CA2087919A1 - Electrical connector - Google Patents
Electrical connectorInfo
- Publication number
- CA2087919A1 CA2087919A1 CA002087919A CA2087919A CA2087919A1 CA 2087919 A1 CA2087919 A1 CA 2087919A1 CA 002087919 A CA002087919 A CA 002087919A CA 2087919 A CA2087919 A CA 2087919A CA 2087919 A1 CA2087919 A1 CA 2087919A1
- Authority
- CA
- Canada
- Prior art keywords
- wire
- electrically conductive
- recess
- electrical connector
- recesses
- 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.)
- Abandoned
Links
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/24—Connections using contact members penetrating or cutting insulation or cable strands
- H01R4/2416—Connections using contact members penetrating or cutting insulation or cable strands the contact members having insulation-cutting edges, e.g. of tuning fork type
- H01R4/242—Connections using contact members penetrating or cutting insulation or cable strands the contact members having insulation-cutting edges, e.g. of tuning fork type the contact members being plates having a single slot
- H01R4/2425—Flat plates, e.g. multi-layered flat plates
- H01R4/2429—Flat plates, e.g. multi-layered flat plates mounted in an insulating base
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/24—Connections using contact members penetrating or cutting insulation or cable strands
- H01R4/2404—Connections using contact members penetrating or cutting insulation or cable strands the contact members having teeth, prongs, pins or needles penetrating the insulation
Abstract
ABSTRACT OF THE DISCLOSURE
An electrical connector comprises a housing of electrically insulating material and at lea t two recesses each of which is sized and adapted to receive an insulated wire. The electrical connector also has an electrically conductive extension member positioned in the housing. A
cutting edge is fixedly mounted in each recess and is electrically conductively connected to the extension member.
An electrical connector comprises a housing of electrically insulating material and at lea t two recesses each of which is sized and adapted to receive an insulated wire. The electrical connector also has an electrically conductive extension member positioned in the housing. A
cutting edge is fixedly mounted in each recess and is electrically conductively connected to the extension member.
Description
~P Fil~ No. 6883-002 2 0 ~ 7 ~
Title: ELECTRIC~ CON~lECrl~OR
FIELD OF l~IE INVENTION
This invention relates to a device for making an electrical connection with one or more insulated electrical wires. In particular, this invention relates to a device for making electrical connection with an insulated wire without stripping the insulation from the wire.
BAC~GROUND OF T~E INVE~TIO~
In various fields, it has always been necessary to make an electrical connection with one or more electrical wires. In particular, it has been necessary to connect electrical wires together to form a circuit. For example, in the construction of a building, electrical wires are run throughout the building to provicle light housings and electrical outlets. As the wires are piaced throughout the building, a single wire from a fusebox will be connected ~o several other wires so that a plura~ity of lights or electrical outlets ars operated by the same fuse.
Currently, in order to make a connection with insulated wires, the insulation is removed from the wire, the wires are then twisted together and excess wire is removed. Finally, the bare connected wires are capped with an insulated sleeve which may consist of an exterior insulator and a core of copper or other acceptable material which is twisted onto the bare wires.
There are several disadvantages with this approach. First, the insulation must be removed from the wire without cutting, scraping or otherwise damaging the wire conductor. If the wire is damaged, then as the insulated sleeve is twisted on, the wire may break creating a gap in the circuit. Much time would be occupied in tracing all of the wires to locate -the break.
2 ~ 8 7 9 1 9 - 2 ~
Once the insulated sleeve has been placed on the bare wires, the sleeve and the wires are inserted into a ;~;
.
housing. Subsequently, the housing is closed. During this process, the insulated sleeve may become loose. In this case, the bare wires could come into contact with the junction box and cause a short.
SUNMARY OF THE INVENTION
It has now been found that these disadvantages may be overcome by using an electrical connector comprising a housing of electrically insulating material having at least two recesses, each of the recesses having an open end and an inner sealed end and being sized and -::
adapted to receive an insulated electrical wire;
electrically conductive e~tension means positioned in the housing; and, electrically conducted insulation penetration means fixedly mounted in each of the recesse~
and electrically conductively connected to the extension means, the penetration means having a cutting means for -cutting the insulation and contacting the wire.
In a further embodiment, the housing may be adapted to received both hot wires and neutral wires. In such an embodimen~, the housing has two sets of recesses and two electrically conducted extension means. One of the extension means is in contact with each of the recesses and one of the sets of recesses. The other extension means is in contact with each of the recesses in the othsr set of recesses. The two electrically conductivs extension means are positioned in the housing with a portion of said insulating material therebetween. Accordingly, the housing is adapted to receive a plurality of hot wires and a plurality of neutral wires.
- In a further embodiment of the instant invention, the housing may have two recesses and an electrically conductive extension means in contact with the insulation penetration means of a respective recess.
