GB2292641A - Electric Coupler - Google Patents

Abstract

An electric coupler comprises a closable non-conducting housing having means to prevent reopening after electrical connections have been made by crushing means 1, 2 which can be ridged and wiping. The housing parts can be integrally hinged and held closed by a toothed part 21, interengaging projection and recess or by a non-conducting sealant within the housing. The sealant can be enclosed within a container 19 ruptured by projections 20 on closing of the housing. The coupler joins wires 10, 11 or wires to plug or socket extensions and housing parts 8 grip the wire insulation. Seals or corrugated split sleeves and nuts are provided. <IMAGE>

Description

ELECTRIC COUPLER The present invention is concerned with making electrical connections between one or more pairs of conductors.

The invention includes embodiments adapted to plugs and sockets.

The present invention is characterised in that the coupler is contained in a non-conducting housing, electrical connection between conductors being made by crushing the bared ends of the conductors between pairs of members, one member at least being electrically conducting, the housing adapted to indent the insulation of the conductors by gripping means being part of the housing, the housing being then non-re-openable and the coupling thus substantially non-re-wirable and having resistance to tensile forces on the conductors.

One embodiment shows the voids within the housing substantially filled by a sealant.

For convenience only the housing is described as having an upper and lower part.

The housing may be made in one piece as say an injection moulding having a hinging portion between the upper and lower parts non-re-opening of the housing is achieved by the upper and lower parts being engagably connected on closing by mortise and tenon type connection or by ratchet or other unidirectional locking action between the upper and lower parts.

Advantages of the coupler according to the invention include that the housing may maade in one piece, the electrical connections are made without the necessary use of screws to crush the bared ends of the conductors, the action of closing the upper and lower parts together provides the crushing force, no special tools are necessarily required.

resistance to the pulling apart of the conductors, is high, the coupler is non-re-wirable without causing damage to the coupling housing, and is adaptable for single or multi-core conductois.

The invention is an electric coupler between elect@@cal conductois comprising a non-conducting housing consisting of uppe@ and lower parts, conductor insulation gripping means being part of the housing, irreversible engagement means bvtwee@ the said upper and lower parts, bared conductor @rushing means, electrical connection means being part of the said @rushing means.

In one embodiment a non-conducting sealing material preferably a hydrophobic flowable substance advantageously with setting and or thixotropic and or adhesive properties, is used to fill the voids within the housing after electrical connections have been made. The selection of a suitable material is made by those skilled in the art te suit a particular environment such as resistance to penetration by electrically conducting, flammable or corrosive liquids or gases.

The sealant may be a commercially available self or multi-part hardening resin, jelly like plastics and the like.

Preferably the sealing material or components thereof are contained in a rupturable hollow body or bodies situated within the housing such that the said body is ruptured by the action of forcibly closing the upper and lower parts of the housing together, the sealant being released substantially filling the voids in the housing after electrical continuity between the conductors has been achieved.

In a further embodiment the housing has hollow extensions at the points of entry of the conductors formed from the upper and lower parts to form tapered, split, hollow, screwed nipples. These nipples thus have tapered threads and matching nuts so that a nut having previously been placed over the end of such conductor and the bared conductors inserted into the housing and the housing closed, the nut may be screwed onto its corresponding nipple thus forcing the upper and lower parts together.

Alternatively1 the above nipples may be profiled to receive a hollow substantially conical form of a nonconducting elastomeric material pushed over each conductor prior to assembly of the coupler and then over the nipple after assembly thus providing an additional seal suitable for severe conditions, such as under water or for flame proof specifications. In general the upper and lower parts may be joined by a hinge along one edge for convenience such hinge may advantageously be an integral part or an injection moulding ccmprising the upte and lower parts of the housing.

A @@t and bolt system preferably with a captive nut may advantageous I y be used to connect the upper ad lower low so that extra pressure may be exerted on the bared conductors by the members.

The housing may be of any configuratifan to suit a particular need. For multi-core electronic cable, for amp only. the housing nculd have a flattened form.

Where one or more of the pairs of conductors is a bare projecting conducting part forming a plug, then the plug may be extended internally to be part of the member or members receiving the bared conductor to which it has to be connected. A socket may be similarly adapted. This adaption is particularly useful where a plug or socket must be integrally connected to an electrical lead solidly connected to an electrical apparatus.

Where the conductors are sheathed in a conducting overing to provide shielding from electrical interferene, the upper and lower parts of the housing may have shielding either externally or incorporated within the material forming the housing, such shielding being subsequently electrically connected to the shielding around the conductors after the assembly of the coupler.

Further embodiments of the invention are now described by way of example only and do not limit the application of the invention.

In a further embodiment, the upper and or lower parts carry on their abutting surfaces a soft insulating material which forms a water resistant seal when the said parts are forcibly brought together. The said insulating material being shaped to encompass the insulation of the conductors at their points of entry into the housing.

The embodiments described may be used in combination.

By way of example only particular embodiments and combinations of embodiments are now more particularly described.

Figure 1 refers: X & Y - Upper and lower Parts of a Housing, being an injection moulding of a plastic material such as for example only, Nylon (T.M.), Polypropylene, PVC, rubber, possessing good tensile strength so that a hinge 4 may be formed by a reduction in thickness.

