WO2001033670A1 - Connecteur de cables electriques et insert associe - Google Patents

Connecteur de cables electriques et insert associe Download PDF

Info

Publication number
WO2001033670A1
WO2001033670A1 PCT/GB2000/004172 GB0004172W WO0133670A1 WO 2001033670 A1 WO2001033670 A1 WO 2001033670A1 GB 0004172 W GB0004172 W GB 0004172W WO 0133670 A1 WO0133670 A1 WO 0133670A1
Authority
WO
WIPO (PCT)
Prior art keywords
wire
tap
electrically conductive
source
source wire
Prior art date
Application number
PCT/GB2000/004172
Other languages
English (en)
Inventor
Albert Renaud Perrin
Roland Sion Timsit
Original Assignee
Tyco Electronics Canada Limited
Tyco Electronics Uk Limited
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Tyco Electronics Canada Limited, Tyco Electronics Uk Limited filed Critical Tyco Electronics Canada Limited
Priority to AU11542/01A priority Critical patent/AU1154201A/en
Publication of WO2001033670A1 publication Critical patent/WO2001033670A1/fr

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
    • H01R4/28—Clamped connections, spring connections
    • H01R4/50—Clamped connections, spring connections utilising a cam, wedge, cone or ball also combined with a screw
    • H01R4/5083—Clamped connections, spring connections utilising a cam, wedge, cone or ball also combined with a screw using a wedge

