US3644875A

US3644875A - Electrical connector

Info

Publication number: US3644875A
Application number: US4388A
Authority: US
Inventors: Francis A O'loughlin
Original assignee: Thomas and Betts Corp
Current assignee: ABB Installation Products Inc
Priority date: 1970-01-20
Filing date: 1970-01-20
Publication date: 1972-02-22
Anticipated expiration: 1989-02-22

Abstract

The connector is formed with a longitudinal bore to receive the rectangular-shaped post as well as with a recess which extends either longitudinally or transversely of the bore. In either embodiment, the bore is in communication with the recess so that at least one of the sharp corners of the post projects into the recess and thus into an insulation coated wire disposed within the recess to form an electrical connection with the wire.

Description

United States Patent [151 3,644,875

OLoughlin Feb. 22, 1972 [54] ELECTRICAL CONNECTOR 1,328,784 1/1920 Benjamin et al. ..339/95 2,296,443 9/1942 Kleinfelder ...339/276 [721 smch Hams 3,249,908 5/1966 Fuller et al ..339/98 [73] Assignee; Thomas 8; Beflg Corporation, Elizabeth, 3,345,452 10/1967 Logan et al. ..339/276 NJ. Primary Examiner.loseph H. McGlynn [22] med: 1970 Attorney-Thomas M. Marshall 21 A l. N .1 4 88 l 1 PP 9 ,3 57 ABSTRACT [52] us. Cl. 339/97 R, 339/273 R The is fmmed with IOhEihIdhIaI bore receive 511 int. Cl .1101.- 9/08 the mammal-shaped as as with a recess which [58] Field of Seam h .339/ 97-100 ends either bhghhdihhhY transversely the hore- 5 57 53 174/95 R either embodiment, the bore is in communication with the recess so that at least one of the sharp corners of the post projects into the recess and thus into an insulation coated wire [56] References Cmd disposed within the recess to form an electrical connection UNITED STATES PATENTS with the 177,318 5/1876 Barbour ..339/273 11 Claims, 8 Drawing Figures PATENTED FEB 22 I972 l N VENTOR.

FRANCIS A. O'LOUGHLIN ATTORNEY 4 ELECTRICAL CONNECTOR This invention relates to an electrical connector. More particularly, this invention relates to an electrical connector for electrically and mechanically connecting an insulated wire or magnet wire to a square or rectangular post.

Heretofore, various connectors have been devised for connecting electrical wires together. In many instances, in order to provide an efficient electrical contact between the two wires any insulation which was on the wires was stripped so as to expose the wires. Thereafter, the connector was placed about the exposed portions of the conductors and crimped or otherwise secured thereto. However, this stripping operation required time to perform and in some instances has led to destruction of the wire or other impairment of the wire due to improper manipulation of the stripping tools.

In order to overcome the disadvantages of stripping of the insulation from an insulated coated wire, various other techniques have been used. For example, various connectors have been devised with sharp points which pierce through the insulation coating of a conductor into the wire located therein. These connectors, however, have generally been used where one wire is being connected to a second wire. In the case where a wire is to be connected to a post of substantial configuration and hardness, the use of a projecting sharp point has not been practical. Consequently, various types of solder joints have been used in order to connect a wire to a post or a number of crimping steps have been utilized'first to crimp a connector to a wire and second to connect the connector to the post. However, the soldered joints have not always been reliable and the latter technique requires a relatively great deal of time and space.

Accordingly, it is an object of this invention to connect a wire to a post in a single operation.

It is another object of this invention to electrically connect an insulation coated wire directly to a post.

It is another object of this invention to provide a simple and economic technique of connecting insulated wires to posts.

Briefly, the invention provides a connector for forming a connection between an insulated electrical conductor and a post having at least one sharp corner thereon. The connector is formed of a body of compressible material, such as sintered powdered metal particles, having a bore which extends longitudinally therethrough in order to slidably receive a post therein. In addition, the connector body has a recess which extends through the body adjacent to the bore so as to be in at least partial communication with the bore. This recess receives the insulated'electrical conductor in facing relation to the sharp corner of the post. The connector is sized so as to initially slide over the post with the conductor being received within the recess. Once the connector has been put in position on a post with the conductor therein, the connector is compressed under a substantially circumferentially applied load onto the post. As the connector deforms, the sharp comer of the post projects into the recess containing the conductor such that the sharp corner passes through or pierces the coating of insulation of the conductor to electrically contact the wire or wires of the conductor.