A - General view of a coupler for a single pair of terminations.

B - Section on arrows B-B.

C - Section on arrows C-C.

1 - A projecting Member of a conducting material such as copper, moulded into or attached to item X preferably having irregularities to grip items 3 & BR< 12 below.

2 - A receiving Member of a conducting material such as copper, moulded into or attached to item Y.

Member 2 has a profile suited to receive Member 1, preferably with a wiping contact between contacting surfaces nearest the hinge 4, to assist in providing sealing pressure between portion 5 and X.

3 - Termination of insulated conductor 10 that is, the exposed core of the conductor shown distorted by pressure from 1 and 2 when X and Y are engaged.

4 - A hinge provided by a flexible junction between X and Y.

5 - An extended portion of Y pressing against the side of X, by means of an interference fit between and Y, to form a seal.

and and 7 - An engaging connection between X and Y: the engagement in this embodiment comprising the wec shaped male projection 7 entering the female att 6 in X. profiled to engage with 7 so that 7 an enter 5 by exerting pressure between X and Y.

forming a lock so that it is difficult for X and to be separated without destroying the Housing.

8 - Tooth like projections part of or attached to X and @ respectively so that when 6 and 7 are engaged. the parts 8 indent and grip the insulation of 10 and 11.

9 - Soft rubber or a foamed plastic non-conducting seals which may be siliconised or otherwise treated to confer water repellent properties.

Seals 9 may be split so that the conductors 10 and li may be placed in the positions shown so that when the two halves X and Y are engaged the seal 9 is compressed against 10 and 11 and adjacent parts. The profile of 9 may be such that it is compressed against the inside surface of 5.

Alternatively 9 may be in one piece, in which case 10 and 11 must be threaded through before X and Y are engaged.

10 and ll-Insulated conductors shown partly cut away to show the action of 8.

In use, the Housing is supplied open. The two terminations 10 and 11 are prepared by cutting back insulation so that the conducting core is exposed sufficiently to penetrate at least half way into 2. The exposed cores may be laid so as to overlap or be turned back on themselves. The insulation of the terminations must be within the Housing and where the teeth 8 can indent. The half X is now turned about the hinge 4 and parts 6 and 7 forcibly engaged.

Forceable engageability may be improved by a screw (not shown) between the two halves of the housing one half acting as or containing a nut.

The above embodiment exemplifies advantages which may be obtained from the invention, which include a one piece injection moulding for the Housing, the elimination of the necessary us of special tools, a large area of electrical contact, water resistant sealing between the two halves of the Housing, tamper resistant non-rewirability, two provisions to resist tensile forces from the conductors i.e.

the crimping effect of the engaging Members and the gripping effect from the indenting of the insulation of the ct ciuctors.

Fig g, 2 shcws an adaption of the above embodiment to a suhstantially cylindrical form, for providing a couple@ for 3 palis f terminations 3a, 3b, 3c from conductor '0.

- a terminations from conductor 11.

ra and 7a are adaptions of parts 6 and 7 in Fig. I p@ov de greater security from an attempt to re-open the coupler, n a relatively small space. 1 and 2 are for@ibly engageable ale and female conducting Members.

is a view of the coupler in the open position where the conductors 10 and 11 have been prepared but not yet placed in position.

E is an enlarged view of portions of 6a and 7a.

Fig. 3: A further embodiment is now described, where the conductors on one side are pins, whereby the coupler is typically an integral part of a plug for engagement with a socket. The plug may be single or multi-pin. The plug is not necessarily in halves as in present practice, and represents a means of a providing a non-re-openable coupler where plugs are required to be connected to electrical apparatus before sale, and where the live parts of the plug are to be inaccessible.

FIG. 3 refers to a typical arrangement for a 3 pin plug of standard pin arrangement for 13 amp 240V use but the embodiment may be readily adapted for a variety of electronic and other special plugs. No claim is made for any particular design or type of pins or housing.

Preferably the portion 12 carrying pins 13, 14a, 14b is integral with Part Y in Fig. 1. Pins may be replaced by hollow parts forming sockets within the housing 12 or extensions thereto The connections between the pins 13, 14a and 14b and their corresponding Members 2c, 2a and 2b respectively, are preferably integral with those respective Members as shown in Fig. 3, and similar preferable equivalent connections if the pins are replaced by sockets.

VIEW A is an external view of the combined coupler/plug. VIEW 13 is a sectional view on B-B, not showing seals 9 or engaging parts b and 7. The earth pin 13 has a conducting connection 15 to 2C. Pins 14a, 14b are similarly connected to 2a and 2b equivalents to 2 in FIG. I for a single conductor connection. Engaging equivalents to 1 in FIG. 1 are not shown. Part X in VIEW B is shown in the open position.

3a, 3b.. 3c are the terminations of 3 conductors inside insulated carrier 10.

A conductor 3a for example may be made the live onnection to the mains supply, 3b would then be neutral and 3c to earth. Preferably suitable visual and touch codes may be used to indicate the function of each termination and appropriate Members 2a. 2b and 2c.