The electrically conductive extension means extends .- ~: :
. . ~ ~ :-:
'~
2 ~
Title: ELECTRIC~ CON~lECrl~OR
FIELD OF l~IE INVENTION
This invention relates to a device for making an electrical connection with one or more insulated electrical wires. In particular, this invention relates to a device for making electrical connection with an insulated wire without stripping the insulation from the wire.
BAC~GROUND OF T~E INVE~TIO~
In various fields, it has always been necessary to make an electrical connection with one or more electrical wires. In particular, it has been necessary to connect electrical wires together to form a circuit. For example, in the construction of a building, electrical wires are run throughout the building to provicle light housings and electrical outlets. As the wires are piaced throughout the building, a single wire from a fusebox will be connected ~o several other wires so that a plura~ity of lights or electrical outlets ars operated by the same fuse.
Currently, in order to make a connection with insulated wires, the insulation is removed from the wire, the wires are then twisted together and excess wire is removed. Finally, the bare connected wires are capped with an insulated sleeve which may consist of an exterior insulator and a core of copper or other acceptable material which is twisted onto the bare wires.
There are several disadvantages with this approach. First, the insulation must be removed from the wire without cutting, scraping or otherwise damaging the wire conductor. If the wire is damaged, then as the insulated sleeve is twisted on, the wire may break creating a gap in the circuit. Much time would be occupied in tracing all of the wires to locate -the break.
2 ~ 8 7 9 1 9 - 2 ~
Once the insulated sleeve has been placed on the bare wires, the sleeve and the wires are inserted into a ;~;
.
housing. Subsequently, the housing is closed. During this process, the insulated sleeve may become loose. In this case, the bare wires could come into contact with the junction box and cause a short.
SUNMARY OF THE INVENTION
It has now been found that these disadvantages may be overcome by using an electrical connector comprising a housing of electrically insulating material having at least two recesses, each of the recesses having an open end and an inner sealed end and being sized and -::
adapted to receive an insulated electrical wire;
electrically conductive e~tension means positioned in the housing; and, electrically conducted insulation penetration means fixedly mounted in each of the recesse~
and electrically conductively connected to the extension means, the penetration means having a cutting means for -cutting the insulation and contacting the wire.
In a further embodiment, the housing may be adapted to received both hot wires and neutral wires. In such an embodimen~, the housing has two sets of recesses and two electrically conducted extension means. One of the extension means is in contact with each of the recesses and one of the sets of recesses. The other extension means is in contact with each of the recesses in the othsr set of recesses. The two electrically conductivs extension means are positioned in the housing with a portion of said insulating material therebetween. Accordingly, the housing is adapted to receive a plurality of hot wires and a plurality of neutral wires.
- In a further embodiment of the instant invention, the housing may have two recesses and an electrically conductive extension means in contact with the insulation penetration means of a respective recess.
The electrically conductive extension means extends .- ~: :
. . ~ ~ :-:
'~
2 ~
outwaxdly from said housing and may be adapted to be received into an electrical outlet. One of the recesses may receive a hot wire and the other recess may receive a neutral wire. In this embodiment, the housing would be in the form of an electrical plug.
In a further embodiment of the instant invention, the electrical connector may comprise a housing of electrically insulating material having a recess, the recess having an open end and an inner sealed end and being sized and adapted to receive an insulated electrical wire; an electrically conductive extension means having a first end and a second end, the first end extending outwardly of the housing and the second being positioned in the housing; and, electrically conductive insulation penetration means mounted in the recess, the penetration means being electrically conductively connected to the second end of the extenSiQn means, the penetration means having cutting means for cutting the insulation encasing the wire and contacting the wire By using the device of the instant invention, it is possible to make an electrical connection with a wire without the need of carefully stripping the insulation ~rom the wire. Further, the use of the instant device provides a very quick way to make an electrical connection with an insulated wire. The electrical connection may simply be made by inserting a wire into a recess and, in one embodiment, applying an outward pressure to the wire.
ESRIRF DE:SCRIPTION OF THE I)RAWINGS
The substance and advantages of the invention may be more completely and fully understood by means of the following description of the accompanying drawings of a preferred embodiment of the electrical conductor which is the subject of this invention in which:
Fig. 1 is a perspective view of an electrical connector according to the instant invention.
"~`.. :~"~-,,, ,,, ,~ ! . " ' ' ' ~ ' Fig. 2 is a cross-sectîon along the lines 2-2 in Fig. l without the insulated wires inserted into the electrical connector.
Fig. 3 is a cross-section along the lines 2-2 in Fig. 1 with the electrical wires insert~ed therein.
Fig. 4 is a top plan view of an electrically conductive extension means and an electxically conductive insulation penetration means according to the embodiment of Figure 1.
Fig. 5 is a top view of the combined extension means/penetration means of Fig. 4 with the device folded for insertion into a mold for a housing.
