FR2800207A1 - ELECTRICAL CONNECTOR AND METHOD FOR MANUFACTURING SUCH A CONNECTOR - Google Patents

Abstract

The present invention relates to a method of manufacturing electrical connectors (1) intended for connecting wireless electrical devices to a power supply circuit, which connectors comprise a base (2) and at least one contact strip (4), electrically connected to a supply cable (14), characterized in that at least one conductor (12) of the supply cable (14) is electrically directly connected in an irremovable manner on a strip (4).

Description

ELECTRICAL CONNECTOR AND METHOD FOR MANUFACTURING A

SUCH A CONNECTOR.

  The present invention relates to the field of electrical connectors for connecting wireless electrical devices to a power supply circuit. In particular, they may be electrical connectors of receptacles intended for heating water, such as

pitchers or kettles.

  We already know, from document WO 95/08204, an electrical connector 1 intended for the connection of wireless electrical devices to a supply circuit, comprising a base 2 and contact strips 4 (FIG. 1). Each contact strip 4 has a tongue: 6 capable of forming a male element on which a female element 10 is fitted. On this female element 10 is crimped one of the conductors 12

  constituting the power cable 14 of the electrical appliance.

  An object of the invention is to provide a method for manufacturing

  more economical electrical connectors.

  This object is achieved by a method of manufacturing electrical connectors intended for the connection of wireless electrical devices, to a supply circuit, which connectors include a base and at least one contact strip, electrically connected to a cable. power supply, characterized in that at least one non-removable electrically connected directly

  power cable conductor on a strip.

  Thus, the fact of directly electrically connecting the conductors of the power cable, on a strip, makes it possible not to use

  of female elements. This avoids the additional cost of these female elements.

  In addition, the method according to the invention thus makes it possible to dispense with the step consisting in engaging each female element on a tongue, and which corresponds to a manual operation which induces labor costs.

  and a slowdown in the production chain.

  The irremovable electrical connection is advantageously produced by crimping, electrical welding, by laser or ultrasound, soldering,

  piercing of insulation or displacement of insulation.

  Another object of the invention is to allow automation of the wiring of these electrical connectors. To this end, according to an embodiment of the method according to the invention, there is provided a method comprising a step consisting in inserting, in the base, a strip comprising a tongue and a crimping barrel, so that the barrel of crimping is projecting by

  compared to the external contours of the base.

  This arrangement is particularly advantageous when this process comprises a step consisting of inserting, by means of an automatic crimping tool, a conductor into a crimping barrel, since it allows easy access to the barrels, crimping tools

  automatic, to insert and crimp the conductors therein.

  This arrangement also makes it possible to avoid perforating the base and

  thus exposing connections to water inlets.

  Advantageously, the method according to the invention comprises an automated step of folding the barrel, to bring it into a plane of the base comprising a device for holding conductors in the base. This step is concomitant with (or immediately followed by) the fixing of each conductor in a holding device. The fact that each conductor is both crimped in a barrel and engaged in a holding device allows a connection of the power cable to the connector, particularly resistant to the efforts of

traction on the cable.

  According to another embodiment of the method according to the invention, an automated step is provided which consists in inserting, in the base, a strip capable of being connected to a conductor by

insulation displacement.

  Advantageously, according to this other embodiment of the method according to the invention, an automated step is also provided

  consisting of folding a non-removable tab on. the driver.

  Advantageously, the method according to the invention comprises an automated step consisting in introducing the power cable into a device for holding the cable in the base. This makes it even more resistant to traction, the cable connection

on the connector.

  Advantageously, the method according to the invention comprises an automated step of fixing a cover locked by at least one clip on the base. Thus, the assembly consisting of the base and the cover forms an independent standard functional unit which can be marketed as such to an appliance manufacturer which may

  incorporate it into various types of devices.

  For example, advantageously, the connector can be fixed

  automatically on a base by snap-fastening by means of a clip.

  Advantageously, the method according to the invention comprises an automated step consisting in inserting into the base, several strips extending parallel to each other. This advantageous characteristic considerably facilitates the automation steps, since the conductors can be brought in a single direction, in contact with the strips on which they will be fixed.

irremovable.

  According to another aspect, the invention is a connector obtained by

  the implementation of the method described above.

  Advantageously then, it is a connector intended for the connection of wireless electrical devices, to a supply circuit, comprising a base and at least one contact strip, electrically connected to a supply cable. It is characterized in that at least one conductor of the supply cable is electrically connected directly to the strip, of

irremovable manner.

