GB2545278A - A method and apparatus for forming an electrical connection - Google Patents
A method and apparatus for forming an electrical connection Download PDFInfo
- Publication number
- GB2545278A GB2545278A GB1521928.0A GB201521928A GB2545278A GB 2545278 A GB2545278 A GB 2545278A GB 201521928 A GB201521928 A GB 201521928A GB 2545278 A GB2545278 A GB 2545278A
- Authority
- GB
- United Kingdom
- Prior art keywords
- bore
- conductive member
- electrical connection
- slug
- forming
- 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.)
- Granted
Links
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
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/02—Soldered or welded connections
- H01R4/021—Soldered or welded connections between two or more cables or wires
- H01R4/022—Soldered or welded connections between two or more cables or wires comprising preapplied solder
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/02—Soldered or welded connections
- H01R4/021—Soldered or welded connections between two or more cables or wires
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R33/00—Coupling devices specially adapted for supporting apparatus and having one part acting as a holder providing support and electrical connection via a counterpart which is structurally associated with the apparatus, e.g. lamp holders; Separate parts thereof
- H01R33/74—Devices having four or more poles, e.g. holders for compact fluorescent lamps
- H01R33/76—Holders with sockets, clips, or analogous contacts adapted for axially-sliding engagement with parallely-arranged pins, blades, or analogous contacts on counterpart, e.g. electronic tube socket
- H01R33/7607—Holders with sockets, clips, or analogous contacts adapted for axially-sliding engagement with parallely-arranged pins, blades, or analogous contacts on counterpart, e.g. electronic tube socket the parallel terminal pins having a circular disposition
- H01R33/7614—Holders with sockets, clips, or analogous contacts adapted for axially-sliding engagement with parallely-arranged pins, blades, or analogous contacts on counterpart, e.g. electronic tube socket the parallel terminal pins having a circular disposition the terminals being connected to individual wires
- H01R33/7628—Holders with sockets, clips, or analogous contacts adapted for axially-sliding engagement with parallely-arranged pins, blades, or analogous contacts on counterpart, e.g. electronic tube socket the parallel terminal pins having a circular disposition the terminals being connected to individual wires the wires being connected using solder
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/02—Soldered or welded connections
- H01R4/023—Soldered or welded connections between cables or wires and terminals
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/28—Clamped connections, spring connections
- H01R4/30—Clamped connections, spring connections utilising a screw or nut clamping member
- H01R4/36—Conductive members located under tip of screw
- H01R4/363—Conductive members located under tip of screw with intermediate part between tip and conductive member
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
- H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
Abstract
A method for forming an electrical connection between a first conductive member 18 and a second conductive member 4, the method comprising: inserting the first conductive member 18 into a first bore 12; driving a slug 14 of cold-flowable metal (such as a soft metal alloy) into a second bore 10 which intersects the first bore such that the cold-flowable metal flows around the first conductive member thereby forming the electrical connection with the second conductive member 4. The first and second conductive members may be in a connector block (20, figure 5). Preferably a threaded fastening driving element 16 is used to drive the slug, and the second bore is threaded so that the slug is driven by screwing the threaded fastener into the second bore. Preferably the threaded fastener has a frangible head which shears if the fastener is screwed after the electrical connection is formed.
Description
A METHOD AND APPARATUS FOR FORMING AN ELECTRICAL CONNECTION
The invention relates to a method and apparatus for forming an electrical connection using a cold-flowable metal.
It is often necessary, in industrial or domestic applications, to electrically connect two or more electrically conductive members, for example, stranded or solid wires, flat or shaped conductive strips, or solid electrical components in various forms, such as plates, tubes, bars, housings or casings.
Conventional methods for forming an electrical connection include crimping, insulation displacement, screw-in terminals, soldering and ultrasonic welding. Although these techniques are suitable for many applications, they are not well-suited to applications in which access is restricted, where their usage is either not feasible or leads to unsatisfactory results.
The invention seeks to address the issues with conventional methods for forming an electrical connection highlighted above.
In accordance with an aspect of the invention, there is provided a method for forming an electrical connection between a first conductive member and a second conductive member, the method comprising: inserting the first conductive member into a first bore; driving a slug of cold-flowable metal into a second bore which intersects the first bore such that the cold-flowable metal flows around the first conductive member thereby forming the electrical connection with the second conductive member.
The slug may be driven into the second bore by translating a driving element into the second bore.
