GB2465609A

GB2465609A - Electrical connector

Info

Publication number: GB2465609A
Application number: GB0821528A
Authority: GB
Inventors: Paul John Carter; Michael Bruce Borthwick
Original assignee: C & C Marshall Ltd
Current assignee: C & C Marshall Ltd
Priority date: 2008-11-25
Filing date: 2008-11-25
Publication date: 2010-05-26
Anticipated expiration: 2028-11-25
Also published as: GB2465609B; GB0821528D0

Abstract

A connector has a housing 100, 102 having a mating end for enabling connections to be made with the ends of a plurality of wires. It also has a closure 120, connectable to the housing to define an inlet for receiving the wires, the inlet having an aperture 122 configured to enable the wires to pass therethrough. The closure 120 is configured to engage the wires and to resiliently deform the wires to inhibit the wires from being extracted from the connector. The closure may be sealed to the housing 100, 102 to inhibit tampering with the connector and may be vibration welded to the housing. The wire-ends may be held in a spaced configuration within the housing such that the closure 120 is configured to hold the wiring together and the insert is configured to splay the wires away from one another. The exterior perimeter surface of the closure 120 may be smooth such that the connector is inhibited from being caught against objects.

Description

CONNECTOR

The invention relates to an electrical connector and in particular to an electrical connector that can be connectably engaged with a corresponding connector, an example of which can be found in known male-female connector assemblies. Further, the invention relates to cables configured with connectors, such as an extension cable having a connector. The invention also relates to a method of assembling an electrical connector upon a cable.

Known connectors are used to terminate cables. A known connector has a housing and terminates conductors of the cable at a terminal pin, and then secures said terminal pin within the housing of the connector. The housing provides a secure mounting and interface for making an electrical connection to a mating connector, and terminal pins are prevented from being pulled out of the connector housing by a bracket, which holds the terminal pins securely within the housing.

In addition, the bracket extends out from the housing of the connector engages with a fixing nut and an insulating sheath that protects a cable located therein. The bracket functions to provide a biting action upon the sheath within an assembled connector.

The nut, through which the cable is inserted, effects the biting action. When the nut is screwed on to the housing the bracket is compressed by the interior surface of the nut such that a tooth of the bracket bites into the sheath of a cable, thus holding it in place.

Unfortunately, known connectors have a number of disadvantages. One such disadvantage is that the nut is not tamper proof and, therefore, an unqualified or unskilled person could easily take the connector apart and modify the connector in a way that could detriment the performance or function of the connector.

Further, the bracket extends from the connector housing and, therefore, increase the overall length of a connector because the nut must be suitably sized to acconimodate an engaging screw portion and the sections of the bracket that extend outside the housing.

As a result, the minimum bend radius of a cable incorporating a known male-female connector package cannot be manipulated through a standard junction box and into adjoining conduit.

Moreover, when a cable having a known connector is being fed through a conduit system the nut upon the connector is susceptible to being caught on edges between conduits, or on interfaces between conduits and junction boxes. This can cause a problem when a cable is being forcibly pulled through a conduit system. If caught, the pulling force applied to the cable applies directly against the nut and, in effect, the force may lead to the electrical connection between the cable and connector being weakened or even broken.

The electrical connector of the invention is configured to secure a wire, or a plurality of wires in a housing of the connector by securing the wire in the housing using a fixing device. Together, the housing and the fixing device function together to apply resilient bias to the wire or wires to hold the wire or wires in place.

In one aspect, the invention resides in an electrical connector comprising: a housing having a mating end for enabling connections to be made with the end of at least one wire; a closure, connectable to the housing to define an inlet for receiving the wire, the inlet having an aperture configured to enable the wire to pass therethrough, wherein the closure is configured to engage the wire and to resiliently deform the wire to inhibit the wire from being extracted from the connector. In other words, the wire is shaped, formed, and/or configured in such a way that it is guided to inhibit the wires from being extracted from the connector.

By resiliently shaping the wire to inhibit the wire from being extracted from the connector a number of advantages can be achieved.