  The connector then has the following advantageous, independent (but which can be taken in combination) and optional characteristics: - the strip has a tongue and a crimping barrel; - The strip is adapted to be connected to a conductor by displacement of insulation; - the strip has a non-removable tab; - The base includes a device for holding conductors in the base; and - the base comprises a device for holding the cable in the base. This last characteristic corresponding to the integration of a device for holding the cable, such as a cable clamp, to the connector, makes it possible in particular to save, on the length of cable, compared to the baffle devices filling the same function but

  requiring a folding of the cable on ten centimeters.

  According to yet another aspect, the invention is a base intended for the connection of wireless electrical devices to a supply circuit, comprising an electrical connector which comprises a base and at least one contact strip, electrically connected to a cable d power supply, which base is characterized in that at least one strand of the power cable is electrically connected

  directly on the coverslip, in a non-removable manner.

  In this case, advantageously, the base is fixed to the base by

at least one clip.

  Other aspects, aims and advantages of the invention will become apparent from

  reading the detailed description which follows. The invention will be better

  understood with reference to the drawings in which: - Figure 1 shows a bottom view, a connector of the prior art; - Figure 2 is a perspective representation, corresponding to a top view, of an electric kettle base, provided with a connector according to the present invention; - Figure 3 is a perspective representation, corresponding to a bottom view, of a connector obtained by the method according to the invention, after a step of inserting the strips in the base - Figure 4 shows a connector in perspective obtained by the method according to the invention, after a step consisting in inserting the conductors of the supply cable, into the crimp drums; - Figure 5 is a perspective representation, corresponding to a bottom view, of a connector obtained by the method according to the invention, after a step of bending the barrel in the base and engaging the conductors in devices maintenance; Figure 6 is a perspective representation of the connector shown in Figure 5, but this time seen from above; - Figure 7 is a perspective representation of a variant of the connector obtained by the method according to the invention, at the same manufacturing level as that corresponding to Figure 3; - Figure 8 is a perspective representation of the variant of the connector shown in Figure 7, in a manufacturing step equivalent to that of Figure 4; - Figure 9 is a perspective representation of the variant of the connector shown in Figures 7 and 8, in a step of the method according to the invention corresponding to Figure 5; - Figure 10 is a perspective representation of the variant of the connector shown in Figures 7 to 9, in a step of the method according to the invention, consisting in closing the base with a cover; - Figure 11 is a perspective representation of the variant of the connector shown in Figures 7 to 10, after the step of the method according to the invention of fixing a cover on the base - Figure 12 is a perspective representation of the variant of the connector shown in Figures 7 to 1 1, a step of the method according to the invention of fixing the connector on a base; - Figure 13 is a perspective representation of the variant of the connector shown in Figures 7 to 12, after the step of the method according to the invention of fixing the connector on a base; and - Figure 14 is a perspective representation of another variant of the connector obtained by the method according to the invention at the same manufacturing level as that corresponding to Figures 3 and 7; - Figure 15 is a perspective representation of the variant of the connector shown in Figure 14, in a manufacturing step equivalent to Figures 4 and 8; FIG. 16 is a perspective representation of the variant of the connector shown in FIGS. 14 and 15 at one stage of the method according to the invention corresponding to FIGS. 5 and

9;

  - Figure 17 is a perspective representation of the variant of the connector shown in Figures 14 to 16, in a step of the method according to the invention, consisting in closing the base with a cover; and FIG. 18 is a perspective representation of the variant of the connector shown in FIGS. 14 to 17, after the step of the method according to the invention consisting in attaching a cover to the base, the connector being seen from above, while the

  Figures 14 to 17 correspond to views from below.

  An example of implementation of the method according to the invention will be described below in detail. '' This method of implementing the method according to the invention is described below in correlation with the wiring of three variants

a connector 1.

  By way of example, these three variants of the connector 1 are described in the context of their use in a base 16 for a container intended for heating water, such as a pitcher or a kettle (Figure 2). For this example, connector 1 is

  positioned in a generally central orifice in the base 16.

  These three variants of connector 1 consist of a

  base 2 and terminals 8 (Figures 3, 7 and 14).

  The terminals 8 correspond to the female part intended to be fitted into a male part integral with the container to be heated. This female part of connector 1 is described in international application WO 95/8204. The terminals 8 comprise concentric inner 34 and outer 36 cylindrical walls which extend parallel to the axis of the cylinder 18 (Figures 2, 6 and 18). In Figures 3 to 5, and 7 to 17, only the cylindrical wall

external 36 is shown.

  The base 2 consists of a support of conductors 22 and a cylinder 18 surmounted by a frustoconical element 20 (Figures

4, 6 and 8).