The second bore may be threaded and the driving element may be a threaded fastener, the slug being driven into the second bore by screwing the threaded fastener into the second bore.
The threaded fastener may comprise a frangible head which shears if the fastener is screwed after the electrical connection is formed.
The first and second bores may be perpendicular to one another.
The first and second bores may be formed in the second conductive member.
The first and second bores may be formed in a connector block into which the second conductive member is also inserted.
The connector block may comprise an electrically insulative material.
In accordance with another aspect of the invention, there is provided an apparatus for forming an electrical connection between a first conductive member and a second conductive member, the apparatus comprising: a slug of cold-flowable metal configured to be inserted into a second bore which intersects a first bore into which the first conductive member is inserted; and a driving element for driving the cold-flowable metal into the second bore such that the cold-flowable metal flows around the first conductive member thereby forming the electrical connection with the second conductive member.
The driving element may be a threaded fastener which is configured to drive the slug into the second bore by screwing the threaded fastener into the second bore.
The threaded fastener may comprise a frangible head which shears if the fastener is screwed after the electrical connection is formed.
The apparatus may further comprise a connector block in which the first and second bores are formed, and into which the second conductive member is also inserted.
The connector block may be formed from an electrically insulative material.
For a better understanding of the invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:-
Figure 1 is a perspective view of an electrical connector according to an embodiment of the invention;
Figure 2 is a cross-sectional view of the electrical connector in a first stage of forming an electrical connection;
Figure 3 is a cross-sectional view of the electrical connector in a second stage of forming the electrical connection;
Figure 4 is a cross-sectional view of the electrical connector in a third stage of forming the electrical connection; and
Figure 5 is a cross-sectional view of an electrical connector according to another embodiment of the invention.
Figure 1 shows an electrical connector 2 according to an embodiment of the invention. The electrical connector 2 comprises a central pin or rod 4 and an outer sleeve 6 within which the central pin 4 is disposed (see also Figures 2 to 4).
The central pin 4 is cylindrical and substantially solid along its length. The outer sleeve 6 is tubular and has an internal diameter which is sized to receive the central pin 4 such that the central pin 4 and outer sleeve 6 are arranged concentrically. As shown, the central pin 4 has a greater axial length than the outer sleeve 6 such that a portion of the central pin 4 extends out of the outer sleeve 6. Both the central pin 4 and outer sleeve 6 (or at least a part thereof) are formed from conductive metals. For example, an aluminium alloy may be used, but other materials including, but not limited to, copper, brass or steel may also be used.
Disposed between the central pin 4 and the outer sleeve 6 is an insulating layer 8. The insulating layer 8 may be a discrete tubular element disposed between the central pin 4 and outer sleeve 6 or may be a layer formed on either (or both) of (or between) the central pin 4 and the outer sleeve 6. The insulating layer 8 extends along at least the axial length of the outer sleeve 6 and electrically insulates the central pin 4 from the outer sleeve 6. The insulating layer 8 may be a reinforced thermoplastic or thermoset material, such as a fibre-reinforced epoxy material, with the three components being bonded together, for example using an epoxy adhesive, to form a composite unit.
The electrical connector 2 may be used to form separate electrical connections to the central pin 4 and the outer sleeve 6. In particular, the portion of the central pin 4 below the outer sleeve 6 may be received within an opening in a first rail and the outer sleeve 6 may be received within an opening in a second rail to form electrical connections with the first and second rails. A method for forming an electrical connection with the central pin 4 (at the other end of the central pin 4 to the first rail described above) will now be described with reference to Figures 2 to 4.
As shown in Figure 2, the central pin 4 comprises a blind bore 10 which extends from one end of the central pin 4 axially along part of its length. In the example shown, the axial bore 10 has a diameter of approximately 3.3mm in a central pin 4 of outside diameter 8mm. A radial bore 12 is formed through the outer sleeve 6, the insulating layer 8 and into the central pin 4 such that it intersects the axial bore 10 at or near its base. As shown, the radial bore 12 may be formed such that a radially innermost portion has a smaller diameter than the radially outer portion. For example, the final 1mm of the radial bore 12 may have a diameter of 2mm whereas the remainder of the radial bore 12 has a diameter of 3mm. A slug 14 formed of a soft, ductile metal is located within the axial bore 10. The slug 14 is formed from a metal which is cold-flowable under pressure. For example, the slug 14 may be a cylinder of solder (having a tin content of -99%, for example). The slug 14 has an outside diameter which is slightly smaller than the diameter of the axial bore 10. In this example, the slug 14 has an outside diameter of approximately 3.2mm and has a length of 5mm. The axial bore 10 is threaded along its length. A grub screw 16 (or other threaded fastener) is driven along the axial bore 10 such that the cold-flowable slug 14 is disposed between the grub screw 16 and the base of the axial bore 10.
