MXPA96003352A - Electric wedge connector with retenc cups - Google Patents

Abstract

The present invention relates to a wedge connector comprising: a wedge, and a helmet sized and configured appropriately to receive the wedge, and a conductor in a receiving area, with the driver being sandwiched between the wedge and the helmet, having the helmet a cured wall against which the conductor is placed, the wall having a hole through it, one edge of the wall in the hole projects inward to the receiving area

Description

"ELECTRIC WEDGE CONNECTOR WITH RETENTION PENS" BACKGROUND OF THE INVENTION FIELD OF THE INVENTION The present invention relates to electrical connectors and, more particularly, to a wedge connector. 2. PREVIOUS TECHNIQUE U.S. Patent No. 5,044,996 discloses a wedge connector having a member C with a lance projecting inwardly to engage the wedge. U.S. Patent Number 4,650,273 discloses an electrical connector with a "C" shaped sleeve and a wedge. The wedge is punched and shaped into sheet metal and has a tongue at its front end. The wedge engages a front end of the sleeve to resist withdrawal of the wedge from the sleeve. U.S. Patent No. 5,006,081 discloses a wedge connector with a "C" shaped sleeve having a hole in its middle section for coupling a concavity in a wedge of rolled and shaped laminated metal. U.S. Patent No. 5,244,422 discloses a wedge connector with a member C having an internal surface of each channel with a knurled finish. Other US patents that relate to wedge connectors include the following: 2,106,724 2,814,025 2,828,147 3,065,449 3,275,974 3,329,928 3,349,167 3,462,543 3,504,332 3,516,050 3,588,791 3,920,310 4,059,333 4,533,205 4,600,264 4,634,205 4,723,920 4,723,921 4,730,087 4,734,062 4,813,894 4,863,403 4,872,856 4,915,653 5,145,420 COMPENDIUM OF THE INVENTION In accordance with one embodiment of the present invention, there is provided a wedge connector comprising a wedge and a helmet. The hull is appropriately sized and configured to receive the wedge and a conductor in the receiving area, with the driver being sandwiched between the wedge and the hull. The helmet has a curved wall against which the driver is placed. The wall has a hole through it. One edge of the wall in the hole projects inward toward the receiving area. In accordance with another embodiment of the present invention, a wedge conductor comprising a wedge and a helmet is provided. The hull is appropriately sized and configured to receive the wedge and a conductor in a receiving area with the driver being sandwiched between the wedge and the hull. The helmet has a curved wall against which the driver is placed. The curved wall has a portion inwardly punched with a pointed edge projecting towards the receiving area. In accordance with a method of the present invention, there is provided a method for forming a hull for a wedge connector comprising the steps of forming a general member in the form of a "C"; forming a hole through the member in a curve of the extremity of the member; and forming a projection on the edge of the hole projecting towards a member receiving area. According to another method of the present invention, there is provided a method for forming a hull for a wedge connector comprising the steps of forming a flat rolled metal member in a general "C" shape; cutting a cut on an end edge of the member and deforming a portion of the member from the cut toward the receiving area of the general "C" shape to form an edge projecting inwardly.