Fig. 6 is a cross-section of'a second embodiment of the instant invention along the lines 2-2 in Fig. 1.
Fig. 7 is a top plan view of the combined extension means/insulation penetration means of the embodiment of Fig. 6.
Fig. 8 is,a cross-section alon~ the lines 2-2 of Fig. 1 of a second alternate embodiment of the instant invention.
~ig. 9 is a cross-section along the lines 2-2 in Fig. 1 of a third alternate embodiment of the instant invention.
DE:SCRIPq'ION OF 1~ PREFERRlED EMBODIMENq~
As shown in Figs. 1-4, the electrical connector - is generally designated by reference numeral 10 and comprises a housing 12, one or more recesses 14, electrically conductive insulation penetration means 16 and electrically conductive extension means 18. As discussed further below, electrical connector 10 may also comprise retention means.
Housing 12 may be mad~ from any electrically insulating material known to those skilled in the art.
Purther, housing 12 may be of a~y desixed shape pro~ided that the housing is large enouyh to have the desired number of recesses provided therein. The embodiment shown 2087919 :
In a further embodiment of the instant invention, the electrical connector may comprise a housing of electrically insulating material having a recess, the recess having an open end and an inner sealed end and being sized and adapted to receive an insulated electrical wire; an electrically conductive extension means having a first end and a second end, the first end extending outwardly of the housing and the second being positioned in the housing; and, electrically conductive insulation penetration means mounted in the recess, the penetration means being electrically conductively connected to the second end of the extenSiQn means, the penetration means having cutting means for cutting the insulation encasing the wire and contacting the wire By using the device of the instant invention, it is possible to make an electrical connection with a wire without the need of carefully stripping the insulation ~rom the wire. Further, the use of the instant device provides a very quick way to make an electrical connection with an insulated wire. The electrical connection may simply be made by inserting a wire into a recess and, in one embodiment, applying an outward pressure to the wire.
ESRIRF DE:SCRIPTION OF THE I)RAWINGS
The substance and advantages of the invention may be more completely and fully understood by means of the following description of the accompanying drawings of a preferred embodiment of the electrical conductor which is the subject of this invention in which:
Fig. 1 is a perspective view of an electrical connector according to the instant invention.
"~`.. :~"~-,,, ,,, ,~ ! . " ' ' ' ~ ' Fig. 2 is a cross-sectîon along the lines 2-2 in Fig. l without the insulated wires inserted into the electrical connector.
Fig. 3 is a cross-section along the lines 2-2 in Fig. 1 with the electrical wires insert~ed therein.
Fig. 4 is a top plan view of an electrically conductive extension means and an electxically conductive insulation penetration means according to the embodiment of Figure 1.
Fig. 5 is a top view of the combined extension means/penetration means of Fig. 4 with the device folded for insertion into a mold for a housing.
Fig. 6 is a cross-section of'a second embodiment of the instant invention along the lines 2-2 in Fig. 1.
Fig. 7 is a top plan view of the combined extension means/insulation penetration means of the embodiment of Fig. 6.
Fig. 8 is,a cross-section alon~ the lines 2-2 of Fig. 1 of a second alternate embodiment of the instant invention.
~ig. 9 is a cross-section along the lines 2-2 in Fig. 1 of a third alternate embodiment of the instant invention.
DE:SCRIPq'ION OF 1~ PREFERRlED EMBODIMENq~
As shown in Figs. 1-4, the electrical connector - is generally designated by reference numeral 10 and comprises a housing 12, one or more recesses 14, electrically conductive insulation penetration means 16 and electrically conductive extension means 18. As discussed further below, electrical connector 10 may also comprise retention means.
Housing 12 may be mad~ from any electrically insulating material known to those skilled in the art.
Purther, housing 12 may be of a~y desixed shape pro~ided that the housing is large enouyh to have the desired number of recesses provided therein. The embodiment shown 2087919 :
~' in Figs. 1-4 is adapted to receive four insulated wires.
As referred to herein, the insulated wire has an outer layer of insulation 24 and an inner core of electrically conductive wire 22. Each recess has an open end generally designated ~y reference numeral 30 and a sealed inner end generally designated by reference numeral 32. The length of the recess from open end 30 to inner sealed end 32 is sufficient to receive enough wire to make the desired electrical connection. The actual length of each recess 14 may vary to a large degree.
Insulated electrical wires come in a variety of standard gauge sizes. Each recess 14 is sized to receive a predetermined gauge of insulated electrical wire.
Accordingly, a different electrical connector must be manufactured for each different size gauge wire. The size of the recess can be easily determined by reference to the gauge of wire which the electrical connector is designed to house. Preferably, the recess is slightly larger in diameter than the diameter of the respective gauge wire which recess 14 is to receive. However, recess 14 may be approximately the same diameter as the wire so that thsre is a frictional force between the outside o~ insulation 24 and the wall of recess 14 impeding the withdrawal o the wire from recess 14.
