GB1595783A - Electrical plug and lead assembly - Google Patents

Electrical plug and lead assembly Download PDF

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Publication number
GB1595783A
GB1595783A GB18172/80A GB1817280A GB1595783A GB 1595783 A GB1595783 A GB 1595783A GB 18172/80 A GB18172/80 A GB 18172/80A GB 1817280 A GB1817280 A GB 1817280A GB 1595783 A GB1595783 A GB 1595783A
Authority
GB
United Kingdom
Prior art keywords
base
assembly
gaiter
lead
protective cap
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
GB18172/80A
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ZF International UK Ltd
Original Assignee
Lucas Industries Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Lucas Industries Ltd filed Critical Lucas Industries Ltd
Priority to GB18172/80A priority Critical patent/GB1595783A/en
Publication of GB1595783A publication Critical patent/GB1595783A/en
Expired legal-status Critical Current

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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
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/502—Bases; Cases composed of different pieces
    • H01R13/504—Bases; Cases composed of different pieces different pieces being moulded, cemented, welded, e.g. ultrasonic, or swaged together
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/56—Means for preventing chafing or fracture of flexible leads at outlet from coupling part
    • H01R13/567—Traverse cable outlet or wire connection
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2103/00—Two poles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
    • H01R24/28—Coupling parts carrying pins, blades or analogous contacts and secured only to wire or cable

Landscapes

  • Connector Housings Or Holding Contact Members (AREA)