In one embodiment, the connector is made in a substantially cubic form with a rectangular-shaped bore passing longitudinally therethrough and with a recess extending substantially transversely of the bore at one end of the body of the connector. In this form, the conductor is disposed transversely of the post upon compression of the connector onto the post, the

sharp corner of the post pierces into a small segment of the conductor.

In another embodiment, the connector is formed with a here as above and a recess as above. However, the bore is disposed with respect to the recess such that a pair of sharp corners of the post project into the plane of the recess. In this embodiment, a pair of sharp corners of the post pass through the coat of insulation of the conductor into contact with the wire therein.

In still another embodiment of the invention, the connector has a bore and a recess which extend longitudinally therethrough in parallel relation. The recess is sized to receive a conductor while the bore is sized to receive the post. Upon compression of the connector onto the post, a single sharp corner of the post pierces through the insulation coating of the conductor to electrically contact the wire along a longitudinal axis or line.

In still another embodiment of the invention, a recess is disposed centrally of the connector at one end while the bore for receiving the post extends longitudinally through the bore laterally spaced from the recess. With this connector, the conductor is centrally placed in the recess either before or after the connector is slide over the post. As above, during compression of the connector onto the post, the sharp corner of the post pierces into the insulation coating of the conductor to contact the wires therein.

These and other objects and advantages of the invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 illustrates an exploded perspective view of a connector and a conductor according to the invention;

FIG. 2 illustrates an exploded perspective view of a connector of the invention with relation to a post and an insulation coated conductor;

FIG. 3 illustrates a connection made between the connector post and conductor of FIG. 2;

FIG. 4 illustrates a connection of a modified connector according to the invention with a post and conductor;

FIG. 5 illustrates an exploded perspective view of another modified connector of the invention with relation to a post and conductor;

FIG. 6 illustrates a plane view of the connector of FIG. 5 with a conductor in place;

FIG. 7 illustrates a connection made between the connector, conductor and post of FIG. 5; and

FIG. 8 illustrates a connection between a modified connector according to the invention with a post and a conductor.

Referring to FIG. 1, the connector 10 is constructed in a cubic form of any suitable compressible material such as powdered metal particles which have been sintered together into a cohesive mass. The connector 10 includes a central bore 11, for example, of rectangular configuration which passes longitudinally through the body of the connector 10. In addition, the connector 10 has a recess 12 which extends transversely through the body adjacent to the bore 11. The recess 12 communicates at least partially with the bore 11 through a narrow slot 13 which is common to the wall 14 of the bore 11 and recess 12. More specifically, the plane of the bore 11 projects into the plane of the recess 12 at one corner thereof.

The connector 10 is also provided with at least one groove 15 in a side which communicates with the recess 12 so as to provide a strain relief as described hereinafter.

The material of the connector I0 is such that the connector 10 can be subjected to a compressive force applied substantially circumferentially of the bore 11 so as to be deformed inwardly of itself to close up the bore 11 and recess 12. To this end, the connector 10 can be made of a sintered mass of powder'ed metal particles such as copper, aluminum and copper of any other suitably electricallyconductive metal or alloy. In order to fabricate the connector 10 into the appropriate shape, various types of molds can be used. The techniques for fabricating such a connector are known, as evidenced by U.S. Pat. No. 3,345,452, issued Oct. 3, I967.

Referring to FIGS. 2 and 3, in order to make a connection between a post 16 and an insulated electrical conductor 17 having at least one wire 18 and a coating of insulation 19 around the wire 18, the connector 10 is initially made with the bore 11 of a shape to matingly slide onto and around the post 16. Further, in this regard the post 16 is provided in any suitable shape with at least one sharp corner 20 thereon, for example, the post 16 is formed as a square or rectangular post having four sides thereon. The recess 12 of the connector 10 is likewise sized to receive the electrical conductor 17 therein in a recessed manner. In forming the connection, the electrical conductor 17 is initially placed into the recess 12 in the connector with the end of the conductor 17 being inserted into the grooves communicating with the recess 12 in a substantially flush manner. Next, the connector 10 with the conductor 17 seated therein is slid down onto the post 16. After the connector 10 is positioned at a suitable point on the post 16 the connector 10 is compressed onto the post 16 by a suitable tool exerting a substantially circumferentially compressive force on the connector 10 about the axis of the bore 11 and post 16.

