means which may comprise, for example, one or more longitudinal slits ~n the end portion.
me end portion that is shaped to contact a flat conductor may have, for example, the shape of a flattened oval or a generally flat shape.
The article of the invention may be positioned within a hollow body of electrically insulating material, the hollow body having two open ends, to form a connector.
The hollow body is advantageously heat-recoverable and may comprise, for example a crosslinked polymeric material. The hollow body is preferably transparent to permit viewing the soldered connection. The hollow body may extend beyond the ends of the article, and may, if desired, be shaped to guide the conductors into contact with the article. A heat-activatable in~ulating material may be provided on the hollow body.
1~7~:65 In one embodiment of the connector, the hollow body may have a sheath portion and a plurality of spaced integrally connected tubular member~ communicating with the sheath portion, at least one, and preferably all, of the tubular members having an article of the invention therein.
Alternatively, the hollow body may have a series of longi-tudinal seam~ which extend from one end of the body to the other, which seams bond opposite walls of the mernber to each other to define and interconnect a plurality of tubular members, at least one, and preferably alL of the tubular members having an article of the invention therein.
The present invention substantially overcomes the disadvantages of the prior art devices and makes it possible to form a reliable electrical and mechanical connection between two or more conductors. This may be accornplished by, for example, the use of an article comprising a unitary conductive metallic member having two open ends which contain a coating of solder alloy and flux adjacent to at least a portion of the inner surface of the insert. At least part of the article is of open form to permit the viewing of the connection after completion. An article having one round end and one flat open end is particularly useful for joining a round conductor to a flat conductor. One end of the article rnay be in the form of a socket contact which can plug into a wire wrap pin.
~0~7265 One of the adYantage~ o~ a connector which in¢lude~
one or more articl~ of the in~ention is that it can have a small overall thicknes~ and thus can be u~ed, ~or e~ample, for the direct co~nection o~ a ilat cable with conductors whoee centres are ~paoed 0.100 inches apart and wire plns in a printed circult boardO ~he iact that the conne¢tor can be thin (ior e~ample approIimately 0.070 inchee) allow~ stacking on rowe Or 0.100 inch ~pacing. In some circumstancee, the de~ice may be only 0.030 inche~ thlck and, with ~uch a devics, conductor~
Nhose centre~ are spaced 0.050 inches apart mag be connected.
In the in~tallation oi the connectoriwhlch mag be made u81ng the article o~ the invention, the conductor end~, stripped if neces~ary, are in~erted into the connector a~d the a~embly i~ heated thu~ cau~ing the hollow body (1~ this ie heat-~hrinkable) to ~hrink about the conductor and to hold the etrippea ends a~ainst the article(s). Th0 heat ~urther cau~e~ the solder tand ilux, if used) to melt and electrically to connect a pair oi conductore to each article thereby electrically Joining the pair oi conductors~ When the connector compri~ee a plurality of articles held within the hollow body in a parallel and ~paced relation~hip, a parti-cularly u~eiul devioe re~ulto.
A paxticularly ~imple and yet e~ective electri¢al connection can re~ult ~rom the combinatio~ o~ an article oi the invention and a heat-recoverable member. The article ma~
have a completely open, ilat, end and yet may give an exoellent electrical oonta¢tO ~hi~ escellen¢e oi connection i~ a result o~ the iact that the conductor is held tightly again~t the article while the solder i~ heated to a temperature su~icient ~0 to cau~e it to melt and then cooled to allow it to ~olidi~y.
The invention will now be ds~cribed, by way oi 10~7265 example only, with reference to the accompanying drawings, in which:
Figure 1 is a perspective view of an article con3tructed in accordance with the pre-sent invention together with the strip-ped ends of two in3ulated conductors;
Figure 2 i~ a perspective view of a connector containing an article constructed in accordance with the present invention, Figure 3 i8 a perspective view of the connector of Figure 2 installed in the ends o two in~ulated conductors, the plastic sleeve which forms part of the connector being shown in phantom lines;
: 15 Figure 4 is a section taken along line 4-4 of Figure 1;
Figure 5 is a perspective view of a second em-bodiment o~ the present invention, Figure 6 is an end view taken along line 6-6 of Figure 5;
Figure 7 i~ a section taken along line 7-7 of Figure 5:
Figure 8 is a perspective view of a connector containing a plurality of artid es of ; 25 the present invention, . Figure 9 i-Y a perspective view of a third em-; bodiment of the present invention; and Figure 10 is a perspective view of the s~ipped end of a cable which comprises a 1i;)~7265 plurality of flat conductorq.