Description

(54) ELECTRICAL PLUG AND LEAD ASSEMBLY (71) We, LUCAS INDUSTRIES LIMITED, a British company of Great King Street, Birmingham B19 2XF do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed to be particularly described in and by the following statement: This invention relates to an electrical plug and lead assembly and is particularly concerned with an electrical plug and lead assembly in which the electrical plug pins extend from one side of an electrically insulating base and bared ends of wires of the electrical lead are secured to terminals on the opposite side of the base, there being an in situ moulded (usually by injection), electrically insulating cover extending over the terminals and the tend of the lead whereby the electrical plug is permanently connected with the lead. This type of electrical plug and lead assembly is now very widely fitted to domestic electrical equipment as originally supplied.
A disadvantage which has arisen in practice with such an electrical plug and lead assembly is that, during the injection moulding operation of the cover, there is a danger that the connection between the electrical wires of Ithe lead and the terminals of the plug can become deformed and there is also a danger that strands of the wires can also be detached from the terminals.
In certain cases, this can cause portions of the bare conductor to be exposed on the external surface of the cover. Clearly, this is potentially very dangerous.
An object of the present invention is to obviate the above disadvantage.
According to the present invention, there is provided an electrical plug and lead assembly comprising an electrically insusating base, a plurality of electrical plug pins extending from one side of the base and supported by the base, an electrical lead having wires with bared ends electrically connected to respective terminals on the opposite side of the base, an electrically insulating, protective cap overlying at least a live terminal of the plug and also overlying the bared end of at least a live wire of the lead, and an electrically insulating cover in situ moulded over the base, the cap and an end portion of the electrical lead.
Embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a side elevation of part of one embodiment of an electrical plug and lead assembly according to the present invention, shown in one of the initial stages of manufacture, Figure 2 is a plan view of Figure 1, Figure 3 is a plan view of an electrically insulating protective cap forming another part of said one embodiment of electrical plug and lead assembly, Figure 4 is a view in the direction of arrow 4 in Figure 3, Figure 5 is a side elevation of the part of the electrical plug and lead assembly shown in Figure 1 fitted with the protective cap of Figures 3 and 4, Figure 6 is a side elevation, on a smaller scale, of the finished electrical plug and lead assembly of Figures 1-5, Figure 7 is a plan view of an alternative form of electrically insulating protective cap, Figure 8 is an end view in the direction of arrow 8 of Figure 7, Figure 9 is a view of the opposite end of the protective cap, Figure 10 is a side elevation of the protective cap of Figures 7-9, and Figure 11 is a plan view of an electrically insulating base for which the cap of Figures 7 to 10 is designed, Referring to Figures 1 and 2 of the drawings, the electrical plug and lead- assembly comprises an electrically insulating, rigid base 100 having an earth pin 101 a live pin 102 and a neutral pin (not shown) extending from one side of the base 100 and being supported thereby. Qn the opposite side of the base 100 to the electrical plug pins there are provided three terminals 103, 104 and 105; Terminal 103 is connected elec trically directly with the earth pin 101, terminal 104 is connected directly with the neutral pin, and terminal 105 is connected with the live pin 102 via a fuse (not shown) disposed in the recess (also not shown) in the body 100, a stud 106, a crank connector strip 107 and a rivet 108. The terminals 103, 104, 105 have connected thereto by a rivetting operation terminal connectors 109, 110 and 111 respectively which are crimped to respective bared ends of earth, neutral and live wires 112, 113, 114 of a lead 115.
The earth wire 112 passes through a recess 116 in the base defined by a pair of stepped formations 117 forming part of the base 100.
Referring now to Figures 3-5, the electrical plug and lead assembly also includes an electrically insulating protective cap in the form of a flexible gaiter formed of neoprene. The gaiter 118 consists of a hollow body 119 shaped to overlie the stepped formations 117 of the base 100, and an integral sleeve 120 extending from the body 119. The sleeve 120 is arranged to receive the cable 115. In use, the cable 115 is threaded through the sleeve 120 before the wires 112-114 are connected with the respective terminals 103-105. The sleeve 120 is provided with a pair of apertures 121 therein. The hollow body -119 is also provided with an aperture 122 therein which permits passage of the earth wire 112 and terminal connector 109 therethrough.
After the gaiter 118 has been mounted on the lead 115 and the terminal connectors 109-111 have been secured to the terminals 103-105, the gaiter 118 is slid along the lead 115 and engaged over the stepped formations 117 of the base 100 to lie in the position illustrated in Figure 5. In this position, the hollow body 119 of the gaiter 118 overlies the terminals 104 and 105, the terminal connectors 110 and 111, the bared ends of the neutral and live wires 113 and 114, the stud 106, the cranked connector strip 107 and the rivet 108.
Finally, the assembly of gaiter 118, base 100 and lead 115 is placed in a mould where an electrically insulating plastics material is injection moulded around the assembly to form an in situ moulded, electrically insulating cover 123 which is provided over the base 100, the gaiter 118 and an end portion of the electrical lead 115.
The cover 123 completely covers the gaiter 118 so the presence of the latter is not apparent from an external examination of the completed electrical plug and lead assembly. During the injection moulding process, plastics material enters the gaiter 118 via the apertures 121 and air is expelled through the aperture 122 so that substantially complete filling of the gaiter 118 can occur. In this example, injection moulding is effected in the direction of arrow I in Figure 5.
It will be manifest from the above that the provision of the gaiter 118 obviates any risk of bare, live or neutral parts of the plug becoming exposed on the surface of the cover 123 since all these parts are positively contained within the gaiter 118.
Referring to Figures 7-10, there is illustrated an electrically insulating protective cap in the form of a relatively rigid housing 218 which is intended to replace the gaiter 118 illustrated in Figures 3-5. In this embodiment, the rigid housing 218 is formed of for example, nylon 66. This housing 218 is used in conjunction with an electrically insulating base 300 (Figure 11) provided with six apertures 301-306 therethrough.
The base 300 is also provided with three further apertures 307-309 therethrough for receiving the live, neutral and earth terminals (not shown) and is arranged to have mounted thereon the parts corresponding to stud 106, rivet 108, strip 107 and terminal 105 as described with reference to Figures 1 to 6. The housing 218 is provided with hooked tongues 219-222 and lugs 223 224 which extend integrally from the wall of an open base of the housing 218. The hooked-tongues are a snap-fit in the respective apertures 301-304 in the base 300 whilst the lugs 223 and 224 engage in the respective apertures 305 and 306 to locate the housing 218 positively on the base.
The housing 218 is provided with an aperture 225 at one end thereof to permit passage therethrough of the earth wire and the terminal connector (not shown in Figure 11) corresponding to terminal connector 109 and is also provided with an integral U-shaped sleeve 226 which accommodates the electrical supply lead. When assembled on the base 300 the rigid housing 218 occupies substantially the same position as that occupied by gaiter 118 as shown in Figure 5.
The housing 218 has the advantage that it can be assembled onto the base 300 after the wires of the electrical supply lead have been connected with the respective terminals (not shown in Figure 11).
After assembly of the housing 218 on the base 300, a cover corresponding to cover 123 is injection moulded to overlie completely the housing 218 so that the latter is not externally visible. The injection moulded cover, in this embodiment, covers the same electrically conductive parts of the assembly as the gaiter 118.
WHAT WE CLAIM IS:- 1. An electrical plug and lead assembly comprising an electrically insulating base, a plurality of electrical plug pins extending from one side of the base and supported by
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (17)