As shown in Figure 3, an insulated wire 18 (for example, a 1mm2 stranded, insulated copper wire) is passed into the axial bore 10 via the radial bore 12 such that the exposed conductor of the wire lies at or near the base of the axial bore 10 and thus is located between the base and the cold-flowable slug 14. The wire 18 is pushed into the radial bore 12 until the end reaches the far wall of the axial bore 10. The end of the insulated wire 18 is preferably stripped such that the exposed conductor extends slightly more than the diameter of the axial bore 10 and thus the insulation begins within the reduced-diameter portion of the radial bore 12. In the present example, the last 4mm of the wire 18 is therefore stripped.
As shown in Figure 4, the grub screw 16 is driven further along the axial bore 10 such that it contacts the cold-flowable slug 14 and forces it against the wire 18 and the base of the axial bore 10. The pressure exerted by the grub screw causes the slug 14 to flow thus wetting the wire 18 and the inner surface of the axial bore 10 so as to physically and electrically connect the wire 18 to the central pin 4.
The material of the slug 14 may also prevent the grub screw 16 from being over tightened and/or withdrawn. In some arrangements, the head of the grub screw 16 may shear if further tightened. This may therefore provide confirmation to the user that the connection has been satisfactorily formed and the grub screw 16 may be formed specifically to allow for the head to shear off in this manner (for example, using a thinned portion to create a frangible head).
The material of the central pin 4, the wire 18 and the grub screw 16 is harder than that of the slug 14, so that the pressure required to cause the slug 14 to deform and flow, does not lead to significant flow of the material of those elements.
Although the wire 18 is surrounded by the cold-flowed metal and hole surrounding it is completely filled with the cold-flowed metal, additional environmental sealing may be provided by filling the axial bore 10 with epoxy resin or the like, and inserting a silicone tube (in this case of approximately 3mm outside diameter and 2mm inside diameter) around the insulation of the wire 18 and into the radial bore 12.
It will be appreciated that the method for forming an electrical connection has been described with respect to a specific example (which itself happens to be an electrical connector), but has broader applications wherever two (or more) electrically conductive members are to be connected. The central pin 4 therefore may be a wire or the wire 18 may be formed as a solid conductor.
For example, Figure 5 shows another embodiment in which a connector block 20 has a pair of diametrically-opposed first bores 110a, 110b for receiving a pair of wires 18a, 18b and a second bore 112 for receiving a cold-flowable slug and a grub screw 16. In a similar manner, the grub screw 16 can be driven into the connector block to cause the slug to flow around the exposed ends of the wires 18a, 18b thereby electrically connecting them to one another. In this embodiment, the connector block 20 itself may be formed from (or comprise) an insulating material, rather than a conductor. The top section of the connector block 20 may be removable with the grub screw 16 after the electrical connection is formed in order to reduce the size of the connector block. Although the first bores 110a, 110b are shown as being opposite one another, they may instead be positioned in any orientation provided they terminate at the second bore 112. Moreover, the wires 18a, 18b may be inserted into the second bore 112 via a single first bore 110. The connector block 20 may have any cross-section, such as circular or rectangular.
The cold-flowable slug 14 need not be driven by a threaded fastener, such as grub screw 16, but may instead be forced along the bore using any suitable driving element (such as a ramrod or the like) which may or may not be retractable from the bore following the formation of the electrical connection.
To avoid unnecessary duplication of effort and repetition of text in the specification, certain features are described in relation to only one or several aspects or embodiments of the invention. However, it is to be understood that, where it is technically possible, features described in relation to any aspect or embodiment of the invention may also be used with any other aspect or embodiment of the invention.
The invention is not limited to the embodiments described herein, and may be modified or adapted without departing from the scope of the present invention.
Claims (15)
1. A method for forming an electrical connection between a first conductive member and a second conductive member, the method comprising: inserting the first conductive member into a first bore; driving a slug of cold-flowable metal into a second bore which intersects the first bore such that the cold-flowable metal flows around the first conductive member thereby forming the electrical connection with the second conductive member.