Each recess 14 is provided with an electrically conductive insulation penetration means 16. Penetration means 16 has a cutting edge 34 which is adapted for cutting insulation 24 and contacting wire 22. Since penetration means makes electrical contact with wire 22, penetration means 16 is made from copper or any other suitable electrically conductive material.
Penetration means 16 is fixedly mounted in housing 12. As shown in Fig. 2, penetration means 16 is mounted in the wall of recess 14 with cutting edge 34 pro~imate the center of recess 14. Cutting edge 34 extends a sufficient distance in~o recess 14 so as to contact wire 22. Penetration means 16 and cutting edge 34 are 2 ~ 8 7 ~ 1 9 :
sufficiently rigid so as not to deflect as wire 2Z 1~
inserted into recess 14 and is also sufficiently rigid to cut insulation 24. Accordingly, the specific thickness of penetration means 16 will vary depending on the type and amount of insulation surrounding wire 22 and this, in turn, is dependant upon the gauge wire which rece~s 14 i9 sized to receive. ~
Penetration means 16 may also be provided with angled cutting edge 36 (see Fig. 4). Angled cutting edge 36 extends from the wall of recess 14 to cutting edge 34.
Accordingly, angled cutting edge 34 extends radially towards the center of recess 14 and inwardly towards sealed end 32. Accordingly, as the insulated wire is inserted into recess 14, insulation 24 fir~t contacts angled cutting edge 34. Subsequently, insuIation 24 comes into contact with cutting edge 34 and cutting edge 34 makes contact with wire 22.
Penetration means 16 is electrically conductively connected to electrically conductive extension means 18. In the embodiment shown in Fig. 3, two recesses are positioned in side-by-side relationship. In this embodiment, the extension means may comprise a piece of electrically conductive material extending from one penetration means 16 to a second means 16.
As discussed earlier, electrical connector 10 may also contain retention means 20. The retention means maintains each of the wires in its respective recess. The retention means may comprise a frictional fit between the electrical wire and the walls of the respective recess 14.
However, as shown in Figs. 3 and 4, retention means 20 may comprise a leaf spring 20 in each recess 14. At least one leaf spring extends into each of the recesses. Each leaf spring is fixedly biased inwardly towards sealed end 32 of recess 14. Each leaf spring 20 may be provided with a cutting edge which is generally designated by reference numeral 38. In operation, as a wire is inserted into recess 14, leaf spring 20 deflects inwardly and radially _ 7 _ 20879~
outwardly towards the wall of housing 12 to permit the wire to penetrate into recess 14. Once the wire has been inserted into recess 14, an outward pressure is applied to the wire. As the wire is pulled outwardly, cutting edge 38 digs into insulation 24 and causes leaf spring 20 to bend outwardly and radially inwardly thus causing cutting edge 38 to dig deeper into insulation 24. Once leaf spring 20 has cut into insulation 24, further outward movement of the wire is restrained.
The penetration means and retention means may be stamped from a single blank of electrically conductive material such as 1/32 inch brass. The stamped blank comprises a plate 42 having a plurality of holes 44. As will become more apparent, the blank may be stamped into first half 46 and second half 48. ~irst half 46 has two holes 44, two penetration means 16 and one extension means 18. Each hole 44 has a leaf spring 20 extending into each recess 14. Hole 44 has a diameter larger than that of recess 14. Accordingly, the insulated wire may enter recess 14 without contacting the portion of plate 42 surrounding hole 44. The advantage of the instant design is that, once plate 42 is encased in housing 12, no portion of the plate, with the exception of leaf spring 20, is exposed.
In Fig. 5, the stamped blank is shown in position where it is ready for insertion into the mold to form electrical contactor 10. Extension means 18 has been folded to extend upwardly towards what will be sealed ends 32 of recesses 14. Once the housing ha~ been completed, the electrical connector will be adapted to receive two hot wires into recesses 14a and two neutral wires into recesses 14b (see Fig.l). Suitable markings need be applied to the housing so that the person using the electrical connector will know which are the recesses which form the circuit for the hot wires and which are the two recesses which form the circuit for the neutral wires.
2~879~
The electrical connector may be modified to receive any desired number of hot wires and any desirQd number of neutral wires. Accordingly, plate 42 may contain a plurality of extension means 18 attached integrally thereto, each of which may have two perletration means 16 attached integrally therewith. Each half 46 and 48 would have an equal number of holes 44 so that an equal number o~ hot wires and neutral wires may be connected.
A further preferred embodiment is shown in Figs.
6 and 7. In Fig. 7, a stamped blank is shown which is adapted to receive four hot wires or four neutral wires.
In this case, the blank is provided as a one-piece unit.