Definitions

  • the present invention relates to an electrical connector for electrically connecting together a source wire and a tap wire. More specifically, the invention relates to an electrical connector including an outer member, an inner member, and a conductive insert that provides an electrical path between the connected wires .
  • electrical connector including an outer member, an inner member, and a conductive insert that provides an electrical path between the connected wires .
  • Conventional electrical cable connectors include a generally C-shaped member for electrically connecting lead wires with a wedge member, for example U.S. Patent Number 5,567,186, issued on October 22, 1996, to Diniz et al .
  • the C-shaped members are made by extruding a conductive material and blanking thereof followed by press forming and heat treating.
  • non- conductive material and non- electrically conductive material are meant to mean non-highly electrically conductive material, e.g., steel, or electrical insulative material, e.g., non-conductive polymer or ceramic material.
  • Manufacturing steps are necessary with a conductive material such as aluminum, a copper alloy, or a composite material in order to obtain the necessary material properties, such as strength, ductility and acceptably high electrical conductivity. Similar manufacturing methods may also be necessary in order to produce the wedge members of these electrical connectors that are often made by casting.
  • the present invention solves this problem by inserting a conductive member within an outer, generally C-shaped, member between the source wire and the tap wire and an inner member inserted within the conductive member.
  • the conductive member is responsible for electrically connecting the source and tap wires together, therefore, allowing the outer C-shaped member and the inner member to be made from less conductive, cheaper, yet adequately strong materials.
  • the present invention provides a novel electrical connector designed to address one or more of the aforementioned needs.
  • the invention embodies an electrical connector having an electrically conductive insert that provides an electrical connection path between a source wire and a tap wire.
  • the conductive insert eliminates the need for constructing the outer member and the inner member of the electrical connector from expensive electrically conductive materials. More importantly, the outer member and the inner member do not have to be highly electrically conductive but rather are preferred to be non-highly-electrically conductive or insulating material .
  • the outer member and the inner members may be made from material such as various forms of relatively inexpensive steel or other materials such as polymers and ceramics.
  • the steel material provides strength for the outer member and for the inner member, thereby avoiding the problems of constructing the outer member and the inner member from thicker bodies of weaker materials which need to be press-formed and/or heat treated in order to provide structure stability so as to prevent failure.
  • the present invention relates to an electrical connector for electrically connecting together a first wire or cable (e.g. a source wire) and a second wire or cable (e.g. a tap wire) .
  • the invention relates to an electrical connector including an outer member preferably having a generally C-shaped configuration, an inner member, and an electrically conductive insert that provide an electrical connection path between the wires.
  • the outer member has a first inner recess that houses the first (tap) wire or cable and an opposing second inner recess that houses the second (source) wire or cable.
  • the invention hereinafter will be described for convenience in terms of the aforementioned tap wire and source wire, but without limitation to those specific forms or uses of wires or cables.
  • the electrically conductive member is inserted between the tap wire and the source wire, whereby the conductive member provides an electrical connection between the source wire and the tap wire.
  • the inner member is inserted or wedged within the outer member, whereby a first portion of the electrically conductive member is positioned between the inner member and the tap wire, and a second portion of the electrically conductive member is positioned between the inner member and the source wire .
  • the electrically conductive member includes a U-shaped, or C-shaped, portion connecting between the first portion and the second portion thereof.
  • the U-shaped, or C-shaped, connecting portion of the conductive member may be flexed or compressed as the electrically conductive member is being inserted whereby the first portion and the second portion thereof are moved toward each other, thereby facilitating the insertion of the electrically conductive member between the source wire and the tap wire.
  • the electrically conductive member has a flat connecting portion extending between the first portion and the second portion thereof. In this embodiment, the conductive member is snapped or locked into position on the inner member, and the resulting assembly may be inserted within the outer member.
  • the electrically conductive member can be configured in a variety of different sizes and shapes using a variety of different manufacturing processes.
  • the electrical connector assemblies may be provided for electrical connection between insulated and uninsulated conductors, preferably with an implementation of at least one insulation-piercing serration.
  • at least one piercing serration is provided on both the electrically conductive member and on the outer member, and in another embodiment at least one piercing serration is provided on each of opposing surfaces on one side of the electrically conductive member.
  • Figure 2A is a cross-sectional end view of an outer member with a source wire and a tap wire inserted therein according to the present invention.
  • Figure 2B is a cross-sectional end view of an outer member with a source wire and tap wire inserted therein according to the present invention and depicting a conductive insert being inserted between the wires.
  • Figure 2C is a cross-sectional end view of an outer member with a source wire and tap wire inserted therein and a conductive member inserted between the wires according to the present invention.
  • Figure 2D is a cross-sectional end view of an outer member with a source wire and tap wire inserted therein, a conductive member inserted between the wires, and an inner member inserted therein according to the present invention. 4-1