  1. **WARNING** start of CLMS field may overlap end of DESC **.
    trically directly with the earth pin 101, terminal 104 is connected directly with the neutral pin, and terminal 105 is connected with the live pin 102 via a fuse (not shown) disposed in the recess (also not shown) in the body 100, a stud 106, a crank connector strip 107 and a rivet 108. The terminals 103, 104, 105 have connected thereto by a rivetting operation terminal connectors 109, 110 and 111 respectively which are crimped to respective bared ends of earth, neutral and live wires 112, 113, 114 of a lead 115.
    The earth wire 112 passes through a recess 116 in the base defined by a pair of stepped formations 117 forming part of the base 100.
    Referring now to Figures 3-5, the electrical plug and lead assembly also includes an electrically insulating protective cap in the form of a flexible gaiter formed of neoprene. The gaiter 118 consists of a hollow body 119 shaped to overlie the stepped formations 117 of the base 100, and an integral sleeve 120 extending from the body 119. The sleeve 120 is arranged to receive the cable 115. In use, the cable 115 is threaded through the sleeve 120 before the wires 112-114 are connected with the respective terminals 103-105. The sleeve 120 is provided with a pair of apertures 121 therein. The hollow body -119 is also provided with an aperture 122 therein which permits passage of the earth wire 112 and terminal connector 109 therethrough.
    After the gaiter 118 has been mounted on the lead 115 and the terminal connectors 109-111 have been secured to the terminals 103-105, the gaiter 118 is slid along the lead 115 and engaged over the stepped formations 117 of the base 100 to lie in the position illustrated in Figure 5. In this position, the hollow body 119 of the gaiter 118 overlies the terminals 104 and 105, the terminal connectors 110 and 111, the bared ends of the neutral and live wires 113 and 114, the stud 106, the cranked connector strip 107 and the rivet 108.
    Finally, the assembly of gaiter 118, base 100 and lead 115 is placed in a mould where an electrically insulating plastics material is injection moulded around the assembly to form an in situ moulded, electrically insulating cover 123 which is provided over the base 100, the gaiter 118 and an end portion of the electrical lead 115.
    The cover 123 completely covers the gaiter 118 so the presence of the latter is not apparent from an external examination of the completed electrical plug and lead assembly. During the injection moulding process, plastics material enters the gaiter 118 via the apertures 121 and air is expelled through the aperture 122 so that substantially complete filling of the gaiter 118 can occur. In this example, injection moulding is effected in the direction of arrow I in Figure 5.
    It will be manifest from the above that the provision of the gaiter 118 obviates any risk of bare, live or neutral parts of the plug becoming exposed on the surface of the cover 123 since all these parts are positively contained within the gaiter 118.
    Referring to Figures 7-10, there is illustrated an electrically insulating protective cap in the form of a relatively rigid housing 218 which is intended to replace the gaiter
    118 illustrated in Figures 3-5. In this embodiment, the rigid housing 218 is formed of for example, nylon 66. This housing 218 is used in conjunction with an electrically insulating base 300 (Figure 11) provided with six apertures 301-306 therethrough.
    The base 300 is also provided with three further apertures 307-309 therethrough for receiving the live, neutral and earth terminals (not shown) and is arranged to have mounted thereon the parts corresponding to stud 106, rivet 108, strip 107 and terminal 105 as described with reference to Figures 1 to 6. The housing 218 is provided with hooked tongues 219-222 and lugs 223 224 which extend integrally from the wall of an open base of the housing 218. The hooked-tongues are a snap-fit in the respective apertures 301-304 in the base 300 whilst the lugs 223 and 224 engage in the respective apertures 305 and 306 to locate the housing 218 positively on the base.
    The housing 218 is provided with an aperture 225 at one end thereof to permit passage therethrough of the earth wire and the terminal connector (not shown in Figure 11) corresponding to terminal connector 109 and is also provided with an integral U-shaped sleeve 226 which accommodates the electrical supply lead. When assembled on the base 300 the rigid housing 218 occupies substantially the same position as that occupied by gaiter 118 as shown in Figure 5.
    The housing 218 has the advantage that it can be assembled onto the base 300 after the wires of the electrical supply lead have been connected with the respective terminals (not shown in Figure 11).
    After assembly of the housing 218 on the base 300, a cover corresponding to cover 123 is injection moulded to overlie completely the housing 218 so that the latter is not externally visible. The injection moulded cover, in this embodiment, covers the same electrically conductive parts of the assembly as the gaiter 118.
    WHAT WE CLAIM IS:- 1. An electrical plug and lead assembly comprising an electrically insulating base, a plurality of electrical plug pins extending from one side of the base and supported by
    the base, an electrical lead having wires with bared ends electrically connected to respective terminals on the opposite side of the base, an electrically insulating, protective cap overlying at least a live terminal of the plug and also overlying the bared end of at least a live wire of the lead, and an electrically insulating cover in situ moulded over the base, the cap and an end portion of the electrical lead.
  2. 2. An assembly as claimed in Claim 1, wherein the electrically insulating protective cap overlies the live terminal and a neutral terminal of the plug and the bare ends of the live and neutral wires of the lead.
  3. 3. An assembly as claimed in Claim 2, wherein an earth terminal and a bare end of an earth wire of the electrical lead are disposed externally of the protective cap.
  4. 4. An assembly as claimed in Claim 3, wherein the earth wire passes through the protective cap.
  5. 5. An assembly as claimed in Claim 4, wherein the protective cap has a first opening through which the live, neutral and earth wires pass into the caps and a second opening through which the earth wire passes out of the cap, the bared ends of the live and neutral wires being disposed within the protective cap.
  6. 6. An assembly as claimed in claim 5, wherein the first and second openings are provided at opposite ends of the protective cap.
  7. 7. An assembly as claimed in claim 5 or 6, wherein the first opening is in the form of a recess in the protective cap.
  8. 8. An assembly as claimed in claim 5, 6 or 7, wherein the second opening is in the form of a recess in the protective cap.
  9. 9. An assembly as claimed in any preceding claim, wherein the live terminal is connected with the live pin of the plug via a fuse and a cranked connector strip.
  10. 10. An assembly as claimed in any preceding claim, wherein the live terminal is disposed on the same side of the electrical lead as the neutral terminal.
  11. 11. An assembly as claimed in any preceding claim, wherein the protective cap is in the form of a resilient gaiter which is pushed into position and held in place by frictional engagement with the base.
  12. 12. An assembly as claimed in claim 11, wherein the gaiter includes an integral sleeve through which the electrical lead passes.
  13. 13. An assembly as claimed in any one of claims 1 to 10, wherein the protective cap is relatively rigid and provided with formations thereon which are mechanically engaged with corresponding formations on the base.
  14. 14. An assembly as claimed in claim 13, wherein the mechanical engagement is in the form of a snap-fit tongue and recess connection.
  15. 15. An assembly as claimed in any one of claims 1 to 10, 13 and 14, wherein the protective cap is shaped so that it can be assembled onto the base after the wires of the electrical lead have been connected with the respective terminals.
  16. 16. An assembly as claimed in claim 15, wherein the protective cap includes an integral U-shaped sleeve which receives the electrical lead.
  17. 17. An electrical plug and lead assembly substantially as hereinbefore described with reference to Figs. 1 to 6 or Figs. 7 to 11 of the accompanying drawings.
GB18172/80A 1977-09-30 1977-09-30 Electrical plug and lead assembly Expired GB1595783A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB18172/80A GB1595783A (en) 1977-09-30 1977-09-30 Electrical plug and lead assembly