Plate 42 has four holes 44 provided therein. Each hole is provided with two leaf springs 50. Leaf springs are provided with cutting edg~ 52. As with leaf springs 20, leaf springs 50 are fixedly biased inwardly towards sealed end 32 of the respective recess 14. The leaf springs are also flexible so as to deflect inwardly as the insulated wire is inserted into recess 14. Once the insulated wire has been inserted into recess 14, an outward pressure is applied to the wire. The outward pressure causes cutting edge 52 to dig into insulation 24. Leaf spring 50 is of a sufficient length such that cutting edge 52 is positioned on the leaf spring at a position proximate the center of recess 14. Accordingly, further outward movement of the insulation encased wire 22 causes cutting edge 52 to pierce all the way through insulation 24 and to contact electrically conductive wire 2~. Plate 42 is made of an electrically conductive material. Accordingly, plate 42 comprises the electrically conductive Sextension means 18 which connects leaf springs 50 and completes the electrical circuit.
Accordingly, the embodiment shown in Figs.`6 and 7 is adapted to receive up to four hot wires or up to four neutral wires. If only three wires are insertedr then a proper electrical connection is made between the three inserted wires. As leaf springs 50 are recessed some - 208791~
distance into housing 12, there are no exposed electrically conductive elements which extend outwardly of the elec~rical connector and accordingly not all :recesses 14 need be occupied.
Accordingly, a workman would use two electrical connectors 10 of ~he type shown in Figs. 6 and 7. One electrical connector 10 would be used to connect a plurality of hot wires and one electrical connector 10 would be used to connect an equal number of neutral wires.
Once again, plate 42 may have any desired number of holes 44 each having one or more leaf springs 50. Similarly, the embodiment of Figures 3 and 4 could be prepared without a break so that the unit would not comprise two halves 46 and 48 but a single, integral unit. In this form, plate 42 ~5 would comprise part of e~tension means 18 so as to form part of the circuit connecting the penetration means 16 of two of recesses 14 with the penetration means 16 of the other two recesses 14.
In the embodiment shown in Figs. 6 and 7, leaf springs 50 form both the retention means and penetration means 16. Further, plate 42 comprises extension means 18.
In the alternate preferred embodiment shown in Fig. 8, housing 12 has only one recess 14. A penetration means 16 is provided in recess 14. Electrically conductive extension means 18 has a first end 54 and a second end S6.
First end 54 extends out of housing 120 Second end 56 of extension means 18 is in electrically conductive contact with penetration means 16.
A further alternate preferred embodiment is shown in Fig. 9. This embodiment is similar to that shown in Fig. 8 except that -two recesses 14 are provided and two extension means 18 are provided. Each end 54 of each extension means 18 is adapted to be received into an electrical ou-tlet. Accordingly, Fig. 9 shows an alternate embodiment of the invention in which housing 12 in fact comprises an electrical plug. Second ends 56 of extension means 18 are the male engagement means of an electrical .
~, ~ ; :
plug which are to be received into an electrical outlet.
It would be apparent to those skilled in the art that numerous other variations of the instant invention may be prepared which are within th~e scope of this -invention including the number of recesses which are provided in the housing and the design of the penetration means, the extension means and the retention means.
As referred to herein, the insulated wire has an outer layer of insulation 24 and an inner core of electrically conductive wire 22. Each recess has an open end generally designated ~y reference numeral 30 and a sealed inner end generally designated by reference numeral 32. The length of the recess from open end 30 to inner sealed end 32 is sufficient to receive enough wire to make the desired electrical connection. The actual length of each recess 14 may vary to a large degree.
Insulated electrical wires come in a variety of standard gauge sizes. Each recess 14 is sized to receive a predetermined gauge of insulated electrical wire.
Accordingly, a different electrical connector must be manufactured for each different size gauge wire. The size of the recess can be easily determined by reference to the gauge of wire which the electrical connector is designed to house. Preferably, the recess is slightly larger in diameter than the diameter of the respective gauge wire which recess 14 is to receive. However, recess 14 may be approximately the same diameter as the wire so that thsre is a frictional force between the outside o~ insulation 24 and the wall of recess 14 impeding the withdrawal o the wire from recess 14.
Each recess 14 is provided with an electrically conductive insulation penetration means 16. Penetration means 16 has a cutting edge 34 which is adapted for cutting insulation 24 and contacting wire 22. Since penetration means makes electrical contact with wire 22, penetration means 16 is made from copper or any other suitable electrically conductive material.