Referring to FIG. 3, during compression of the connector 10 onto the'post 16 the material of the connector 10 is caused to compress inwardly of itself causing a relative movement between the conductor 17 in the recess 15 and the post 16 in the bore 11. As a result, the sharp corner of the post 16 which is exposed to the recess 12 by way of the slot 13 begins to pierce or pass through the coating of insulation 19 of the conductor 17 and thereafter comes into electrical contact with the wire 18 within the coating of insulation 19. After the compressive force is removed, a secure gastight efficient permanent electrical and mechanical connection is made between the conductor 17, connector 10 and post 16.

It is noted that while the connector 10 can be of any suitable size with respect to any suitable sized conductors and posts, the elements are usually of a relatively small size such that the degree of relative movement between the recess and the bore of the connector during compression is also relatively small. That is, the degree of relative movement need only approximate the thickness of the insulation coating of the conductor so as to permit sufficient penetration of the sharp corner of the post through the insulation coating into contact with the internal wire.

Referring to FIG. 4, the connector 10 can be used so as to permit a pair of sharp corners 20 of a polygonal-shaped post 16 to pierce through the insulation coating 19 of an electrical conductor 17. To this end, the bore 11 of the connector 10 which is shown as being a square is disposed with two points projecting into the plane of the recess 12. In this way, as the connector 10 is compressed or otherwise crimped, the post 16 having two sharp corners 20 projecting into the recess 12, the two sharp corners 20 will pierce through or otherwise pass through the insulation coating 19 of the conductor 17 into electrical contact with the wire or wires 18 therein. This connector 10 is otherwise constructed in a similar manner as the connector described above with respect to FIG. 1.

Referring to FIGS. 5 to 7, the connector 21 can be modified so as to have a bore 22 extend longitudinally therethrough to receive a post 23 in sliding fit relation and with a recess 24 which extends substantially in parallel to the bore 22 while extending longitudinally through the connector body. To this end, the recess 24 is shaped with a curvilinear cross section so as to receive an insulated electrical conductor 25 therein. Accordingly, instead of being made in a cubic form the connector 21 is made with a substantially random-shaped cross section so as to accommodate the rectangular-shaped bore 22 and the curvilinear recess 24 therein.

Referring to FIG. 5, in order to made a connection between the square post 23 and insulated electrical conductor 25, the conductor 25 is initially inserted into the connector 21 so as to be received within the recess 24 in a substantially snug fit manner. To this end, the recess 24 may be slightly undersized so as to receive the conductor 25 or can be sized to be the same size as the conductor 25 so that the conductor is received in a slip fit arrangement. Thereafter, the connector 21 with the conductor 25 in place is slid down over post 23 so that one corner 26 of the post 23 is in abutting contact with the outside surface of the conductor 25. Next, the connector 21 is compressed onto the post 23, as above, so that the sharp corner 26 of the post passes through the insulation coating 27 of the conductor 25 into electrical contact with the wire 28 therein (FIG. 7).

, Referring to FIG; 8, the connector 30 can alternatively be made with the recess 31 extending substantially centrally of one end of the connector 30 with a bore 32 to receive a post 33 extending through a plane laterally spaced from the recess 31. As shown, the recess 31 extends diametrically across the end of the connector 30 to receive a conductor 35 while the post 33 extends longitudinally through the connector 30 with one corner 34 thereof projecting through the plane of the recess 31. In addition, the connector 30 can be provided with a longitudinal slot 36 to one side of the recess 31 opposite the bore 32. This slot 36 can function as a strain relief for the material of the connector 30 as the connector 30 is compressed onto a post 33 or can function to receive a second conductor (not shown) having an exposed section of wire therein. In either event, the connector 30 is utilized in a similar manner as above. That is, the insulated conductor 35 is inserted into the recess 31 while the connector 30 is slid over the post 33 which is received in the bore 32. Thereafter, as the connector 30 is compressed onto the post 33, the exposed sharp corner 34 of the post 33 pierces through the insulation coating 37 of the conductor 35 into electrical contact with the wire 38 therein. As shown, this connector 30 is formed with a substantially cylindrical shape.