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB18172/80A GB1595783A (en) 1977-09-30 1977-09-30 Electrical plug and lead assembly

Publications (1)

Publication Number Publication Date
GB1595783A true GB1595783A (en) 1981-08-19

Family

ID=10107887

Family Applications (1)

Application Number Title Priority Date Filing Date
GB18172/80A Expired GB1595783A (en) 1977-09-30 1977-09-30 Electrical plug and lead assembly

Country Status (1)

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GB (1) GB1595783A (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0272470A1 (en) * 1986-12-18 1988-06-29 kabelmetal electro GmbH Electrical plug and method of producing the same
EP0274605A1 (en) * 1986-11-29 1988-07-20 Taller GmbH Plug with protective contact provided with pin supporting bridge and protection cap
EP0411281B1 (en) * 1989-07-29 1996-09-11 F. Wieland Elektrische Industrie GmbH Electrical terminal
GB2383201A (en) * 2001-12-14 2003-06-18 Packway Ind Ltd Electrical power plug with eye end piece connectors

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0274605A1 (en) * 1986-11-29 1988-07-20 Taller GmbH Plug with protective contact provided with pin supporting bridge and protection cap
EP0272470A1 (en) * 1986-12-18 1988-06-29 kabelmetal electro GmbH Electrical plug and method of producing the same
EP0411281B1 (en) * 1989-07-29 1996-09-11 F. Wieland Elektrische Industrie GmbH Electrical terminal
GB2383201A (en) * 2001-12-14 2003-06-18 Packway Ind Ltd Electrical power plug with eye end piece connectors

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PS Patent sealed
PCNP Patent ceased through non-payment of renewal fee