Referring now to the drawings, Figure 1 shows a unitary conductive metallic member 10. The member 10 has a generally U-shaped oval end 11, which i8 shaped to contact a round conductor, and a flattened oval end 12, which i9 shaped to ~ontact a flat conductor. The transition between these ends is indicated by the reference numeral 18. A
round insulated conductor 13 has a stripped end 14 which will fit within the U-shaped end 11 of the member 10, and a flat inRulated conductor 15 has a stripped end 16 which is capable of fitting w~thin the flattened oval end 12. The round oval end 11 i8 not closed in cross-section but has an opening 11a so that it is of open form and the completed soldered joint may thus be inspected. Similarly, the flattened oval end 12 is provided with an inspection slot 12a (see Figure 4~, and is thus of open form.
Each end of the unitary conductive metallic member 10 is flared to facilitate the insertion of the stripped ends 14 and 16. The member 10 is coated with a thin layer of a solder alloy 17 and is also provided with a portion of flux.
Although the solder layer is shown in the drawings as a continuous coating on both the inner and outer surface~ of the member, t may, instead, cover only a portion of the member 10. For instance, the layer 17 could cover only the inner surface of the member 10 or it could cover only those parts of the inner surface that will contact the stripped ends 14 and 16.
In operation, the stripped end 14 of conductor 13 is inserted into the U-~qhaped end 11, preferably ~o that it extends to the transition 18 betwéen the round andfLattened portions of the member 10. Similarly, the stripped end 16 _ 10 -~0~7265 of the conductor 15 i9 inserted into the flattened oval end 12, and preferably also extends transition 18. The member 10 and stripped ends are then heated by any suitable means, for example, infrared, hot air or induction heating, in order to melt the flux and solder alloy layer 17 which then flowR
onto stripped ends 14 and 16 thereby creating a secure electrical and mechanical connection. The amount of solder used is preferably sufficient to fill the space~ between the member 10 and the conductors. Although this is not essential, the ends of the conductors may be tinned to facili~ate the soldering step.
Turning now to Figure 2, the unitary member 10 of Figure 1 is shown positioned within a heat-recoverable sleeve 25. T~,e sleeve is preferably formed from an electrically insulating plastics material which has been conver~ed to a heat-recoverable state so that it will tend to shrink when it is heated to its heat-recovery temperature. Such heat-recoverable sleeves, and some of their many uses, are dis-closed in U.S. Patents Nos. 2,027,962 (Currie), 3,086,242 (Cook) and 3,243,211 (Wetmore). The sleeve 25 extends beyond the ends of the member 10 so that it can cover the stripped portions of the conductors which will be in~erted within member 10.
Figure 3 shows the connector of Figure 2 after it has been installed on the insulated conductors 13 and 15. The heat-recov~rable sleeve 25, which is shown in phantom lines, shrinks around the insulated conductors 13 and 15 and the con-ductive member 10. Although the member 10 and the heat-recoverable sleeve 25 are preferably installed simultaneously (that i~, in the form of the connector device of Figure 2), the sleeve 25 could be shrunk around an assembly made as ~L~8726~i described with re~pect to Figure 1. In the latter case, the sleeve 25 must, of course, be ~lipped over one of the con-ductor~ 13 and 15 before the latter are joined by the member 1O, and after such joining is moved into position around the mem~er 10 to form the complete connector.
A ~econd embodiment of the present invention i5 shown in Figure 5. This Figure shows an article 30 which comprises an outer layer 31 of a conductive material, for example copper or beryllium/copper alloy, and an inner layer 32 of a solder alloy. The article 30 ha~ a flat end 33 (that i9, an end with a generally flat shape) for contacting a flat conductor and a rounded end 34 for contacting a round conductor, and the solder layer 32 extends from the flat end to the rounded end. An opening 35 i8 located midway along the rounded portion of article 30. The opening 35 makes it pos~ible to inspect the interior of article 30 when a trans-parent heat-recoverable member is used around the article 30, thus allowing visual confirmation that a satisfactory soldered joint has been made.