  The frustoconical element 20 has a narrow end in continuity of material with the part of the connector 1 comprising the terminals 8 and a wide end in continuity of material with an edge of the cylinder 18. The other edge of the cylinder 18 is an edge

free 24.

  The frustoconical element 20 is placed on the cylinder 18, so as to form a cap, the wide end of the frustoconical element 20 projecting from the external face of the cylinder 18 ′, so as to form a flange 26 (FIGS. 3, 4 and 18). The ledge 26

  has two flats 27 extending on either side of it

  ci, in a plane perpendicular to the axis of the cylinder 18. One of these flats 27 abuts with the internal face of the base 16

  and cooperates in maintaining the connector 2 thereon.

  The support of conductors 22 extends, from the external face of the cylinder 18, parallel to the plane in which the free edge is located 24. The support of conductors 22 comprises three parallel channels 28 which open out inside the base 2 In section perpendicular to the axis of the channels 28, each channel has a U shape with a bottom 30 and two side walls 32. The three channels 28 are side by side, the central channel 28 having its two side walls 32 in common. with the other channels 28 (Figures

3, 7 and 14).

  According to the embodiment of the first variant of the connector 1 according to the invention (Figures 3 to 6), each channel 28 is provided near its end furthest from the cylinder 18 with two hooks 40, facing each other (Figure 3). Each hook 40 consists of a tab 42. Each tab 42 being in continuity of material, at one of its ends, with the bottom 30 of each channel 28. The other end of each tab 42 is provided with a tip 44 extending from the longitudinal axis of each tab 42 towards the middle zone of each channel 38, and projecting with respect to each tab 42. When a conductor 12 is pressed between the tips 44 of each pair of hooks 40, the flexible tabs 42 move apart and then tighten on the conductor 12 (Figure 5). The tips 44 prevent the conductor 12 from coming out of the channel 28 and the lugs 42 tighten on the conductor 12 so as to pinch the latter and participate in maintaining each conductor 12 in each channel 28,

  when a traction or a twist is applied between the cable '14-

and connector 1.

  According to the embodiment of the second and third variants of the connector 1 according to the present invention, the

  conductor support 22 also corresponds to the description of

  previous paragraph but is further extended, with respect to the first variant, on the side of the channels 28, furthest from the cylinder 18, by a part which narrows into a single channel

  intended for the insertion and maintenance of the cable 14 (Figures 7 to 17).

  This part constitutes a device for holding the cable in the base, hereinafter called a cable clamp "46. The internal faces of the walls and of the bottom of the cable clamp 46 are provided with two ribs 48 projecting from these internal faces ( 7, 8 and 14 to 17) These ribs 48 form walls perpendicular to the axis of the cable clamp 46, which locally reduce the dimensions

  of the cable clamp 46, so as to pinch the cable 14 when it

  this is inserted in the cable clamp 46 (Figure 9). Like the hooks, the ribs 48 participate in holding the cable 14 and the conductors 12 in the support of conductors 22 when a traction or a torsion is applied between the cable 14 and the

connector 1.

  The conductor supports 22, connectors 1 described above, are provided with lamellae 4 by the method according to the invention (Figures 3, 7 and 14). These strips 4 provide electrical conduction between the terminals 8 and the power cable

14.

  According to the first two variants (Figures 3 to 13), each strip 4 consists of a tongue 6 and a barrel 7. Each strip 4 is made of a conductive material capable of being deformed

  plastically. Such a material is for example brass.

  Each tongue 6 forms a spatula extending in a plane parallel to the longitudinal axis of each strip 4 (Figure's 3 '

and 7).

  Each barrel 7 is initially formed into a groove whose axis extends parallel to the longitudinal axis of each strip

  4. This groove has two side walls.

  According to the third variant (Figures 14 to 18), each strip 4 consists of a plate folded into a U-shaped channel with three walls 70, 71 perpendicular and connected

  longitudinally two by two by a fold.

  At one of the longitudinal ends of this channel, the two walls 70 which are opposite, has a notch 72 in V, the bottom of which continues with a notch 74. The notches 74 have dimensions corresponding approximately to the section of the conductors' cores 12 The wall of each strip 4 perpendicular to those comprising the notches 72, has at the longitudinal end of the walls, located on the same side as the notches 72, two cutouts near the folds, at a corresponding height to that of notches 72, to define

a leg 76 of non-dismantling.

  The base 2 is closed by a cover 50 (Figures 10 to 13).

  This cover 50 consists of a plate 55, generally in the form of a keyhole, comprising a disc-shaped part, in continuity of material with a mainly rectangular part. The disc-shaped part essentially closes the cylinder 18. The mainly rectangular part essentially closes the conductor support 22. The plate 55 is

  bordered by a peripheral wall 54 perpendicular thereto.