Firstly, the size of the connector can be reduced because it is not necessary to use clamping arms or other such extra clamping features to hold the sheath of a cable. This enables the connector to be shorter m length with respect to the cable axis and reduces the component cost and manufacturing cost. Further, a smaller connector means that the minimum bend radius of a cable, or bundle of wires, can be reduced, which facilitates the installation of such cables with connectors in use.

Secondly, by using the resilience of the wire, the pull-out force of a wire secured in an electrical connector is increased, thus improving the performance of the connector and reducing the stress applied to the pins.

In addition, the closure may have a resilient portion that functions to resiliently shape the wire to further inhibit the wire from being extracted from the connector. A resilient portion on the closure may be conligured around the aperture and serve to distribute the pressure applied to the wire.

The connector may be configured to receive two wires, or it may be configured to receive a number of wires, but preferably receives four wires. The ends of the wire, or wire-ends, may be provided with terminal pins or the wires may connect directly to a connector.

The connector may comprise an insert configured to receive the wire ends and to engage with the housing. An insert may increase part complexity but may improve the ease of assembly of a wire into the connector and may improve the connector performance, for example the pull-out performance. The insert may be clipped into the housing.

The closure may be sealed to the housing to inhibit tampering with the connector. A vibration weld may be used to provide the seal and, therefore, the seal is made tamper-proof. Functionally, the seal prevents an assembled connector from being easily taken apart, and requires that a seal is broken before a connector can be opened. Further, if the seal is broken, this will be evidence to a user that the connector has been tampered with.

The wire-ends may be held in a spaced configuration within the housing. The spacing of the wires may be such that the wires are inhibited from being extracted from the connector. The aperture may be configured to hold the wiring together and the insert may be configured to deform the shape of the wire by splaying the wires away from one another.

The insert may have a protrusion that extends from the insert to effect splaying of the wires. Alternatively, the protrusion may be provided in the housing itself. The protrusion may extend into the aperture of the closure and may extend therethrough. By extending therethrough, the wires are forcibly separated to assist in defining a shape that inhibits extraction of the wires.

One or more of the functions of the insert may be implemented by the housing.

The closure may be configured such that the aperture is larger, or substantially the same diameter as the outer dimension of a wire, or a bundle of adjacent wires located therein, the aperture being resiliently biased against said wire or wires when the closure is connected to the housing and the wire or wires adopts a deformed configuration. In this way, the aperture is resiliently compressed against the insulation of the or each wire after the closure is secured in place.

Alternatively, the aperture may be smaller than the outer dimension of a wire or a bundle of adjacent wires located therein such that the aperture deforms the wire or wires by being resiliently biased against said wire or wires when closure is connected to the housing. In this configuration, the compression of the closure against the or each wire is increased to increase the holding force thereon.

The aperture is preferably circular.

It should be noted that the radius of the aperture of the closure is greater than that of the radii of wires passing therethrough and, therefore, damage to the wires is avoided.

Further, the aperture may be configured to distribute the pressure applied to the wire by, for example, having a rounded or bevelled edge portion.

The housing and the closure may be configured to engage a single wire and to resiliently shape the wire to inhibit the wire from being extracted from the connector.

The exterior perimeter surface of the closure may be smooth such that the connector is inhibited from being caught against objects. It follows that at least a portion of the closure arid/or the housing of the connector may be shaped to have arcuate, rounded, curved or similar shapes that inhibit the connector from catching upon objects.

An exterior perimeter surface of the closure may be convexly curved and extend from the aperture to a point at which the closure interfaces with the housing such that each part of the exterior perimeter surface of the closure is ftirther away from the aperture than a part of the exterior perimeter surface of the closure adjacent the aperture.

The connector may be a male connector, or a female connector.

In another aspect, the invention resides in a cable assembly having an electrical connector according to the first aspect of the invention. The cable assembly may have one male connector and/or one female connector.