The article 30 is shown in end view in Figure 6 and in longitudinal section in Figure 7. The flat end 33 of the article 30 i~ adapted for electrical connection with a flat conductor. A stripped end portion of a cable having a plurality of flat conductors 70, 71 and 72 which may be electrically connected to the flat end 33 is shown in Figure 10, the flat conductors 70, 71, and 72 are insulated from one another by electrically insulating material 73. The round end 34 of the artic]e 30 is adapted for electrical connection to a round conductor, for example that identified by reference numeral 14 in Figure 1 of the drawings.
A connector containing a plurality of conductive articles is shown in Figure 8. A heat-recoverable member 40 : ` ' of electrically in~ulating material has an open end 41 adapted to receive a plurality of flat conductors, the ends of which have been stripped (see, for example Figure 13). The member 40 has a second open end 42 which is adapted to receive a plurality of round conductors or a plurality of wire-wrapped conductor~ or the like, the ends of which have also been stripped. The open end 41 communicates with a sheath por-tion of the member 40 and the open end 42 communicates with a plurality of parallel tubular members. The extent to which the conductors are stripped should be auch that the conductor in~ulator i8 received within member 40 but does not extend into conductive articles, ~or example articles 43, 44 and 45, with which the member 40 is provided. The member 40 may be provided with a heat-activatable adhesive or oth~r softenable material which serves to insulate and seal a conductor from the adjacent conductors. This provides maximum voltage break down and insulating resi3tance values after the member 40 has been heated.
In operation, a plurality of flat conductors are stripped and inserted into open end 41. One conductor is in-serted against each of the conductive articles 43, 44, 45 etc., each of which article~ has one end which has a generally flat shape. Similarly, a stripped end of a round insulated conductor is inserted into the other end of each of the insert~, this second end being cylindrical in each case. The ~tripped ends of the conductors may be tinned to facilitate the soldering step. The member 40 is then heated by any con-ventional means, for example infrared, hot air or induction heating, in order to cause the heat-recoverable member 40 to recover against the inserted conductor~ and to cause the flux and solder layers of the conductive articles to melt and electrically connect the conductors to the inserts.
A third embodiment of the invention i~ shown in Figure 9. The conductive article 65 ~hown in Figure 9 ha~
a ~ocket end 66 and an end 67 having a generally flat shape.
At least the flat end 67 is coated with older. The flat end 67 functions in a manner analogous to the flat end 33 of insert 30 in Figure 5. The socket end 66 i~ flared outwardly to facilitate the insertion of a conductive pin therein. A
pair of slits 68 and 69 are provided in the side wall of the socket end 66 to give a spring action which tends to retain a pin of an appropriate diameter which has been inserted into end 66. The article 65 is preferably made from a metal having good resiliency and strength, for example beryllium copper.
.. ~ .. ~, .
Claims (25)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. An article suitable for use in a connector suitable for making a butt joint between a round electrical conductor and a flat electrical conductor, which article comprises an elongate electrically conductive member having two end portions, one of which end portions is shaped to contact the round conductor and the other of which end portions is shaped to contact the flat conductor, and the end portion which is shaped to contact the flat conductor having a generally flat surface portion for engagement with the flat conductor, the electrically conductive member being provided with a quantity of solder on at least the surface(s) thereof that will contact the conductors and being substan-tially infusible at the temperature to which the article is heated to cause fusing of the solder, and at least part of the electrically conductive member being of open form so that at least one of the soldered connections made, in use, to the article can be inspected.
2. An article as claimed in claim 1, wherein at least part of each end portion is of open form.
3. An article as claimed in claim 1, wherein the surfaces of the electrically conductive member that are provided with solder are those surfaces of the end portions that will contact the conductors.
4. An article as claimed in claim 1, wherein the solder is in the form of a coating layer on the electrically conductive member.
5. An article as claimed in claim 1, wherein every surface of the electrically conductive member is coated with solder.
6. An article as claimed in claim 1, wherein the electrically conductive member is formed from a single sheet of electrically conductive material.
7. An article as claimed in claim 1, wherein the electrically conductive member comprises a metal.
8. An article as claimed in claim 7, wherein the metal comprises copper or an alloy thereof.
9. An article as claimed in claim 7, wherein the metal is a heat-recoverable metal.
10. An article as claimed in claim 1, wherein the end portion which is shaped to contact the round con-ductor is U-shaped in cross-section.
11. An article as claimed in claim 1, wherein the end portion which is shaped to contact the round conductor is cylindrical.