BRIEF DESCRIPTION OF THE DRAWINGS The aforementioned aspects and other features of the invention are explained in the following description, which is taken in conjunction with the accompanying drawings in which: Figure 1 is a detailed side view of an electric wedge connector incorporating the features of the present invention, with two connectors and showing the helmet in the form of "C" in cross section; Figure 2 is an enlarged view of the area C shown in Figure 1; Figure 3 is a top plan view of the hull shown in Figure 1; Figure 4 is a cross-sectional view of a portion of a helmet in an alternative embodiment of the present invention; Figure 5 is a cross-sectional view of a portion of a helmet of an alternative embodiment of the present invention; and Figure 6 is a cross-sectional view of a helmet of an alternative embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED MODALITIES Referring to Figure 1, there is shown a detailed side view of an electric wedge connector incorporating the features of the present invention and two conductors A, B. Although the present invention will be described with reference to the embodiments shown in the drawings , it should be understood that the present invention may be encompassed in several forms of different modalities. In addition, any size, configuration or type of appropriate elements or materials could be used. The wedge connector comprises a hull 10 and a wedge 12. In the embodiment shown, the wedge 12 consists of a single elongated rolled metal member that has been formed in the configuration shown. The rolled metal member has been bent over itself in a longitudinal direction, several times, along its length, so as to form the wedge 12. In alternative embodiments, a greater or lesser amount of folds could be provided. The wedge 12 has two adjacent main loop sections 14, 16, interconnected by a third loop section 18. The two longitudinal ends 20, 22 of the rolled metal member are placed on the two main loops 14, 16, respectively. The third loop 18, in addition to interconnecting the first and second main loops 14, 16, can also function as a back support or containment support for the main loops 14, 16. The sides 24, 26 are sized and configured appropriately to couple the conductors A, B, to sandwich the conductors A, B, against the inner sides of the helmet 10. The wedge 12 also has a latch (not shown) for coupling the helmet of the hole 28 in order to hold the wedge 12 in the hull 10. An additional description of the wedge 12 can be found in the North American Patent Application Number 08 / 306,463, filed on September 15, 1994 and which is incorporated herein by reference in its entirety. However, in alternative modes, any type of appropriate wedge could be used. The helmet 10 is a one-piece member that is preferably made of rolled metal, but could also be a molded, stretched or extruded member. The hull 10 has two opposite channel sections 30, 32, interconnected by an intermediate section 34, to form a general "C" configuration, with a receiving area 35 for receiving the wedge 12 and the conductors A, B. The configuration " C "is used from the end 36 back to the front end 38. The intermediate section 34 includes a rear end tab 40 and a slot or depression 42 and the slot 28. The slot 28 is positioned proximate the rear end of the helmet and forms a stop shoulder 44. The slot 28 extends entirely through the intermediate section 34 from the inner surface to the outer surface. However, in an alternative embodiment, that slot 28 does not need to extend entirely through the intermediate section 34. The depression 42 extends from the slot 28 to the front end 38 of the helmet 10. In another alternative embodiment, the depression 42 does not need to be provided nor does it need to extend toward the front end 38, but if provided, the slot 28 must be placed in the housing. rear end of the depression 42. With reference also to Figures 2 and 3, the channel sections 30, 32 are formed of the walls 46, 48, in those sections that are curved. In the embodiment shown, each curved wall 46, 48 has three holes 50 therethrough. In the alternative modalities, an amount greater than or less than three holes could be provided. Also, in an alternative mode, only one walls 46, 48, I could have a hole 50 through them. At an edge 52 of each hole 50, the edge 52 was punched or otherwise moved into the receiving area. Therefore, in each hole 50, a projection or puma 54 is formed at the steep edge. In the embodiment shown, only a portion of the total edge of the hole 50 moves toward the receiving area. However, in an alternative embodiment, the entire edge of the hole could move toward the receiving area. As can be seen by a comparison of the projections in the upper channel section 30 versus the lower channel section 32 in Figure 1, the projections can also be on either side of the holes. In the embodiment shown, the holes 50 have a general oval configuration and only one side or a little less than 50 percent of the edge of the oval configuration moves toward the receiving area. However, in alternative embodiments, holes of different configuration could be used to provide projections configured differently. By not deforming the tip 56 of the projections 54, the tip 56 can be kept very sharp for better coupling with the conductors A, B.When the conductors A, B, and the wedge 12 are inserted into the helmet 10, the wedge 12 presses the conductors A, B, against the walls 46, 48. The projections 54 penetrate the conductors A, B, to help retain the conductors in a stationary position in the hull 10. The very sharp tips 56, ensure penetration towards the conductors A, B and, a depth of penetration sufficient to securely retain the connectors with the helmet 10. Referring now to Figure 4, a cross-sectional view of an alternative embodiment of a curved wall is shown. In this embodiment, the wall 48a has projection 54a. The wall 48a has been punched out to cut the wall in the areas 58 in order to form edges 60 cut upwards. The ramp sections 61 are formed behind the edges 60 to help guide the driver over the edges 60 during insertion. However, a careful examination of the tips of the edges 60 found that they are not as sharp as the tips 56 as in the embodiment shown in Figure 1, but this type of modality could still be used in some applications. Additional operations on tools can be used to increase the sharpening of the tips. Referring now to Figure 5, a cross-sectional view of a curved wall 48b of another alternative embodiment is shown. In this embodiment, the flat laminated metal wall 48b was pierced by a tool (not shown) to form areas 62 attempted. In the wall 48b it is deviated outwards in the areas 64 and inwards in the areas 66. The resulting tip or edge 68 has been found to be extremely sharp. The ramp sections 70 are formed behind the tip 68 to help guide the driver over the tips 68 during insertion. However, the areas 64 could also have sharp or sharp edges that could be used to hold a conductor if it were placed inside the helmet. Referring now to Figure 6, a cross-sectional view of an alternative embodiment of a helmet 80 is shown. In this embodiment, the cuts or upsetting are cut or formed towards the front end edge 82 and the end edge 84. back in sections 86, 88, channel. The portions 90, 92 then deform and move in other direction towards the receiving area 93. These portions 90, 92, therefore, form projections 94 projecting inwards with sharp or pronounced edges to couple the conductors. In an alternative embodiment, both the end projections 94 and the projection on the inside of the channel sections could be provided.