In yet another aspect, the invention resides in an electrical connector assembly having a male connector configured to mate with a female connector, the or each connector comprising: a housing having a mating end for enabling connections to be made with the end of at least one wire; a closure, connectable to the housing to define an inlet for receiving the wire, the inlet having an aperture configured to enable the wire to pass therethrough, wherein the closure is configured to engage the wire and to resiliently shape the wire to inhibit the wire from being extracted from the connector.

In yet another aspect, the invention resides in a method of assembling an electrical connector by: preparing a wire; inserting the end of the wire through an aperture of a closure; inserting the end in a housing for enabling connections to be made with the end of the wire; and connecting the closure to the housing to define an inlet for receiving the wire, the inlet having an aperture configured to enable the wire to pass therethrough, wherein the closure is configured to engage the wire and to resiliently shape the wire to inhibit the wire from being extracted from the connector.

It is against this background that the invention has been made. This invention results from efforts to overcome the problems of known connectors. Other aims of the invention will be apparent from the following description.

In order that the invention may be more readily understood, reference will now be made, by way of example, to the drawings in which: Figure la and lb are views of a known male and a known female terminal pin respectively; Figure 2a shows front and rear perspective views of a known connector housing for receiving the female terminal pin of Figure ib, and Figure 2b is an elevation view of the housing shown in Figure 2a; Figure 3a shows front and rear perspective views of a known connector housing for receiving the male terminal pin of Figure Ia, while Figure 3b is an elevation view of the housing shown in Figure 3b; Figure 4a is an end elevation view of a known bracket for use in a connector housing, while Figure 4b is a side elevation view of the bracket shown in Figure 4a; Figure 5 is a cross-sectional view of a known nut, which can be screwed on to the threaded portions of the connector housings shown in Figures 2a to 3b; Figure 6a is a perspective view of one connector housing of the present invention engaging with another connector housing, said connector housings providing a connection for four wires; Figure 6b shows a closure of the present invention, located on the wires of Figure 6a, prior to being fixed upon the distal ends of the connector housings shown in Figure 6a; Figure 7 shows pair of assembled connectors of the present invention having the closure of Figure 6b attached to the connector housings of Figure 6a, said connector connecting three wires; and Figure 8a and 8b are partial cross-sectional views of a connector of the present invention configured on a pair of wires and a single wire, respectively.

In Figures la and ib, terminal pins 2 have a recess (shown on the left-hand side, as viewed). The pins are fixed to the end of a wire conductor that is part of a cable having a number of wires enclosed with a sheath (not shown). In practice, a cable would be stripped of a portion of its sheath to expose a number of wires therein, Each wire would then be stripped of a portion of its external insulation to expose the conductor. The conductor is inserted in the recess and fixed in place, typically by means of crimping.

Thereafter, the pins 2 on the ends of the wires are prepared for insertion into the connector housing 4 shown in Figures 2a, 2b, 3a and 3b. Each housing 4 has a terminal portion 6, for receiving the pins 2, a main body 8 and a threaded portion 10.

Figure 4a and 4b show a bracket 12. In order to securably fix the pins 2 within the housing 4, each of the pins 2 are located in recesses 14 provided in the bracket 12. The bracket 12 has a portion 16, and clamping arms 18 extending distally therefrom. Clips are provided on the bracket for engagement with the housing.

During assembly of a connector, each of the pins 2, with a wire extending therefrom, are placed in the recesses 12 of the bracket 14 such that the pins are positioned adjacent the portion 16 and the wires extend from the pins in a longitudinal direction of the clamping arms 18, beside the clamping arms 18.

The bracket 12 has four clips 20 and the clips engage with features in the housing when the terminal pin and bracket assembly are inserted into the housing. In the fixed position the portion 16, in which the pins 2 rest, is located in the main body 8 of the housing 4 such that the pin 2 extends into the terminal portion 6. The at-ms 18 extend from the housing 4 beyond the threaded portion 10.

Figure 5 shows a nut 22 to which the connector is fixed. After the bracket 4 and terminal pin 2 assembly has been inserted into the housing, the nut is screwed onto the housing to compress the clamping arms 18 into the sheath of the cable.