  • QJ 3 > CQ 4-1 QJ ft 4J U rH r- !H CQ 4J QJ QJ TJ rH ⁇ H rH TJ QJ TJ QJ as QJ ⁇ ⁇ CQ QJ QJ r e H ⁇ H ⁇ 0) Q QJ ⁇ rH rH ⁇ - ⁇ H QJ QJ TJ rQ rQ ⁇ rt rQ ⁇ H QJ > QJ QJ > 4J ⁇ QJ 0 rQ fi
  • outer member 20 should also be strong and ductile enough to withstand the application of large bending and tensile forces without cracking or failing, and to ensure acceptable spring-back when used in an electrical connector contemplated by the practice of this invention.
  • the conductive member 30 includes a first portion 32, a second portion 34, and a portion 36 between the first portion 32 and the second portion 34.
  • the conductive member 30 also has bent portions 38 and 40 shown in Figure 2B .
  • the conductive member 30 When the conductive member 30 is inserted within a cavity 26 of the outer member 20, as depicted in Figure 2C, the conductive member 30 has a cavity 42 (also shown in Figure 1) between the first portion 32 and the second portion 34.
  • the first portion 32 includes a contact surface 33 that is generally arcuate in shape and is configured to abut and rest generally adjacent to the tap wire 12.
  • the second portion 34 includes a contact surface 35 that is generally arcuate in shape and is configured to abut and rest generally adjacent to the source wire 14.
  • the contact surfaces 33 and 35 may be configured using a variety of different shapes.
  • portion 36 protrudes beyond the outer member 20 and is generally U-shaped, or C-shaped, as depicted in Figures 1-4.
  • the present invention contemplates other protruding shapes, such as other arcuate shapes, and V- shapes that are able to perform a similar function as described below.
  • the portion 36 is preferably configured such that when a force F is applied thereto, the first portion 32 moves toward the second portion 34 to facilitate the insertion of the conductive member 30 between the tap wire 12 and the source wire 14, one embodiment of which is depicted in Figure 2B .
  • the force F is applied in opposite directions to opposing bends, 38 and 40, of the portion 36.
  • the electrically conductive member 30 of the present invention is made of a conductive material, such as copper, a copper alloy, aluminum, an aluminum alloy, a bimetallic aluminum-copper material, or other conductive material, for example, currently experimental conductive polymers.
  • One method of manufacturing the electrically conductive member 30 is by stamping the conductive member 30 from a sheet of electrically conductive material and bending the resulting stamped piece of material to form the electrically conductive member 30.
  • the conductive member 30 should have a thickness great enough to accommodate the full power range experienced by electrical connectors contemplated by the present invention.
  • the conductive member 30 should also be configured and made of a material capable of withstanding bending of the portion 36 during insertion of the electrically conductive member 30 between the tap wire 12 and the source wire 14.
  • an inner member 50 is preferably slightly tapered for ease of insertion within the cavity 42 of the electrically conductive member 30, although a taper is not essential to proper operation of the present invention.
  • a leading end 52 (best seen in Figure 1) of the inner member 50 that enters the cavity 42 first is narrower than trailing end 54 of the inner member 50.
  • Opposing sides, 56 and 58, of the inner member 50 are shaped to abut the first portion 32 and the second portion 34, respectively, of the conductive member 30.
  • the inner member 50 is dimensioned so as to fit snugly within the cavity 42 (best seen in Figure 2D) of the conductive member 30 such that the first portion 32 and the second portion 34, more particularly surfaces 33 and 35 respectively, of the conductive member 30 are pressed against the tap wire 12 and the source wire 14, respectively, thereby causing a good electrical interconnection to be made therebetween .
  • a benefit of the present invention is that it allows the inner member 50 to be constructed using a variety of different methods and a variety of different materials, such as aluminum, aluminum alloys, copper, copper alloys, brass, plated/coated mild or stainless steel, other types of steel, a bimetallic material, plastics, ceramics, polymers, or other similar materials.
  • the inner member 50 can be constructed of non-electrically conductive materials having poor electrical conductivity or no conductivity at all since the conductive member 30 is being used to electrically connect the tap wire 12 to the source wire 14.
  • the inner member 50 is preferably made from a spring, a spring device or a resilient material.
  • the springy inner member 50 is preferably made from sheet, plate, or other metal or material structure.
  • the inner member 50 may be configured to be inserted within the cavity 42 by an explosively-driven or power actuated portable tool, such as an AMPACT ® tool supplied by AMP Incorporated of Harrisburg, Pennsylvania.
  • the inner member 50 may be configured to be inserted within the cavity 42 by bolting or other mechanical driving tool.
  • Figures 2A-2D depict a method of electrically connecting a tap wire 12 to a source wire 14.
  • Figures 2A depicts the first step that includes positioning the tap wire 12 and the source wire 14 within opposing recesses, 22 and 24, respectively, of the outer member 20.
  • Figure 2B depicts the step of inserting the conductive member 30 between the tap wire 12 and the source wire 14.
  • one method of inserting the conductive member 30 includes using a force, indicated as F, to compress the U-shaped portion 36 so as to move the first portion 32 toward the second portion 34, thereby, facilitating the insertion of the conductive member 30 between the tap wire 12 and the source wire 14.
  • the conductive member 30 may be slid into position between the tap wire 12 and the source wire 14.
  • Figure 2C depicts the conductive member 30 as being inserted between the tap wire 12 and the source wire 14.
  • the inner member 50 is inserted within the outer member 20 whereby the first portion 32 of the conductive member 30 is positioned between the inner member 50 and the tap wire 12 and a second portion 34 of the conductive member 30 is positioned between the inner member 50 and the source wire 14.