2. A method as claimed in claim 1, wherein the slug is driven into the second bore by translating a driving element into the second bore.
3. A method as claimed in claim 2, wherein the second bore is threaded and the driving element is a threaded fastener, the slug being driven into the second bore by screwing the threaded fastener into the second bore.
4. A method as claimed in claim 3, wherein the threaded fastener comprises a frangible head which shears if the fastener is screwed after the electrical connection is formed.
5. A method as claimed in any preceding claim, wherein the first and second bores are perpendicular to one another.
6. A method as claimed in any preceding claim, wherein the first and second bores are formed in the second conductive member.
7. A method as claimed in any of claims 1 to 5, wherein the first and second bores are formed in a connector block into which the second conductive member is also inserted.
8. A method as claimed in claim 7, wherein the connector block comprises an electrically insulative material.
9. A method for forming an electrical connection between a first conductive member and a second conductive member according to claim 1 and substantially as described herein.
10. An apparatus for forming an electrical connection between a first conductive member and a second conductive member, the apparatus comprising: a slug of cold-flowable metal configured to be inserted into a second bore which intersects a first bore into which the first conductive member is inserted; and a driving element for driving the cold-flowable metal into the second bore such that the cold-flowable metal flows around the first conductive member thereby forming the electrical connection with the second conductive member.
11. An apparatus as claimed in claim 10, wherein the driving element is a threaded fastener which is configured to drive the slug into the second bore by screwing the threaded fastener into the second bore.
12. An apparatus as claimed in claim 11, wherein the threaded fastener comprises a frangible head which shears if the fastener is screwed after the electrical connection is formed.
13. An apparatus as claimed in any of claims 10 to 12, further comprising a connector block in which the first and second bores are formed, and into which the second conductive member is also inserted.
14. An apparatus as claimed in claim 13, wherein the connector block is formed from an electrically insulative material.
15. An apparatus for forming an electrical connection between a first conductive member and a second conductive member substantially as described herein with reference to the accompanying drawings.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1521928.0A GB2545278B (en) | 2015-12-12 | 2015-12-12 | A method and apparatus for forming an electrical connection |
| PCT/GB2016/053877 WO2017098253A1 (en) | 2015-12-12 | 2016-12-09 | A method and apparatus for forming an electrical connection |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1521928.0A GB2545278B (en) | 2015-12-12 | 2015-12-12 | A method and apparatus for forming an electrical connection |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB201521928D0 GB201521928D0 (en) | 2016-01-27 |
| GB2545278A true GB2545278A (en) | 2017-06-14 |
| GB2545278B GB2545278B (en) | 2020-04-08 |
Family
ID=55274628
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB1521928.0A Active GB2545278B (en) | 2015-12-12 | 2015-12-12 | A method and apparatus for forming an electrical connection |
Country Status (2)
| Country | Link |
|---|---|
| GB (1) | GB2545278B (en) |
| WO (1) | WO2017098253A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2022136846A1 (en) | 2020-12-23 | 2022-06-30 | Larkfleet Smart Homes Limited | Electrical system for a residential site |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4889506A (en) * | 1988-11-03 | 1989-12-26 | Raychem Corporation | Solder delivery device |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2466901A (en) * | 1947-05-12 | 1949-04-12 | Fred G Krueger | Clamp or anchorage |
| GB778287A (en) * | 1953-09-01 | 1957-07-03 | Heinz Theobald Ludtke | Improvements in or relating to electrical clamping screws |
| DK2071201T3 (en) * | 2007-12-11 | 2010-07-05 | Nexans | Shear-off screw |
-
2015
- 2015-12-12 GB GB1521928.0A patent/GB2545278B/en active Active
-
2016
- 2016-12-09 WO PCT/GB2016/053877 patent/WO2017098253A1/en active Application Filing
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4889506A (en) * | 1988-11-03 | 1989-12-26 | Raychem Corporation | Solder delivery device |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2022136846A1 (en) | 2020-12-23 | 2022-06-30 | Larkfleet Smart Homes Limited | Electrical system for a residential site |
Also Published As
| Publication number | Publication date |
|---|---|
| GB201521928D0 (en) | 2016-01-27 |
| GB2545278B (en) | 2020-04-08 |
| WO2017098253A1 (en) | 2017-06-15 |
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