EP3108542B1

EP3108542B1 - Improved electrical connector

Info

Publication number: EP3108542B1
Application number: EP15711845.6A
Authority: EP
Inventors: Salvatore Prochilo
Original assignee: Wuerth Elektronik Stelvio Kontek SpA
Current assignee: Wuerth Elektronik Stelvio Kontek SpA
Priority date: 2014-02-17
Filing date: 2015-02-17
Publication date: 2019-04-03
Anticipated expiration: 2035-02-17
Also published as: EP3108542A1; WO2015121847A1

Description

The present invention refers to an electrical connector of small dimensions and through which it is possible to perform, in a particularly easy manner, the connection and disconnection of electrical cables with respect to the electrical connector itself.
In the state of the art there are numerous solutions of electrical connectors for the lighting industry, in particular but not exclusively concerning the connections between lighting apparatuses with light emitting diodes (LED). Some of these solutions are described, for example, in documents DE 10 2007 035336 B3 US 7513793 B2 , US 8328586 B2 , US 2011/0312228 A1 , DE 20 2012 103690 U1 and EP 1 555 726 A1 .
In general, the known electrical connectors currently on the market have some drawbacks. A first drawback is due to the fact that such electrical connectors are usually made by assembling a plurality of distinct components, whether they are made from conductive metallic material rather than insulating plastic material, with which the outer shell or casing of the connector is normally made. Current electrical connectors are therefore very bulky, in contrast with the tendency towards miniaturisation of the technical field of lighting apparatuses with light emitting diodes.
Another drawback of known electrical connectors is due to the fact that they do not always allow reliable use of the two main types of electric cables, in other words solid cables and so-called stranded cables, or "multi-strand" cables, which have different thicknesses to each other. A further drawback of known electrical connectors is due to the fact that the connection and disconnection of the electric cables is guaranteed exclusively by the use of additional tools, like for example screwdrivers, nails or similar tools. These tools are indeed necessary to make it possible to open the metallic contacts intended for the mechanical coupling of the electric cables. Yet another drawback of known electrical connectors is finally due to the fact that it is impossible, in many cases, to withdraw the electric cables for the subsequent reuse thereof without compromising the reliability of the connector or of the respective components for connecting and holding the electric cables themselves.
Documents DE 10 2007 035336 B3 and US 8328586 B2 in reality describe respective electrical connectors in which the capability of decoupling the electric cables from the respective metallic contacts is provided. This functionality is entrusted, in the case of document DE 10 2007 035336 B3 , to the use of an additional tool, schematised by a screwdriver, that requires further and suitable functional components on the electrical connector that allow the use of the additional tool itself. These functional components, acting not really in a controlled form, deform critical metallic parts adapted for holding the electric cables. In the case of document US 8328586 B2 , the decoupling functionality is entrusted to the correct operation of an element made of plastic material integrated in the containment body, also made of plastic material, of the electrical connector. However, due to its nature and the type of application to which it is subjected, such an element is deformed not so much by the insertion/removal action of the cables but rather, even before, in the step of reflow soldering (with temperatures close to 300°C for many tens of seconds) that the electrical connector undergoes in the implementation on the corresponding and appropriate electrical circuits.
