US2355387A - Connector for electric wires - Google Patents

Description

1944. w. R. MAIN 2,355,387

CONNECTOR FOR ELECTRIC WIRES Filed May 14, 1942 Patented Aug. 8, 1944 UNITED STATES PATENT OFFICE 2,855,887 CONNEUI'OR FOB m0 WIRES William 3. Main, Delanco, N. I. Application May 14, 1942, Sada! No. 442,956 11 Claims. (01. 174-87) My invention relates to connectors for electric wires, and while it may be employed at various points and for various connections to the main or circuit wires, it is particularlyadapted for making connections between circuit wires at an outlet and the wires of a lighting fixture, under a ceiling canopy for lnstsnce,'or at other points, or at an outlet box or for other relatively inaccessible positions where it would be a slow and awkward job to make a soldered and/or taped Joint and/or splice.

My invention comprises an improved connector in the form of a pair of sleeves or shells in longitudinal interfitting position or arrangement and enclosing the bared ends of the wires to be connected, with securing means carried by the outer shell or sleeve for permanently holding the wires thereto.

In one form of my improved construction I provide an outer shell or sleeve of relatively heavy material-metal or other suitable substanch having a longitudinal opening which may be eccentric to its longitudinal axis, and such opening receives a shell or sleeve of relatively light and compressible metalcopper for instance into which the bared ends or the wires to be connected are introduced; the thicker wall of the outer shell or sleeve of this form of my improved construction being provided with a threaded opening or openings for the reception of a screw or screws'-preferably socketed elements-whereby, after the ends of the wires have been assembled within the inner lighter sleeve or shell which has been previously introduced into the longitudinal opening of said outer shell or sleeve, the screw or screws may be turned down to compress and/or crimp the inner metal sleeve or shell against the bared ends of the wires contained within thesame; thereby securing the latter in proper electrical contact and in permanent en- Basement with the outer shell or sleeve.

After the connection has been assembled in the manner described, the outer shell or sleeve may be enclosed in a jacket or covering of insulating material, with or without the use of a liquid or semi-liquid, air-hardening plastic insulating material at its open end to engage and enclose the wires adjacent to the remaining insulatlng covering of the same; such open end being then tied or taped with a strip of insulating material common to electrical wiring practice and providing a waterproof structure. To facili-' tate application of the insulating jacket or cover, the outer shell or sleeve is quite smooth and the ends thereof have smooth rounded edges.

5 In another form of connector structure within the scope of my invention, I may provide an outer sleeve or shell of metal or other suitable substance which is apertured longitudinally, preferably axially thereof, and this outer sleeve or shell receives an inner sleeve or shell of compressible metal in the same manner as the other construction referred to and is provided with self-contained clamping means arranged to be forced or upset into engagement with said inner shell or sleeve for the purpose of compressing or crimping the same intermediate its ends whereby the wires contained within the same may be held in proper electrical contact and in permanent engagement with the outer shell or sleeve. This structure will receive an outer Jacket or cover of insulating material in the same manner as in the other form of my improved connector structure.

The inner sleeve or shell, preferably 01' copper, may have a relatively tight fit within the longitudinal opening of the outer shell or sleeve in both forms of my improved construction, and with a view of preventing separation of these parts after assembly, the ends of such inner sleeve or shell may be slightly belledby means of a suitable tool or otherwise-the edges of the openings at the ends of the outer sleeve or shell being slightly rounded to permit this belling or shaping of the ends of the inner sleeve or shell.

My improved connecting structure is intended to take the place of what has come to be known in the electrical wiring art as a "pig-tail splice;

the common or frequent practice heretofore followed being to twist together the end of a circuit wire and the end of one of the fixture or other wires to be connected, and then to cover or enclose the ends of such twisted wires with insulating tape. One difllculty with this form of connection is that the tape wrapping frequently comes loose; the joint is not waterproof-a condition necessitated in many places where Joints or connections of this general type have to be made-and such joint or connection is incapable of taking any strain as might be occasioned by the breaking loose of a lighting fixture or other electrically connected part from any cause..

These and other features of my invention are more fully pointed out hereinafter; reference being had to the accompanying drawing, more or less diagrammatic in character, in which:

Figure 1 is a perspective view of a lighting fixture partially displaced from its final position to show connector structures, within the scope of my invention, between the circuit wires and the fixture wires; such connectors being in their final 5 condition of assembly.

Fig. 2 is a longitudinal sectional view of one form of connector structure within the scope of my invention; showing the manner of assembling the wires to be connected therewith.

Fig. 3 is a similar sectional view of a completed connector structure.

Fig. 4 is a cross sectional view, on a larger scale, taken on the line IV-IV, 1"ig. 3.

Fig. 5 is a cross-sectional view illustrating a detail within the scope of my invention.

Fig. 6 is a view in elevation and on a larger scale of another form of connector structure within the scope of my invention, in which the crimping or compressing means for the inner wire-containing sleeve or shell is self-contained.