Penetration means 16 is fixedly mounted in housing 12. As shown in Fig. 2, penetration means 16 is mounted in the wall of recess 14 with cutting edge 34 pro~imate the center of recess 14. Cutting edge 34 extends a sufficient distance in~o recess 14 so as to contact wire 22. Penetration means 16 and cutting edge 34 are 2 ~ 8 7 ~ 1 9 :
sufficiently rigid so as not to deflect as wire 2Z 1~
inserted into recess 14 and is also sufficiently rigid to cut insulation 24. Accordingly, the specific thickness of penetration means 16 will vary depending on the type and amount of insulation surrounding wire 22 and this, in turn, is dependant upon the gauge wire which rece~s 14 i9 sized to receive. ~
Penetration means 16 may also be provided with angled cutting edge 36 (see Fig. 4). Angled cutting edge 36 extends from the wall of recess 14 to cutting edge 34.
Accordingly, angled cutting edge 34 extends radially towards the center of recess 14 and inwardly towards sealed end 32. Accordingly, as the insulated wire is inserted into recess 14, insulation 24 fir~t contacts angled cutting edge 34. Subsequently, insuIation 24 comes into contact with cutting edge 34 and cutting edge 34 makes contact with wire 22.
Penetration means 16 is electrically conductively connected to electrically conductive extension means 18. In the embodiment shown in Fig. 3, two recesses are positioned in side-by-side relationship. In this embodiment, the extension means may comprise a piece of electrically conductive material extending from one penetration means 16 to a second means 16.
As discussed earlier, electrical connector 10 may also contain retention means 20. The retention means maintains each of the wires in its respective recess. The retention means may comprise a frictional fit between the electrical wire and the walls of the respective recess 14.
However, as shown in Figs. 3 and 4, retention means 20 may comprise a leaf spring 20 in each recess 14. At least one leaf spring extends into each of the recesses. Each leaf spring is fixedly biased inwardly towards sealed end 32 of recess 14. Each leaf spring 20 may be provided with a cutting edge which is generally designated by reference numeral 38. In operation, as a wire is inserted into recess 14, leaf spring 20 deflects inwardly and radially _ 7 _ 20879~
outwardly towards the wall of housing 12 to permit the wire to penetrate into recess 14. Once the wire has been inserted into recess 14, an outward pressure is applied to the wire. As the wire is pulled outwardly, cutting edge 38 digs into insulation 24 and causes leaf spring 20 to bend outwardly and radially inwardly thus causing cutting edge 38 to dig deeper into insulation 24. Once leaf spring 20 has cut into insulation 24, further outward movement of the wire is restrained.
The penetration means and retention means may be stamped from a single blank of electrically conductive material such as 1/32 inch brass. The stamped blank comprises a plate 42 having a plurality of holes 44. As will become more apparent, the blank may be stamped into first half 46 and second half 48. ~irst half 46 has two holes 44, two penetration means 16 and one extension means 18. Each hole 44 has a leaf spring 20 extending into each recess 14. Hole 44 has a diameter larger than that of recess 14. Accordingly, the insulated wire may enter recess 14 without contacting the portion of plate 42 surrounding hole 44. The advantage of the instant design is that, once plate 42 is encased in housing 12, no portion of the plate, with the exception of leaf spring 20, is exposed.
In Fig. 5, the stamped blank is shown in position where it is ready for insertion into the mold to form electrical contactor 10. Extension means 18 has been folded to extend upwardly towards what will be sealed ends 32 of recesses 14. Once the housing ha~ been completed, the electrical connector will be adapted to receive two hot wires into recesses 14a and two neutral wires into recesses 14b (see Fig.l). Suitable markings need be applied to the housing so that the person using the electrical connector will know which are the recesses which form the circuit for the hot wires and which are the two recesses which form the circuit for the neutral wires.
2~879~
The electrical connector may be modified to receive any desired number of hot wires and any desirQd number of neutral wires. Accordingly, plate 42 may contain a plurality of extension means 18 attached integrally thereto, each of which may have two perletration means 16 attached integrally therewith. Each half 46 and 48 would have an equal number of holes 44 so that an equal number o~ hot wires and neutral wires may be connected.
A further preferred embodiment is shown in Figs.
6 and 7. In Fig. 7, a stamped blank is shown which is adapted to receive four hot wires or four neutral wires.
In this case, the blank is provided as a one-piece unit.
Plate 42 has four holes 44 provided therein. Each hole is provided with two leaf springs 50. Leaf springs are provided with cutting edg~ 52. As with leaf springs 20, leaf springs 50 are fixedly biased inwardly towards sealed end 32 of the respective recess 14. The leaf springs are also flexible so as to deflect inwardly as the insulated wire is inserted into recess 14. Once the insulated wire has been inserted into recess 14, an outward pressure is applied to the wire. The outward pressure causes cutting edge 52 to dig into insulation 24. Leaf spring 50 is of a sufficient length such that cutting edge 52 is positioned on the leaf spring at a position proximate the center of recess 14. Accordingly, further outward movement of the insulation encased wire 22 causes cutting edge 52 to pierce all the way through insulation 24 and to contact electrically conductive wire 2~. Plate 42 is made of an electrically conductive material. Accordingly, plate 42 comprises the electrically conductive Sextension means 18 which connects leaf springs 50 and completes the electrical circuit.