In addition, the element made of plastic material having a lever function described in document US 8328586 B2 has a mechanical problem due to its relatively small dimensions. Such an element, indeed, is structurally not very suitable for undergoing continuous actuations that facilitate the insertion/removal of the electric cables.
The purpose of the present invention is therefore to make an improved electrical connector and assembly thereof that are capable of overcoming the aforementioned drawbacks of the prior art in an extremely simple, cost-effective and particularly functional manner.
In detail, a purpose of the present invention is to make an electrical connector and assembly thereof that are able to improve the technical and functional aspects of electrical connectors made according to the prior art. In particular, such technical and functional aspects concern the possibility of reducing the number of components necessary for the assembly of the connector, consequently reducing the size and bulk of the connector itself.
Another purpose of the present invention is to make an electrical connector and assembly thereof that do not require the use of additional tools to carry out the decoupling of the electric cables from the respective metallic contacts. The use of such additional tools, indeed, as well as forcing upon the electrical connector the addition of areas and/or components suitable for the purpose, with a consequent increase in the bulk dimensions and complexity of making the connector itself, can cause uncontrolled manoeuvres such as to cause permanent deformations that reduce the coupling capability of the electric cables.
A further purpose of the present invention is to make an electrical connector and assembly thereof that are able to improve the logistical and productive aspects of electrical connectors made according to the prior art. In particular, such logistical and productive aspects concern the possibility of having modular electrical connectors of predetermined shape, as well as modular electrical connectors that allow maximum flexibility of supply and use.
Yet another purpose of the present invention is to make an electrical connector and assembly thereof that are able to improve the economic aspects of electrical connectors made according to the prior art, both in terms of the cost-effectiveness of solutions at the design, constructive and productive level, and in terms of lower implementation cost and greater flexibility of use.
These purposes according to the present invention are accomplished by making an assembly comprising an improved electrical connector and a casing as outlined in claim 1.
Further characteristics of the invention are highlighted by the dependent claims, which are an integral part of the present description.
The characteristics and advantages of an improved electrical connector and assembly thereof according to the present invention will become clearer from the following description, given as a non-limiting example, referring to the attached schematic drawings, in which:

figure 1 is a perspective view of a first embodiment of the improved electrical connector;
figure 2 is a side view of the electrical connector of figure 1;
figure 3 is another side view of the electrical connector of figure 1;
figure 4 is a view from the front side, or open side, of the electrical connector of figure 1;
figure 5 is a view from the rear side, or closed side, of the electrical connector of figure 1;
figure 6 is a perspective view of a second embodiment of the improved electrical connector and assembly thereof according to the present invention;
figure 7 is a side view, partially in section, of the electrical connector of figure 6;
figure 8 is a view from the front side, or open side, of the electrical connector of figure 6;
figure 9 is a view from the rear side, or closed side, of the electrical connector of figure 6;
figure 10 is a longitudinal section view of the electrical connector of figure 6; and
figure 11 is a perspective view that shows the union, through a suitable connection component, of two distinct electrical connectors of the type illustrated in figure 6.

With reference in particular to figures 1 to 5, a first embodiment of an improved electrical connector which is part of an assembly according to the present invention is shown, wholly indicated with reference numeral 10. The electrical connector 10 consists of a containment cage 12 with structural function, made with an electrically conductive material, preferably metal.
The substantially parallelepiped-shaped containment cage 12 is provided with a pair of lateral walls 14, a lower wall 16 and an upper wall 18 that develop according to a substantially longitudinal direction. The containment cage 12 is also provided with a closure wall 20 at a rear end thereof. the containment cage 12 thus delimits a substantially closed inner compartment for housing electric wires or cables (not shown) of various type and size. The containment cage 12 is also provided, at the front end thereof, with an opening 22 for the insertion of at least one electrical wire or cable to be removably connected to the electrical connector 10.
An elastic pressure element 24 configured to hold the electric cable in contact with the lower wall 16 of the containment cage 12 extends from the upper wall 18 towards the inner compartment of said containment cage 12. In other words, the elastic pressure element 24, preferably consisting of a flexible metal tab, operates as electrical contact element and simultaneously holds - by friction - the electric cable, exploiting the opposition force exerted by the lower wall 16 of the containment cage 12. One or more elements 26 for connection with electrical circuits for the transmission of the signals transferred by the electric cable extend from the lower wall 16 towards the outer part of the containment cage 12.
On at least one of the lateral walls 14 of the containment cage 12, at the opening 22, a longitudinal slit 28 extends, adapted for the insertion and guided movement, in the longitudinal direction, of a corresponding pin 30 (figure 7) that, acting as an opening lever, opposes the action of the elastic pressure element 24 and allows the electric cable to be inserted/extracted with respect to the electrical connector 10. The pin 30 is advantageously made of an insulating material, like for example a plastic material.
The lateral walls 14, the lower wall 16, the upper wall 18, the closure wall 20, the elastic pressure element 24 and the one or more elements 26 for connecting with electrical circuits are made from a single block of electrically conductive material, preferably metal, folded over on itself to form the containment cage 12. The structural and box-shaped strength of the block that constitutes the containment cage 12 is guaranteed by a fit-coupling obtained through one or more engagement couplings 32 obtained on one of the longitudinal sides of such a containment cage 12, so that such one or more engagement couplings 32 are capable of irreversibly connecting the lower wall 16 to one of the lateral walls 14 of the containment cage 12.
More specifically, at least two engagement couplings 32 are provided on one of the two longitudinal edges of the lower wall 16 of the containment cage 12, such engagement couplings 32 being formed in an integral manner with the lower wall 16 itself. The engagement couplings 32, of predetermined shape, are configured to fit-couple in corresponding cavities 34 obtained on the lower edge of the corresponding lateral wall 14. The cavities 34 are countersunk-shaped and match with the shape of the corresponding engagement couplings 32, so as to guarantee an irreversible fit-coupling between the lower wall 16 of the containment cage 12 and the corresponding lateral wall 14 of the containment cage 12 itself.
Now with reference to figures 6 to 9, a second embodiment of the electrical connector 10 and assembly thereof according to the present invention is shown. In this second embodiment the containment cage 12 is at least partially enclosed by a substantially box-shaped casing 36, made with an insulating material and thus capable of electrically and thermally insulating the electrical connector 10 with respect to the surrounding environment.
The casing 36 is provided with a pair of lateral walls 40 and an upper wall 42 with longitudinal development, capable of covering the corresponding lateral walls 14 and upper wall 18 of the containment cage 12. The casing 36, on the other hand, is advantageously open at its front and rear ends, both to allow the passage of the electric cables, and to allow an axial sliding movement that will be described hereafter. The sliding coupling between the casing 36 and the containment cage 12 is indeed obtained in a simple manner and without the need to use special or dedicated tools.