Fig. 7 is a sectional view on the line VII-VII, Fig. 6, showing the self-contained clamping or compressing means, and

Fig. 8 is a similar sectional view showing the clamping or compressing means in the operative position of crimping or compressing the inner tube or sleeve against the contained wires to be electrically connected and held in permanent engagement with the outer shell or sleeve.

In Fig. 1 of the drawing 1 have illustrated the application of my improved electrical connection or splice; such view showing a lighting fixture in one stage of its mounting, the wires A of which have been connected to the circuit wires B, by

the connectors C, forming the subject of my in-,

vention; the fixture being now readv to be secured to the backing plate D carried by the wall or other support for such fixture.

In carrying out that form of my invention ilfitted with the set screws n, which have lustrated in Figs. 2, 3 and 4, I provide an outer 'shell or casing II, which may be of metal, of a dimension approximating seven-eighths of an inch in length and seven-sixteenths of an inch in diameter-more or less-as may be desired. The outer surface of this shell or casing is smooth and the edges at its ends are preferably rounded as indicated at It. This shell or casing, which -may be cylindrical, is bored at ll, longitudinally of the same, and such bore may be eccentric to its longitudinal axis; the thicker portion of such shell or casing provided by reason of such eccentricity being tapped and subsequently threaded, as at II, for the reception of suitable retaining members-which may be socketed set screws, indicated at i3-such screws having their inner ends rounded as at It for a purpose hereinafter set forth.

A light metal tube or sleeve, preferably of copper, indicated at It, is inserted in the longitudinal bore ll of the shell or casing l0, and

this inner tube or sleeve receives the bared ends of the wires to be connected or spliced; the fixture wire being indicated at A and the circuit wire at B. (In Figs. 2 and 3, the connector is shown as receiving three wires; since the innertube or sleeve I4 is capable of containing more than two wires, or even more than three wires; a condition that may be necessary in making some types of connections. For a lighting fixture such as diagrammatically illustrated, the third wire is not needed, and the showing is for illustrative purposes only, to indicate that a group of wires may be accommodated within the inner tube or sleeve l4, and all retained in electrical contact and in permanent engagement with the outer shell or casing sleeve in the manner hereinafter set forth.)

The tube or sleeve It is of the same length as the shell or casing sleeve II, and it has a relatively tight fit within the bore i I of the same. It may be retained in place within the outer shell assess-r i ifif ge assessable backed away from the longitudinal bore ll, indicated in Fig. 2, the metal tube or sleev with the contained wires occupies the full length osition which may approximate that illustrated in Fig. 3; making a complete electrical connection between said wires and the metal tube or sleeve enclosing the same and permanently engaging the said inner tube or sleeve and the contained wires with the outer shell or casing sleeve ll.

After the wires to be electrically connected with their containing tube or sleeve introduced into the outer shell or casing sleeve have been confined by the set screws, I preferably encsse the outer shell or easing sleeve ll of the connection or splice in a cover or jacket of suitable material of an insulating character, indicated at II. This may be a pocket of fabric treated with a suitable insulating plastic or other body of a similar nature and of a type of material more or less commonly in use in the covering of electrical connections. This covering is waterproof. and the inner end of the same may be tied in place or wrapped around with insulating tape, as indicated at It. I may also introduce a fiuid or semi-fiuid body of an insulating plastic at the open end of the tubular cover or jacket, as indicatedat i1, whichwillbeconfinedinplaceby the tying or taping operation. when this jacket or cover is employed, a completely waterproof connection is assured.

While I have referred to the use of an outer shell or casing sleeve of metal to receive and contain the metal tube or sleeve receiving and containing the ends of the respective wires to be electrically connected, it is within the scope of my invention to employ a shell or casing sleeve made of a suitable plastic material; hard rubber, synthetic resins, and/or the like, of a size which may be substantially the same as the metal shell or casing sleeve and constructed in all other respects,astoshape.thepositionofthethrough bore, and the apertures for the retaining means. asthemetalshellorcasingsleeve. Thethicker portion of such non-metallic shell or casing sleeve will rovide suificient body for tap l and threading and subsequent application of the retaining screws or other holding means.

While I preferably employ an outer shell or casing sleeve of cylindrical contour in cross-section, it is obvious and that other shapu might be employed: substantially oval, rectangular, and/or the like, and in Fig. ii I have illustrated. diagrammatically, and in cross-section, a shell or casing sleeve contour, substantially oval, that is within the-scope of my invention.

In Figs. 6, 'l and 8, I have shown another form of connector structure within the scope of my invention in which the retaining means for the contained tube or sleeve and the wires to be electrically connected and located within the same are integral with the outer shell or casing sleeve. .This structure may be cylindrical or of the substantially oval cross-sectional contour illustrated in Fig. 5, asindicated by the broken line contour, Fig. 7.