2a may be @ontinued by a connection similar to 15 into @ and form part of a fuse system before being connected @@ 4a . such fuse connection (not shown) preferably having a replaceable fuse in a holder (nct shown) removable from 11 a i suitable aperture in 12 (not shown) .No claim is made for any particalar design of fuse connection or fuse The f SC holder may be provided with a compressible -eal between it and 12 to render the assembl water ssistat. -- In use the outer insulation of 10 is cut back as shown in FIG. 3 and the insulation of the conductors within cut back to provide bare wire where the termination of each conductor lies within 2a, 2b, and 2c. The geometry of the housing 12 and the relative position of X is readily adaptable to provide a more compact form of coupling with pins than that shown in FIG. 3 for clarity.

An example is where the more compact form is that of a conventional 3 pin plug.

Another example is where the pins are arranged to project in the same or parallel plane as the housing 12. Similarly hollow parts as sockets may be substituted for pins and be housed within or in extensions to the housing 12 in the same plane as the housing 12.

FIG. 4 shows an embodiment in the closed position where a rupturable capsule 19 is shown ruptured by piercing means 20 being sharp points moulded into or fixed to one of the parts of the housing. Irreversible closure is effected by means of ratchet 21 of at least one engagement tooth.

Hinge 4 may be omitted, and the upper and lower parts X and Y may be joined by a nut and bolt system to obtain a more secure contact between 10, 11, 1 and 3, before 10 is ruptured, the upper and lower parts engaging, the material of the housing being elastically distorted. The profile of the ratchet being selected to ease forcible closing and maximum resistance to re-opening.

The method of use is as follows. Capsule 19 contains a flowable, non-conducting substance in this case a commercially available polymer such as is used for childrens' amusement. When the capsule 19 is ruptured by the closing of the two parts of the housing, the flowable plastic is ejected into the voids of the housing. Other materials may include a commercially available multicomponent setting resin in which case the components are held in two or more separated but adjoining capsules so that when ruptured, the components are mixed and are forces tj fill the voids within the housing, the combined volume Ir. all cases being calculated to do so without significant excess.

The adhesive nature of most two part resins rende@s the closed housing non-re-openable. liquid and gas proof.

The configuration shown may be adapted for the capsule it rapsules 1 o be situate over the Members 1 or 2, , between sad Members and hinge 4. to obtain a greater lupturing pressu@e, taking care that the adaption provi f@@ elentr@cal conta@ts being made before encasement in @@@@@@ FIG. 5 shows a housing where the upper and lower parts 1 and 2 are extended at each end to form two halves 17 and IS of split cones threaded to receive nuts 16.

View AA is an enlarged section of one end of the housing in the closed position with nut 16 in vos,tion.

Cr-osshatching has not been used to indicate section.

The advantage of this embodiment is that considerable force can be exerted between the upper and lower parts of the housing. The split cones are readily adapted to receive sleeves of elastomeric material threaded over the conductors 11 and i2 before assembly of the coupler, and then after closure of the housing, forcing the sleeves over the cones,thus adding to the housing's resistance to the ingress of undesirable substances.

Claims (14)

1. An electric coupler between at least one pair of conductors comprising a closable non-conducting housing consisting of, for reference purposes only, upper and lower parts, conductor insulation gripping means, re-opening prevention means between said upper and lower parts crushing means of bare conductor ends and electrical connection means being part of the said crushing means

2. An electric coupler as claimed in Claim 1 where the re-opening prevention means is at least one of a sealant between the upper and lower parts and engagement of projections with corresponding recesses between the upper and lower parts.

3. An electric coupler as claimed in Claim 2 where the sealant is a non-conducting setting silicone material.

4. An electric coupler as claimed in any preceding claim where the sealant is contained in at least one rupturable sac between the upper and lower parts such that on firm conjoining of the said parts the said sac is ruptured causing flow of the sealant between the upper and lower parts.

5. An electric coupler as claimed in any preceding claim where the upper and lower parts carry on their abutting surfaces a water resistant insulating jointing material.

6. An electric coupler as claimed in any preceding claim where the upper and lower parts are joined by a hinge.

7. An electric coupler as claimed in Claim 5 where th. hinge is integral with the upper and lower parts forming a single injection moulding of the housing.

8. An electric coupler as claimed in any preceding claim where the upper and lower parts have extensions at the places where the conductors enter, forming elongated conical split nipples when the upper and lower parts are held together by retaining means.

9. An electric coupler as claimed in Claim 8 where the nipples are threaded and the retaining means are nuts.

10. An electric coupler as claimed in Claim 8 where the retaining means are substantially elastically deformable water resistant sleeves placed over the nipples.

11. An electric coupler as claimed in Claim 1 where the crushing means are pairs of engaging toothed members at least one of each pair being a conductor.

12. An electric coupler as claimed in Claim 1 where the conductor insulation gripping means are opposing insulation indenting members in the upper and lower parts at the place of entry of the conductors into the housing.

13. An electric coupler as claimed in any preceding claim where the coupler is shielded electrically.

14. An electric coupler as more particularly described in any figure or embodiment herein.