Accordingly, the embodiment shown in Figs.`6 and 7 is adapted to receive up to four hot wires or up to four neutral wires. If only three wires are insertedr then a proper electrical connection is made between the three inserted wires. As leaf springs 50 are recessed some - 208791~
distance into housing 12, there are no exposed electrically conductive elements which extend outwardly of the elec~rical connector and accordingly not all :recesses 14 need be occupied.
Accordingly, a workman would use two electrical connectors 10 of ~he type shown in Figs. 6 and 7. One electrical connector 10 would be used to connect a plurality of hot wires and one electrical connector 10 would be used to connect an equal number of neutral wires.
Once again, plate 42 may have any desired number of holes 44 each having one or more leaf springs 50. Similarly, the embodiment of Figures 3 and 4 could be prepared without a break so that the unit would not comprise two halves 46 and 48 but a single, integral unit. In this form, plate 42 ~5 would comprise part of e~tension means 18 so as to form part of the circuit connecting the penetration means 16 of two of recesses 14 with the penetration means 16 of the other two recesses 14.
In the embodiment shown in Figs. 6 and 7, leaf springs 50 form both the retention means and penetration means 16. Further, plate 42 comprises extension means 18.
In the alternate preferred embodiment shown in Fig. 8, housing 12 has only one recess 14. A penetration means 16 is provided in recess 14. Electrically conductive extension means 18 has a first end 54 and a second end S6.
First end 54 extends out of housing 120 Second end 56 of extension means 18 is in electrically conductive contact with penetration means 16.
A further alternate preferred embodiment is shown in Fig. 9. This embodiment is similar to that shown in Fig. 8 except that -two recesses 14 are provided and two extension means 18 are provided. Each end 54 of each extension means 18 is adapted to be received into an electrical ou-tlet. Accordingly, Fig. 9 shows an alternate embodiment of the invention in which housing 12 in fact comprises an electrical plug. Second ends 56 of extension means 18 are the male engagement means of an electrical .
~, ~ ; :
plug which are to be received into an electrical outlet.
It would be apparent to those skilled in the art that numerous other variations of the instant invention may be prepared which are within th~e scope of this -invention including the number of recesses which are provided in the housing and the design of the penetration means, the extension means and the retention means.
Claims (20)
1. An electrical connector comprising:
(a) a housing of electrically insulating material having two recesses, each of said recesses having an open end and an inner sealed end and each being sized and adapted to receive an insulated electrical wire, (b) an electrically conductive extension means for each of said recesses, each of said extension means has a first end and a second end, said first end extending outwardly of said housing and adapted to be received into an electrical outlet, and said second end being positioned in said housing, and (c) electrically conductive insulation penetration means fixedly mounted in each of said recesses, one of said penetration means being electrically conductively connected to said second end of a respective extension means, (d) said penetration means having cutting means for cutting said insulation encasing said wire and contacting said wire.
(a) a housing of electrically insulating material having two recesses, each of said recesses having an open end and an inner sealed end and each being sized and adapted to receive an insulated electrical wire, (b) an electrically conductive extension means for each of said recesses, each of said extension means has a first end and a second end, said first end extending outwardly of said housing and adapted to be received into an electrical outlet, and said second end being positioned in said housing, and (c) electrically conductive insulation penetration means fixedly mounted in each of said recesses, one of said penetration means being electrically conductively connected to said second end of a respective extension means, (d) said penetration means having cutting means for cutting said insulation encasing said wire and contacting said wire.
2. The electrical connector of claim 1 further comprising retention means for maintaining each of said wires in each of said respective recesses.
3. The electrical connector of claim 2 wherein said cutting means and said retention means comprise a leaf spring extending into each of said recesses and fixedly biassed inwardly towards said sealed end of said respective recess.
4. The electrical connector of claim 3 wherein each of said leaf springs has a cutting edge positioned on said leaf spring at a position proximate the centre of said recess to pierce said insulation encased wire and to contact said wire.
5. The electrical connector of claim 4 wherein each of said leaf springs is flexibly mounted in said recess to deflect inwardly as said wire is inserted into said recess and said cutting edge is positioned on said leaf spring to cut into said insulation encasing said wire as an outwardly directed force is applied to said wire.
6. The electrical connector as claimed in claim 2 wherein said electrically conductive insulation penetration means comprises a longitudinally extending member, said member having a cutting edge proximate the centre of said recess.
7. The electrical connector as claimed in claim 6 wherein said retention means comprises a leaf spring flexibly mounted in each of said recesses to deflect inwardly as said wire is inserted into said recess, each of said leaf springs being adapted to engage said wire as an outwardly directed force is applied to said wire so as to maintain said wire in said respective recess.