In this construction, the outer shell or casing sleeve, indicated at III, is cross slotted at intervals throughout its length, as indicated at lit, and by removing a portion of the metal between nairs'of these slots at the'upper side of the shell or casing sleeve, as indicated at :r, flanking prongs or fingers Ill are left as shown in Fig. 7, on opposite sides of the through bore Iii receiving the inserted tube or sleeve ill. After the wires to be electrically connected are inserted in the tube or sleeve ill positioned within the outer shell or casing sleeve Ill, these fingers or prongs may be bent inwardly by a suitable tool and forced against the inner tube or 'sleeve ill; thereby compressing or crimping the wall of the same and the wires contained therein opposite said fingers or prongs in the manner indicated in Fig. 8; thereby holding said wires in electrical contact and in permanent engagement with the outer shell or sleeve casing HI.

After this operation, the shell or casing sleeve H may be encased in an insulating jacket or cover-similar to that illustrated in Fig. 3, which will be secured to the wiresbeyond such shell or casing sleeve in a similar manner. The slotting of the shell or casing sleeve may be effected by a saw or a pair of saws set in properly spaced relation to make the pairs of slots to form the portions from which the prongs or fingers are subsequently formed, and a possible are of cut in indicated by dotted lines. The removal of metal from the shell or casing sleeve at the upper side of these portionsconsidering Fig. '1may be effected by drilling or boring the shell or casing sleeve through to the longitudinal bore of the same receiving the inserted tube or sleeve Ill before the cross slots are formed, or in any other suitable manner to produce the desired result.

If desired, I may employ as the inner tube or sleeve receiving the wires to be electrically connected any one of a number of connecting tubes or sleeves now in more or less common use and which have a lining of rough granular materialmetal or other substance-which, upon compression, will bite into the wires and assist in holding them firmly in position.

While I have described the features of my invention with some particularity and have shown' in the'drawing embodiments of my improved connector or splice, it will be understood that such disclosure is for illustrative purposes only and not in any limiting sense since modifications may be made without departing from the spirit of my invention; all of which is deemed to be within the scope of the appended claims.

I claim:

1. An electrical connector comprising a pair of tubular members in telescoping engagement; one

of said members being of metal fitting within the other and permanently secured thereto: said inner member enclosing a group of wires in substantially parallel arrangement to be electrically connected, and means for compressing the inner member and its contained wires with respect to the outer member.

2. A connector for electric wires comprising a pair of tubular members in telescoping engagement; one oi said members being of a compressible metal and snugly fitting within the other member and permanently secured thereto: said inner member enclosing a group of wires in substantially parallel arrangement to be electrically connected, and means movable with respect to the outer member for compressing said inner member and its contained wires with respect to said outer member.

3. A connector for electric wires comprising a I I shell, a tubular sleeve telescopically fitting said shell and permanently secured thereto; said tubular sleeve enclosing the ends of a group of wires in substantially parallel arrangement in be electrically connected, and means for compressing the inner tube and the wires contained within the same.

4. A connector for electric wires comprising a shell, a tubular sleeve of a compressible metal telescopically fitting said shell and permanently secured thereto; said tubular sleeve enclosing the ends of a group of wires in substantially parallel arrangement to be electrically connected, and means carried by the shell and movable with respect to the same for compressing the inner metal tube and the wires contained within the same.

5. A connector for electric wires comprising a shell having a longitudinal through bore, a tube disposed within said bore and permanently secured to the shell; said tube being adapted to receive agroup of wires in substantially parallel arrangement to be electrically connected. and retaining means for said inserted wires carried by the shell and positioned to engage'the inserted tube at right angles to the longitudinal axis of the same.

6. A connector for electric wires comprising a shell having a longitudinal through bore eccentric to its longitudinal axis whereby a thickened wall is left at one side of said bore, a tubular sleeve disposed within said bore and permanently secured to the shell; said sleeve being adapted to receive a group of wires in substantially parallel arrangement to be electrically connected, and retaining means for said wires comprising screw elements disposed in the thicker wall of said shell for engaging and compressing the inserted sleeve at right angles to the longitudinal axis of the same.

7. In a structure as set forth in claim 6, screw elements having rounded ends for engagement with the inserted tube.

8. A connector for electric wires comprising a shell having a longitudinal through bore eccentric to its longitudinal axis whereby a thickened wall is left at one side of said bore, a tubular sleeve disposed within said bore and permanently secured to the shell; said sleeve being adapted to receive a group of wires in substantially paral lel arrangement to be electrically connected, and retaining means for said wires comprising screw elements disposed in the thicker wall of the shell for separately compressing the inserted sleeve and the wires contained within the same.

4 games? 9. A connector for electric wiree comprising e ehell heving e longitudinnl through bore, e oompressibie metnl tube dispoeed within llld bore and having e relatively tight lit therewith end permanently secured to the shell; eeid tube receiving e group of wires in eubetentieily peniielarrangementtobeconnected. endepeiroi screws carried by the shell in position to engage and crimp themeertedmetel tube endthewiree contained within the same.

10. A connector for electric vim comprising 1 shell having 1 longitudinei through bore; l tube disposed within said bore and permenently eecuredtotheshelhseidtubebeingedeptedto oi the outer member at the ends o! it: bore.

WILLIAM it. MAIN.

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