  This peripheral wall 54 is adapted to fit the external face of the cylinder 18 and the external side walls 32 of the two outermost channels 28. The plate 55 is also provided with a peripheral edge 56 extending in a plane parallel to the latter. Three holes 53 are drilled in the edge 56, one at the edge of the disc-shaped part opposite the conductor support 22, and the other two, at the edge of a mainly rectangular part, on either side. of the two outermost channels 28. The cover 50 is also provided with a hole 57 located in the disc-shaped part, in the zone corresponding to the end of the central channel 28, on the side of the

cylinder 18 (Figure 10).

  The edge 56 keeps the cable 14 on the base

  2, when the cable 14 is coiled around the base 2.

  This characteristic is particularly advantageous when one wants to adjust the length of the cable 14 or when one wants to store the electrical appliance equipped with the connector 1 according to the invention.

  The first two variants of connector 1 described below

  above are provided with a pivot 51. This pivot 51 is located at the end of the central channel 28, on the side of the cylinder 18. This pivot 51 is perpendicular to the plane of the free edge 24 of the cylinder 18, and projecting with respect to this plan (Figure 10). This pivot 51 constitutes

  a clip capable of being snapped into hole 57 (Figure 11).

  The cover 50, when it is in place on the base 2,

  participates in maintaining the cable 14 in the cable clamp 46.

  The base 16 consists of a disc resting on a peripheral hem 58 (Figures 2, 12 and 13). This hem 58 raises the disc so as to provide a space between the disc and the plane on which the base 16 is stored during use of the container intended for heating the water. This space makes it possible to accommodate the base 2 in the base 16, leaving mainly the terminals 8 protruding from the face of the base '16, '

  intended to support the container to be heated (Figure 2).

  The internal face of the base 16 is provided with a perpendicular wall 59 mainly in the form of a keyhole, the internal dimensions of which are such that the base 2 provided with a cover 50 can be housed there. This wall 59 comprises, on its external face, three projecting polyhedral elements 60, capable of being snapped into the three orifices 53, to maintain the

connector 1 on the base 16.

  The hem 58 is provided with a notch 61 for the passage of the power cable 14 (Figure 2, 12 and 13). The notch 61 allows

  to pinch the cable 14 after its coiling around the base 2.

  Two examples of connector manufacturing process, according to the invention, are presented in detail in this application. They are used to wire

  connectors 1 of the type of those presented above.

  The first example corresponds to the wiring of the two

  first variants of connector 1, presented above.

  This first example comprises successively: - a step of fitting the slats 4, in the base 2 (Figures 3 and 7); - A step of crimping a conductor 12 on each strip 4 (Figures 4 and 8); - A step of folding each strip 4 (Figures 5 and 9); - A step of fitting a cover 50 (Figures 10 and 11); and - a step of latching the connector 1, closed by the

  cover 50, on the base 16 (Figures 12 and 13).

  According to the step of fitting the strips 4 into the base 2, a strip 4 is inserted at the end of each channel 28, located near the cylinder 18. Each tab 6 closes a channel 28 by forming a wall perpendicular to the axis of this channel 28, the corresponding barrel 7 then projecting from the edge plane

  free 24 of the cylinder 18 (Figures 3 and 7).

  According to the crimping step, each conductor 12 of the cable 14 is stripped so as to reveal the core of each conductor 12 over a certain portion. This portion of the core is inserted into the hollow of each barrel 7. At this stage, the side walls of the groove of each barrel 7 are folded over the part

  stripped of each conductor 12 (Figures 4 and 8).

  According to the step of folding the barrel, the strip 4 is folded at

  level of its intermediate part between the tongue 6 and the barrel 7.

  The folding of each strip 4 is carried out so that each barrel 7, after this operation, is positioned inside each channel 28. The tongue 6 and the barrel 7 then extend perpendicularly to one another. other. During this operation, the

  conductors are inserted between the hooks 40 (Figures 5 and 9).

  When this method is implemented with the second variant of the connector 1, described above, the cable 14 is also inserted.

  at this stage in the cable clamp 46 (Figure 9).

  The step of fitting the cover 50 is described here only

  relationship with the second variant of connector 1, described below

  above. The cover 50 is deposited on the connector 1, so as to close the base 2 and the conductor support 22. The cover 50 is held on the connector 1 by the clip 52

(Figures 10 and 11).

  According to the step of fixing the connector 1 to the base 16, the clips from the base 16 are snapped into the

  holes 53 of the cover 50 (Figures 12 and 13).