It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without deviating from the invention. Accordingly, the present invention is intended to cover all those alternatives, modifications and variations that fall within the scope of the appended claims.

Claims (16)

R E I V I N D I C A C I O N E S;

1. A wedge connector that comprede: a wedge; and a helmet sized and configured appropriately to receive the wedge, and a conductor in a receiving area, with the driver being sandwiched between the wedge and the helmet, the helmet has a curved wall against which it is placed in conductor, the wall has a hole through it, one edge of the wall in the hole projects inward to the receiving area.

A wedge connector according to claim 1, wherein the hull consists of rolled metal.

3. A wedge connector according to claim 1, wherein the hull has a general "C" shape.

A wedge connector according to claim 1, wherein the curved wall has a plurality of holes therethrough with the edges projecting inwardly in each hole.

A wedge connector according to claim 1, wherein the edge extends toward the receiving area from less than 50 percent of the total edge formed by the hole.

6. A wedge connector comprising: a wedge; and a dimensional hull and appropriately configured to receive the wedge and a connector in a receiving area with the driver being sandwiched between the wedge and the hull, the hull having a curved wall against which the conductor is placed, the curved wall having a portion punched inwards with a sharp or sharp edge that projects towards the receiving area.

A wedge connector according to claim 6, wherein the hull consists of rolled metal.

8. A wedge connector according to claim 6, wherein the hull has a general "C" shape.

A wedge connector according to claim 6, wherein the curved wall has a plurality of holes therethrough with one of the inwardly punched portions and the sharp or sharp edge in each hole.

A wedge connector according to claim 9, wherein the edges extend toward the receiving area from less than 50 percent of the total edge formed by each of the holes.

11. A method for forming a hull for a wedge connector, the method comprises the steps of: forming a general member in the form of a "C"; forming a hole through the member in a curve of the extremity of the member; and forming a projection on an edge of the hole projecting towards the receiving area of the member.

12. A method according to claim 11, wherein the step of forming the general "C" configuration member comprises deforming the flat rolled metal in a general "C" configuration.

A method according to claim 11, wherein the step of forming a hole comprises piercing a hole through the "C" configuration member.

A method according to claim 11, wherein the step of forming a projection comprises moving the edge of the hole towards the receiving area of the member.

15. A method for forming a hull for a wedge connector, the method comprising the steps of: forming a flat rolled metal member in a general "C" shape; make a cut towards an end edge of the member; and deforming a portion of the member from the cut toward the receiving area of the general "C" configuration to form an edge projecting inwardly.

16. A method according to claim 15, wherein the cutting step forms a plurality of cuts in a front end edge and a trailing end edge of the member.