12. An article as claimed in claim 11, wherein the cylindrical end portion has one or more apertures therein.
13. An article as claimed in claim 11, wherein the cylindrical end portion comprises pin-retaining means.
14. An article as claimed in claim 13, wherein the pin-retaining means comprises one or more longitudinal slits in the end portion.
15. An article as claimed in claim 11, wherein the cylindrical end portion is flared.
16. An article as claimed in claim 1, wherein the end portion that is shaped to contact the flat conductor has the shape of a flattened oval.
17. An article as claimed in claim 1, wherein the end portion that is shaped to contact the flat conductor has a generally flat shape.
18. An article as claimed in claim 1, wherein the electrically conductive member comprises a layer comprising copper, and the solder is in the form of a layer on one surface of the electrically conductive member.
19. An article as claimed in claim 18, wherein the layer comprising copper is an outer layer of the article and the solder layer is an inner layer.
20. An article as claimed in claim 1, wherein the end portion that is shaped to contact the round conductor is U-shaped in cross-section and the end portion that is shaped to contact the flat conductor has the shape of a flattened oval having a longitudinal slit therein.
21. An article as claimed in claim 1, wherein the end portion that is shaped to contact the round conductor is cylindrical and has a viewing port therein and the end portion that is shaped to contact the flat conductor has a generally flat shape.
22. A modification of an article as claimed in claim 1, wherein the solder is in the form of a coating on the end portion which is shaped to contact the flat conductor, which end portion is generally flat in shape, and the end portion which is shaped to contact the round conductor is provided with pin-holding means.
23. An article as claimed in claim 1, which comprises a unitary conductive metallic member having a first flat flattened oval end for contacting the flat conductor and a second rounded oval end for contacting the round conductor, and a transition therebetween, and solder means within said member capable, upon melting, of joining said conductors to said member.
24. An article suitable for use in a connector suitable for making a butt joint between a round electrical conductor and a flat electrical conductor, which article comprises an elongate electrically conductive member which has first and second end portions and is provided with a quantity of solder on at least the surface(s) thereof that will contact the conductors, the first end portion being shaped to contact the round conductor and being U-shaped in cross-section whereby the said end portion is of open form so that the electrical connection made, in use, to that end portion can be inspected, and the second end portion being shaped to contact the flat conductor and having the shape of a flattened oval, the second end portion having a generally flat surface portion for engagement with the flat conductor and the oval having a longitudinal slit therein whereby the said end portion is of open form so that the electrical connection made, in use, to that end portion can be inspected, the electrically conductive member being substantially infusible at the temperature to which the article is heated to cause fusing of the solder.
25. An article suitable for use in a connector suitable for making a butt joint between a round electrical conductor and a flat electrical conductor, which article comprises an elongate electrically conductive member which has first and second end portions and is provided with a quantity of solder on at least the surface(s) thereof that will contact the conductors, the first end portion being shaped to contact the round conductor and being cylindrical and having a viewing port therein whereby the said end portion is of open form so that the electrical connection made, in use, to that end portion can be inspected, and the second end portion being shaped to contact the flat conductor and having a generally flat shape whereby the said end portion is of open form so that the electrical connection made, in use, to that end portion can be in-spected, the second portion having a generally flat surface portion for engagement with the flat conductor, the electrically conductive member being substantially infusible at the temperature to which the article is heated to cause fusing of the solder.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA288,748A CA1087265A (en) | 1972-06-12 | 1977-10-14 | Butt joint electrical connector |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US00262084A US3852517A (en) | 1972-06-12 | 1972-06-12 | Conductive insert for heat recoverable electrical connector |
| US262,084 | 1972-06-12 | ||
| CA173,664A CA1024627A (en) | 1972-06-12 | 1973-06-11 | Electrical connector having hollow insulator and conductive insert |
| CA288,748A CA1087265A (en) | 1972-06-12 | 1977-10-14 | Butt joint electrical connector |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1087265A true CA1087265A (en) | 1980-10-07 |
Family
ID=27162850
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA288,748A Expired CA1087265A (en) | 1972-06-12 | 1977-10-14 | Butt joint electrical connector |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1087265A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112993701A (en) * | 2019-12-17 | 2021-06-18 | 达昌电子科技(苏州)有限公司 | Wire converter |
-
1977
- 1977-10-14 CA CA288,748A patent/CA1087265A/en not_active Expired
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112993701A (en) * | 2019-12-17 | 2021-06-18 | 达昌电子科技(苏州)有限公司 | Wire converter |
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| MKEX | Expiry |