The nut 22 is shaped and dimensioned to engage with the clamping arms 18. In practice, the configuration of the nut 22 is determined by a threaded portion that is required for engagement with the housing 4, and also by a securing zone 24 internal to the nut 22, which accommodates the clamping arms 18. The securing zone 24 functions to compress the clamping arms 18 as the nut is secured to the housing, thus causing the clamping arms to bite into the sheath of a cable. Once secured in place, the nut maintains the arms 18 in a "biting" condition.

The nut is typically secured by hand and to reduce the torque required to turn the nut and compress the clamping arms, during any one rotation, the threaded portion has a pitch and depth configured to make the fixing of the nut easier when being manually tightened. As a result, the depth of the threaded portion is increased.

Figure 6A shows a male connector housing 100 of the present invention in mating connection with a female connector housing 102 of the present invention, said connector providing a connection for four wires. The wires are not incorporated within a sheath and enter directly into the housing of the connectors. Figure 6B shows a closure 120 of the invention.

Figure 7 shows a male and a female connector 110, 112 assembled together. Each of the connectors has the closure 120 fixed thereon. The embodiment of Figure 7 shows three wires being connected together using the male and female connectors.

The wires may, however, form part of a sheathed cable and the sheath of such a cable would be trimmed such that it did not extend into the connector 110, 112.

The wires are terminated with known terminal pins (not shown). The pins are incorporated onto an insert (not shown) and said insert is located into the housing to fix the terminal pins therein. The insert is configured with a protrusion, and the protrusion is configured to a splay, or separate, the wires located upon the insert, before the insert is inserted and fixed into the connector housing.

Alternatively, the housing 100 may be configured to enable wires, or wires terminated with pins, to be inserted and cormectably fixed directly into the housing 100 of the connector 110. Therefore, the housing 100, in part, would provide the splaying function.

The closure 120 is preassembled over the wires prior to incorporating the wires into the housing. During assembly of a connector 110, the closure 120 is brought in and contacts with the connector housing. The closure is then secured to the connector housing by gluing, vibration welding, or other such forms of tamper-proof fixing means.

The closure 120 has an aperture 122. The size of the aperture 122 is set to be smaller than or substantially equal to the maximum diameter of the wires when bundled together. Further, the depth of the closure in the longitudinal direction, with respect to the longitudinal axis of the cables, the wires and connectors, is set such that when the closure is fixed to the connector housing, the periphery of the aperture compresses against the insulation of the wires. This condition creates a resiliently biased relationship, such that the transition of the wires through the aperture from a tightly bundled condition to a splayed condition secures the wires within the connector through frictional contact with the aperture.

In other words, wires entering the aperture of the closure 120 of the connector enter substantially parallel to one another substantially along the longitudinal axis of the connector. Upon entry to the aperture, the wires are splayed, preferably by a protrusion located upon the insert andlor the housing to which the wire ends, or terminal pins, are located.

By way of example, Figure 8a and 8b show, in partial cross-section, a protrusion 124 installed in the connector housing 100 in relation to the closure 120 and the aperture 122. The protrusion is configured to deform a wire 126. In Figure 8a, the aperture is sized to substantially match the outer dimension of two wires 126, each wire being deformed about the protrusion 124.

In Figure 8b, the aperture 122 is sized to match the outer dimension of a single wire 126 and determine the position of the wire as it passes through the aperture and into the connector. As the wire enters the connector the protrusion deforms the wire.

Although the protrusion is shown as being triangular in cross-section, it may take any such form and may be incorporated with the housing 100, an insert or even the closure.

Further, the protrusion may be formed of more than one component and different parts of the protrusion may be incorporated, or attached, to any part of the connector.

The shape of the wires and the resilient relationship between the wire and the housing and/or insert and the closure is affected by at least one of the resilience of the insulation on the wire, the resilience of the closure or the resilience of the wire in its splayed configuration.

Variations of the invention may include a resilient portion provided on a peripheral portion of the aperture of the closure. The closure itself may be made in whole or in part of one or more resilient materials.