  The second example of a method in accordance with the present invention corresponds to the wiring of the third variant of the connector 1, presented above. This second example comprises successively: - a step of fitting the slats 4, in the base 2 (Figure 14); - A step of fixing a conductor 12 on each strip 4, by displacement of insulator (Figure 15); - A step of folding each tab 71 of non-demountability on the conductor (Figure 16); - A step of fitting a cover 50 (Figures 17 and 18); and - a step of snap-fitting the connector 1, formed by the

cover 50, on the base 16.

  These steps of fitting the strips 4 and of the cover 50 and of snap-fastening the connector 1 on the base 16, are analogous to

those already described above.

  According to the step of fixing the conductor 12 on each strip 4, each conductor 12 of the cable 14 is inserted simultaneously in the two notches 72 of each strip 4. This insertion is carried out by presenting the conductor 12 perpendicular to the walls of the strips 4. Each conductor 12 is then forced into the two notches. The notches 74 having dimensions corresponding approximately to the cross section of the cores of the conductors 12, the insulation of the conductors 12 is moved and cut, allowing the core to come into electrical contact with the strip 4. According to the step of folding each leg 76 of non-demountability, each tab 76 is folded over the conductor

  12, between the two notches 72 of each strip 4.

  The insulator being wedged in the notches 74 and the tab 76 being folded over the conductor 12, the conductor 12 is particularly well maintained on the strips 4 to which it

  are electrically connected in a fixed manner.

  These steps of fixing the conductor and folding '

  non-removable legs are easily automated.

Claims (18)

  1. Method for manufacturing electrical connectors (1) intended for the connection of wireless electrical devices, to a supply circuit, which connectors comprise a base (2) and at least one contact strip (4), electrically connected to a supply cable (14), characterized in that at least one conductor (12) of the supply cable (14) is electrically connected directly to a non-removable form on a strip (4). '' 2. Method according to claim 1, characterized in that it comprises a step consisting in inserting, in the base (2), a strip (4) comprising a tongue (6) and a barrel (7) for crimping, so that the crimping barrel (7) is in   projection from the external contours of the base (2).   3. Method according to claim 2, characterized in that it comprises a step consisting in inserting by means of an automatic crimping tool, a conductor (12) in a barrel (7) crimping.   4. Method according to one of claims 2 and 3, characterized   by the fact that it comprises an automated step of folding the barrel (7), to bring it into a plane of the base (2), comprising a   conductor holding device (12) in the base (2).   5. Method according to one of the preceding claims,   characterized by the fact that it comprises an automated step consisting in introducing the power cable (14) into a   cable holding device (46) in the base (2).   6. Method according to claim 1, characterized in that it comprises an automated step consisting in inserting, in the base (2), a strip (4) capable of being connected to a conductor (12) by displacement of insulation.   7. Method according to claim 6, characterized in that it comprises an automated step consisting in folding down a non-removable tab (76) on the conductor (12).   8. Method according to one of the preceding claims,   characterized by the fact that it comprises an automated step consisting in inserting into the base (2), several strips (4)   extending parallel to each other.   9. Method according to one of the preceding claims,   characterized by the fact that it includes an automated step 'of fixing a cover (50) locked by at least one clip (51) on the base (2).   10. Method according to one of the preceding claims,   characterized by the fact that it comprises a step consisting in automatically fixing the connector (1) on a base (16) by   latching by means of at least one clip (60).   11. Electrical connector (1) intended for the connection of wireless electrical devices, to a supply circuit, which connector (1) comprises a base (2) and at least one contact strip (4), electrically connected to a power cable (14), and is characterized in that at least one conductor (12) of the power cable (14) is electrically connected directly from   cannot be removed from the coverslip (4).   12. Connector according to claim 1 1, characterized in that the strip (4) comprises a tongue (6) and a barrel (7) for crimping. 13. Connector according to claim 11, characterized in that the strip (4) is capable of being connected to a conductor (12) by displacement of insulation.   14. Connector according to claim 13, characterized by the   fact that the strip (4) has a non-removable tab (76).   15. Connector according to one of claims 11 to 14,   characterized in that the base (2) comprises a device for holding conductors (12) in the base (2).   16. Connector according to one of claims 11 to 15,   characterized in that the base (2) comprises a device for   holding the cable (46) in the base (2).   17. Sub-base (16) intended for the connection of electrical devices without wires to a supply circuit, comprising an electrical connector (2) which comprises a base (2) and at the bottom a contact strip (4), electrically connected to a power cable (14), which base (16) is characterized in that at least one conductor (12) of the power cable (14) is   connected directly to the lamella (4), irremovably.   18. Base according to claim 17, characterized by   causes the base (2) to be fixed to it by at least one clip (60).