In detail, the casing 36 is configured to move according to a substantially longitudinal direction with respect to the containment cage 12 once such a containment cage 12 has been connected to the respective electric circuit, for example through welding of the corresponding connection elements 26. The casing 36 is indeed provided, in its lower part, with a pair of sliding guides 38 with longitudinal development, which cooperate with the lower wall 16 of the containment cage 12 to allow a sliding movement of the casing 36 itself with respect to such a containment cage 12.
The axial sliding movement of the casing 36 allows the easy insertion/removal of the electric connection cables with respect to the electrical connector 10. In the case in which the electrical connector 10 is provided with the casing 36, indeed, such a casing 36 is internally provided with at least one abutment nib 56 that acts, with the longitudinal movement action of the casing 36, as a lever for opening the elastic pressure element 24, being inserted and moving in the longitudinal slit 28 of the containment cage 12.
For example, figure 7 shows an electrical connector 10 in an operative configuration in which the opening lever 30 or 56 of the elastic pressure element 24 does not interact with such an elastic pressure element 24. Such an opening lever 30 or 56, irrespective of its specific embodiment, is indeed at a predetermined distance D from the elastic pressure element 24. By making the casing 36 slide longitudinally with respect to the containment cage 12 the distance D can be cancelled out or, in other words, the opening lever 30 or 56 can be brought towards the elastic pressure element 24 until mutual contact is obtained between these two components. A further longitudinal advancement of the casing 36 ensures that the opening lever 30 or 56 opposes the action of the elastic pressure element 24, opening the electrical contact and releasing the electric cable without the need to intervene with external tools.
The casing 36 can in any case be provided, at the front end thereof intended for the insertion of the electric cable, with a notch 46 adapted for the positioning of a generic tool (screwdriver, punch, etc.). Such a tool allows the axial sliding movement of the casing 36 to be performed should accessibility to the electrical connector 10 be limited.
The electrical connector 10 can be provided with at least one connection component 48 capable of mutually connecting two or more analogous casings 36, so as to allow a modular assembly of two or more electrical connectors 10 to be obtained. Such a modular assembly is sometimes necessary when there is a need to selectively connect together multiple electric cables belonging to the same apparatus. The connection component 48 can be removably applied to the casings 36 and can be adapted both to monopolar electrical connectors 10, and to multipolar electrical connectors 10. Figure 11 represents, as an example, a multipolar electrical connector 10 with two connector parts. In the multipolar version the positioning distance between the single casings 36 can be different both in a homogeneous manner (for example different but constant distance for each position), and in a non-homogeneous manner (for example different distances between each single position). This allows the single modules to be assembled in such a way that their positioning on the tracks of the printed circuit can be satisfied irrespective of their number and their distance apart.
Preferably, the connection component 48 is used up to the step of soldering on the electric circuit, which typically takes place by reflow process. Such a connection component 48 can then be removed from the electrical connector 10 by disengaging its respective releasable hooking means 50 that work on the box-shaped body of each single casing 36.
The removal of the connection component 48 in the multipolar solutions allows the withdrawal of each single cable separately, as described earlier. Should the connection component 48 not be removed, the withdrawal functionality of the cables would in any case remain applicable, but allowing the removal of all of the cables in a single operation.
The casing 36 can also be provided, at the front end thereof intended for the insertion of the electric cable, with an abutment wall 44 that operates as safety element for preventing uncoupling to keep the casing 36 always slidably connected to the containment cage 12. The mechanical coupling of the containment cage 12 in the respective casing 36 can however be guaranteed both by the sliding guides 38 of the casing 36 itself, and by a projecting tooth 52 (figure 1), obtained on such a containment cage 12, which fits in a corresponding hollow seat 54 (figure 10) of the casing 36.
It has thus been seen that the improved electrical connector and the assembly thereof according to the present invention achieves the purposes specified earlier.
The improved electrical connector and the assembly thereof according to the present invention thus conceived can in any case undergo numerous modifications and variants, all of which are covered by the same inventive concept; moreover, all of the details can be replaced by technically equivalent elements. In practice, the materials used, as well as the shapes and sizes, can be whatever according to the technical requirements.
The scope of protection of the invention is therefore defined by the attached claims.