8. The electrical connector as claimed in claim 7 wherein each of said electrically conductive insulation penetration means and said respective electrically conductive extension means are integrally formed.
9. An electrical connector comprising:
(a) a housing of electrically insulating material and at least two recesses, each of said recesses being sized and adapted to receive an insulated wire, and having an open end and an inner sealed end, (b) electrically conductive extension means positioned in said housing, and (c) electrically conductive insulation penetration means fixedly mounted in each of said recesses and electrically conductively connected to said extension means, (d) said penetration means having cutting means for cutting said insulation and contacting said wire.
(a) a housing of electrically insulating material and at least two recesses, each of said recesses being sized and adapted to receive an insulated wire, and having an open end and an inner sealed end, (b) electrically conductive extension means positioned in said housing, and (c) electrically conductive insulation penetration means fixedly mounted in each of said recesses and electrically conductively connected to said extension means, (d) said penetration means having cutting means for cutting said insulation and contacting said wire.
10. The electrical connector of claim 9 wherein said housing has four recesses and two electrically conductive extension means, each of said electrically conductive extension means being in contact with two of said two electrically conductive insulation penetration means, said electrically conductive extension means being positioned in said housing with a portion of said electrically insulating material of said housing therebetween.
11. The electrical connector of claim 9 wherein said housing has two electrically conductive extension means, two sets of recesses, each of said sets of recesses comprising at least two recesses, and two sets of electrically conductive insulation penetration means, one of said electrically conductive extension means being in contact with each of said electrically conductive insulation penetration means in one of said sets of penetration means and the other of said electrically conductive extension means being in contact with each of said electrically conductive insulation penetration means in said other set of penetration means, said two electrically conductive extension means being positioned in said housing with a portion of said electrically insulating material of said first portion therebetween.
12. The electrical connector of claim 11 further comprising retention means for maintaining each of said wires in each of said respective recesses.
13. The electrical connector of claim 12 wherein said cutting means and said retention means comprise a leaf spring extending into each of said recesses and fixedly biassed inwardly towards said sealed end of said respective recess.
14. The electrical connector of claim 13 wherein each of said leaf springs has a cutting edge positioned on said leaf spring at a position proximate the centre of said recess to pierce said insulation encased wire and to contact said wire.
15. The electrical connector of claim 14 wherein each of said leaf springs is flexibly mounted in said recess to deflect inwardly as said wire is inserted into said recess and said cutting edge is positioned on said leaf spring to cut into said insulation encasing said wire as an outwardly directed force is applied to said wire.
16. The electrical connector as claimed in claim 11 wherein said electrically conductive insulation penetration means comprises a longitudinally extending member, said member having a cutting edge proximate the centre of said recess.
17. The electrical connector as claimed in claim 16 wherein said retention means comprises a leaf spring flexibly mounted in each of said recesses to deflect inwardly as said wire is inserted into said recess, each of said leaf springs being adapted to engage said wire as an outwardly directed force is applied to said wire so as to maintain said wire in said respective recess.
18. The electrical connector as claimed in claim 17 wherein each set of said electrically conductive insulation penetration means and said respective electrically conductive extension means are integrally formed.
19. An electrical connector comprising:
(a) a housing of electrically insulating material having a recess, said recess having an open end and an inner sealed end and being sized and adapted to receive an insulated electrical wire, (b) an electrically conductive extension means having a first end and a second end, said first end extending outwardly of said housing, and said second end being positioned in said housing, and (c) electrically conductive insulation penetration means fixedly mounted in said recess, said penetration means being electrically conductively connected to said second end of said extension means, (d) said penetration means having cutting means for cutting said insulation encasing said wire and contacting said wire.
(a) a housing of electrically insulating material having a recess, said recess having an open end and an inner sealed end and being sized and adapted to receive an insulated electrical wire, (b) an electrically conductive extension means having a first end and a second end, said first end extending outwardly of said housing, and said second end being positioned in said housing, and (c) electrically conductive insulation penetration means fixedly mounted in said recess, said penetration means being electrically conductively connected to said second end of said extension means, (d) said penetration means having cutting means for cutting said insulation encasing said wire and contacting said wire.
20. The electrical connector of claim 19 further comprising retention means for maintaining said wire in said recess.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002087919A CA2087919A1 (en) | 1993-01-22 | 1993-01-22 | Electrical connector |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002087919A CA2087919A1 (en) | 1993-01-22 | 1993-01-22 | Electrical connector |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2087919A1 true CA2087919A1 (en) | 1994-07-23 |
Family
ID=4151032
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002087919A Abandoned CA2087919A1 (en) | 1993-01-22 | 1993-01-22 | Electrical connector |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2087919A1 (en) |
-
1993
- 1993-01-22 CA CA002087919A patent/CA2087919A1/en not_active Abandoned
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Dead |