The invention thus provides a connector which can be used to readily connect an insulation coated wire to a post having a sharp corner thereon. It is to be noted, however, that the sharpness of the corner of the post is related to the strength of the insulation coating such that in the case where the coating has a minimal resistance against piercing, the corner of the post can approach a degree of bluntness.

It is also noted that the post is generally of a greater degree of hardness than the electrical connector of the invention so as to permit the connector to be compressed onto the post without deformation of the post.

It is also noted that the various grooves or slots provided in the exterior periphery of the connectors described above can be used for strain relief during compression of the connectors onto the various posts described above.

What is claimed is:

1. A connector for mechanically and electrically connecting an electrical conductor to a post having at least one sharp corner thereon comprising a body of compressible material having a bore of rectangular cross section extending longitudinally therethrough to receive the post, and a recess extending transversely thereof to receive the conductor therein, with said bore having one corner thereof projecting into the plane of said recess, said corner of the bore being adapted to receive the sharp corner of the post.

2. A connector as set forth in claim 1 wherein said body further has at least one groove therein in communication with said recess to receive an end of the conductor therein.

3. A connector as set forth in claim 1 wherein said body is made of sintered porous metal powder particles and is compressible under a substantially circumferentially applied compressive force without failure in compression.

4. A connector as set forth in claim 1 wherein said bore is disposed centrally of said body and said recess is laterally spaced therefrom.

5. A connector as set forth in claim 1 wherein said recess is disposed centrally of said body and said bore is laterally spaced therefrom.

6. A connector as set forth in claim 1 wherein said body further has a slot in the periphery thereof extending longitudinally of said connector.

7. In combination,

a post having at least one sharp corner thereon;

a connector having a bore therethrough receiving said post in mating relation therein, and a recess adjacent said bore; and an insulated electrical conductor having at least one wire and a coating of insulation about said wire, said conductor being disposed in said recess of said connector and said sharp corner of said post passing through said coating of insulation into electrical contact with said wire, said connector further including at least one strain relief groove receiving an end of said conductor therein.

a connector having a bore therethrough receiving said post in mating relation therein, and a recess adjacent said bore, said bore having one corner thereof projecting into the plane of said recess, said comer of the bore being adapted to receive the sharp corner of the post; and

an insulated electrical conductor having at least one wire and a coating of insulation about said wire, said conductor being disposed in said recess of said connector and said sharp comer of said post passing through said coating of insulation into electrical contact with said wire.

Claims

7. In combination, a post having at least one sharp corner thereon; a connector having a bore therethrough receiving said post in mating relation therein, and a recess adjacent said bore; and an insulated electrical conductor having at least one wire and a coating of insulation about said wire, said conductor being disposed in said recess of said connector and said sharp corner of said post passing through said coating of insulation into electrical contact with said wire, said connector further including at least one strain relief groove receiving an end of said conductor therein.

8. The combination as set forth in claim 7 wherein said bore is disposed in parallel to said recess.

9. The combination as set forth in claim 7 wherein said recess extends transversely of said bore and said conductor extends at least partially transversely of said corner of said post.

10. The combination as set forth in claim 7 wherein said connector is made of sintered porous metal powder particles and is compressible under a substantially circumferentially applied compressive force without failure in compression.

11. In combination, a post having at least one sharp corner thereon; a connector having a bore therethrough receiving said post in mating relation therein, and a recess adjacent said bore, said bore having one corner thereof projecting into the plane of said recess, said corner of the bore being adapted to receive the sharp corner of the post; and an insulated electrical conductor having at least one wire and a coating of insulation about said wire, said conductor being disposed in said recess of said connector and said sharp corner of said post passing through said coating of insulation into electrical contact with said wire.