Claims

An assembly comprising an electrical connector (10) and a substantially box-shaped casing (36), the electrical connector (10) consisting of a substantially parallelepiped-shaped containment cage (12) with structural function, said containment cage (12) being provided with a pair of lateral walls (14), a lower wall (16) and an upper wall (18) which develop according to a substantially longitudinal direction and define a substantially closed inner compartment for housing at least one electrical wire or cable, said containment cage (12) also being provided, at a front end thereof, with an opening (22) for the insertion of said at least one electrical wire or cable to be removably connected to the electrical connector (10), wherein an elastic pressure element (24) extends from the upper wall (18) towards the inner compartment of the containment cage (12), so as to hold - by friction - said at least one electrical wire or cable in electrical contact with the lower wall (16), and wherein one or more elements (26) for connection with electrical circuits for the transmission of the signals transferred by said at least one electrical wire or cable extend from the lower wall (16) towards the outer part of the containment cage (12), wherein the lateral walls (14), the lower wall (16), the upper wall (18), the elastic pressure element (24) and the one or more elements (26) for connection with electrical circuits are made from a single block of electrically conductive material, folded on itself to form the containment cage (12), the structural and box-shaped strength of the block forming said containment cage (12) being guaranteed by a fit-coupling obtained through one or more engagement couplings (32) formed on one of the longitudinal sides of said containment cage (12), so that said one or more engagement couplings (32) are capable of irreversibly connecting the lower wall (16) to one of the lateral walls (14) of said containment cage (12), wherein on at least one of the lateral walls (14) of the containment cage (12), at the opening (22), a longitudinal slit (28) extends adapted for the insertion and the guided movement, in the longitudinal direction, of a corresponding first opening lever (30) that, opposing the action of the elastic pressure element (24), allows said at least one electrical wire or cable to be inserted/extracted with respect to the electrical connector (10), wherein the containment cage (12) is at least partially enclosed by said substantially box-shaped casing (36), made of insulating material and capable of electrically and thermally insulating the electrical connector (10) with respect to the surrounding environment, said casing (36) being open at its front and rear ends, both to allow the passage of said at least one electrical wire or cable, and to allow said casing (36) to perform an axial sliding movement according to a substantially longitudinal direction with respect to the containment cage (12), said casing (36) being internally provided with at least one abutment nib (56) that acts, with the longitudinal movement action of said casing (36), as a second lever for opening the elastic pressure element (24), being inserted and moving in the longitudinal slit (28) of the containment cage (12).
Assembly according to claim 1, characterised in that said electrical connector (10) comprises at least two engagement couplings (32) on one of the two longitudinal edges of the lower wall (16) of the containment cage (12), said engagement couplings (32) being made integral with said lower wall (16) and being configured to fit in corresponding cavities (34) obtained on the lower edge of the corresponding lateral wall (14).
Assembly according to claim 2, characterised in that the cavities (34) are countersunk-shaped and match with the shape of the corresponding engagement couplings (32), so as to guarantee an irreversible fit-coupling between the lower wall (16) of the containment cage (12) and the corresponding lateral wall (14) of said containment cage (12).
Assembly according to claim 1, characterised in that said first opening lever (30) consists of a pin made from insulating material.
Assembly according to any one of claims 1 to 4, characterised in that the elastic pressure element (24) consists of a flexible metal tab.
Assembly according to any one of claims 1 to 5, characterised in that the containment cage (12) is provided with a closure wall (20) at a rear end thereof, said closure wall (20) being made integral with the single block of electrically conductive material of the electrical connector (10).
Assembly according to claim 1, characterised in that the casing (36) is provided with a pair of lateral walls (40) and an upper wall (42) with longitudinal development, capable of covering the corresponding lateral walls (14) and upper wall (18) of the containment cage (12).
Assembly according to claim 1, characterised in that the casing (36) is provided, at a lower part thereof, with a pair of longitudinal development sliding guides (38), which cooperate with the lower wall (16) of the containment cage (12) to allow the sliding movement of said casing (36) with respect to said containment cage (12).
Assembly according to any one of claims 1 to 8, characterised in that the casing (36) is provided, at the front end thereof intended for the insertion of said at least one electrical wire or cable, with a notch (46) that allows the axial sliding movement of said casing (36) to be performed should accessibility to the electrical connector (10) be limited.
Assembly according to any one of claims 1 to 9, characterised in that the casing (36) is provided with at least one connection component (48) capable of mutually connecting two or more analogous casings (36), so as to allow a modular assembly of two or more electrical connectors (10) to be obtained.
Assembly according to claim 10, characterised in that the connection component (48) can be removably applied to the casings (36) and for such a purposes it is provided with respective releasable hooking means (50) which operate on the box-shaped body of each casing (36).
Assembly according to any one of claims 1 to 11, characterised in that the casing (36) is provided with an abutment wall (44) that acts as safety element for preventing uncoupling and for maintaining the casing (36) always slidably connected to the containment cage (12).
Assembly according to any one of claims 1 to 12, characterised in that the mechanical coupling of the containment cage (12) in the respective casing (36) is guaranteed by a projecting tooth (52), obtained on said containment cage (12), which fits in a corresponding hollow seat (54) of the casing (36).