The housing, insert, closures and resilient portions are preferably made from non-conductive insulating material, such as plastic or rubber.

The present invention has been described above purely by way of example, and modifications can be made within the spirit and scope of the invention, which extends to equivalents of the features described. The invention also consists in any individual features described or implicit herein or shown or implicit in the drawings or any combination of such features or any generalisation of any such features or combination.

Claims

CLAiMS: 1. An electrical connector comprising: a housing having a mating end for enabling a connection to be made with the end of at least one wire; a closure, connectable to the housing to define an inlet for receiving the wire, the inlet having an aperture configured to enable the wire to pass therethrough, wherein the closure is configured to engage the wire and to resiliently deform the wire to inhibit the wire from being extracted from the connector.
2. An electrical connector according to Claim 1, wherein the connector is configured to receive two wires.
3. An electrical connector according to Claim 2, wherein the housing is configured to hold the ends of the wires in a spaced configuration within the housing.
4. An electrical connector according to any preceding Claim, wherein the housing is configured to enable a connection to be made with terminal pins provided at the end of the or each wire,
5. An electrical connector according to any preceding Claim, further comprising an insert configured to receive the or each end and to engage with the housing.
6. An electrical connector according to Claim 5, wherein the insert is clipped into the housing.
7. An electrical connector according to any preceding Claim, wherein the closure is sealed to the housing to inhibit tampering with the connector.
8. An electrical connector according to any preceding Claim, wherein the closure is vibration welded to the housing.
9. An electrical connector according to Claim 2 or 3, or any one of Claims 4 to 8 when dependent on claim 2 or 3, wherein the aperture is configured to hold the wiring together and the insert is configured to splay the wires away from one another.
10. An electrical connector according to Claim 9, wherein the insert has a protrusion that extends from the insert to effect splaying of the wires.
11. An electrical connector according to Claim 10, wherein the protrusion extends into the aperture of the closure.
12. An electrical connector according to any preceding Claim, wherein the closure is configured such that the aperture is larger, or substantially the same diameter as the outer dimension of a wire, or a bundle of adjacent wires located therein, the aperture being resiliently biased against said wire or wires when the closure is connected to the housing, wherein the wire or wires adopts a deformed confguration.
13. An electrical connector according to any one of Claims 1 to 11, wherein the aperture is smaller than the outer dimension of a wire, or a bundle of adjacent wires located therein such that the aperture deforms the wires by being resiliently biased against said wire or wires.
14. An electrical connector according to any preceding Claim, wherein the exterior perimeter surface of the closure is smooth such that the connector is inhibited from being caught against objects.
15. An electrical connector according to any one of Claims 1 to 13, wherein the exterior perimeter surface of the closure is convexly curved and extends from the aperture to a point at which the closure interfaces with the housing such that each part of the exterior perimeter surface of the closure is further away from the aperture than a part of the exterior perimeter surface of the closure adjacent the aperture.
16. An electrical connector according to any preceding Claim, wherein the connector is a male connector.
17. An electrical connector according to any preceding Claim, wherein the connector is a female connector.
18. A cable assembly having an electrical connector according to any preceding Claim.
19. An electrical connector assembly having a male connector configured to mate with a female connector, the or each connector comprising: a housing having a mating end for enabling connection to be made with the end of at least one wire; a closure, connectable to the housing to define an inlet for receiving the wire, the inlet having an aperture configured to enable the wire to pass therethrough, wherein the closure is configured to engage the wire arid to resiliently deform the wire to inhibit the wire from being extracted from the connector.
20. A method of assembling an electrical connector by: preparing a wire; inserting the end of the wire through an aperture of a closure; inserting the end in a housing for enabling connections to be made with the end of the wire; and connecting the closure to the housing to define an inlet for receiving the wire, the inlet having an aperture configured to enable the wire to pass therethrough, wherein the closure is configured to engage the wire and to resiliently deform the wire to inhibit the wire from being extracted from the connector.
21. An electrical connector as hereinbefore described with reference to any of figures 6a to 8b of the accompanying drawings