  • Figure 3 is a schematic view of an assembled electrical connector 10 according to the present invention depicting an electrical current flow path, indicated by the letter C, flowing between the source wire 14, the conductive member 30, and the tap wire 12.
  • some or all of the electrical current may flow through one or both of those conductive members.
  • Figure 4 is a cross-sectional end view of an outer member 20 with a source wire 14 and tap wire 12 inserted therein, an alternative embodiment of a conductive member 130 inserted between the wires, and an inner member 50 inserted therein according to the present invention.
  • the first portion 132 and a second portion 134 of the conductive member 130 can be constructed using a variety of dimensions.
  • the first and second portions, 132 and 134, depicted in Figure 4 are elongated relative to those depicted in Figure 3, for example.
  • the first and second portions 132 and 134 could also be constructed so as to be shorter than those depicted in Figure 3.
  • the present invention contemplates a limitless variety of sizes, shapes, and configurations for all of its members.
  • Figures 5A-5C depict an alternate method of electrically connecting a tap wire 212 to a source wire 214, as contemplated by the present invention.
  • Figure 5A depicts a step that includes positioning a conductive member 230 on an inner member 250 to form an assemblage. Opposing sides, 256 and 258, of the inner member 250 abut the first portion 232 and the second portion 234, respectively, of the conductive member 230.
  • Figure 5B includes positioning the tap wire 212 and the source wire 214 within opposing recesses, 222 and 224, respectively, of an outer member 220.
  • the steps depicted in Figures 5A and 5B can be performed in the opposite order if so desired.
  • Figure 5C depicts the step of inserting the assemblage ⁇ s r- ⁇ o QJ J
  • piercing serration 504 located along its inner wall and facing the insulated conductor 12' having an insulative covering 12A.
  • the electrical connector 500 further comprises the inner member 20 of Figure 1 and an electrically conductive member 506 which is similar to the electrically conductive member 42 of
  • Figure 1 except that it has at least one piercing serration 506 located on its outer wall 32 and facing the insulated conductor 12' .
  • the piercing serration 504 of the outer member 502 and the piercing serration 508 of the conductive member 506 are both suitable for piercing the electrical insulation 12A of the electrical cable 12'.
  • the outer member 502 operatively cooperates with the conductive member 56 as well as with the inner member 50 which may be further described with reference to Figure 9 which illustrates an embodiment which provides for satisfactory electrical connections between cables 12' and 14.
  • Figure 9 is quite similar to Figure 3 , but illustrates the embodiment of Figure 8 rather than Figure 3 illustration of the embodiment of Figure 1.
  • the piercing serrations 504 and 508 are preferably arranged to be in alignment with each other and with both 504 and 508 piercing the insulation 12A of the electrical cable 12'. Further, the inner member 50 is wedged into the conductive member 506.
  • the embodiment of Figure 9 captures the electrical cable 12 ' between the piercing serrations 504 and 506, so as to fix the cable 12' in a stationary position.
  • electrical current need not pass through the outer member 506 and the inner member 50, but rather current only needs to pass from one cable 12 ' to the other cable 14 by conduction only through the conductive member 506 and is shown therein by both path C .
  • the piercing serration 504 need not conduct electricity.
  • the piercing serration 508 penetrates through the conductor insulation 12A to make mechanical contact with the conductor 12 ' .
  • This provides mechanical support directly to the metal conductor 12 ' .
  • Such mechanical support coupled with the mechanical support provided by piercing member 504 of the outer member 502, minimizes mechanical support by the insulation 12A of the cable 12'.
  • This eliminates mechanical flow of the insulation material during service, particularly if the conductor temperature becomes elevated. More particularly, direct mechanical support by the insulation material 12A of the cable 12 ' is to be avoided since the insulation material 12A flows particularly if the cable 12 ' temperature becomes elevated, or if the interface with the cable 12' allows mechanical support by the insulation sleeve making up the insulation 12A.
  • the embodiment 510 of Figure 10 includes the outer member 20 and the inner member 50 (previously described) and a conductive member 512 having at least one piercing serration, but preferably at least two serrations 514 and 516 oppositely disposed from each other on the same side of the conductive member 512, that is, on the side of conductive member 512 that is arranged to come into contact with the insulative covering 12A of the conductor 12'.
  • the conductive member 512 has the same electrical characteristics as those of conductive member 506 of Figure 8 and, also as those of the conductive member 30 of Figure 1.
  • the conductive member 512 may be further described with reference to Figure 11.
  • Figure 11 is quite similar to that of Figure 4 except that Figure 11 illustrates the conductive member 512 as having piercing serrations 514 and 516 that capture the conductor 12 ' .
  • the piercing serrations 514 and 516 along with the conductive member 512 establish the electrical path C" between conductors 12' and 14.
  • Each of the piercing serrations 514 and 516 penetrates through the conductor insulation 12A to make mechanical contact with the conductor metal 12'.
  • Such mechanical support coupled with the mechanical support provided the outer member 50, minimizes

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Abstract

La présente invention concerne un connecteur électrique destiné à raccorder électriquement un fil d'alimentation et un fil de prise, comprenant un élément extérieur et un élément intérieur, constitués d'un matériau isolant ou faiblement conducteur d'électricité et d'un insert électriquement conducteur permettant d'établir une connexion électrique entre les fils. L'élément extérieur comporte une premier creux interne servant à loger le fil de prise et un second creux interne opposé servant à loger le fil d'alimentation. L'élément électriquement conducteur est inséré entre le fil d'alimentation et le fil de prise ce qui permet d'établir une connexion électrique entre eux. L'élément intérieur est inséré ou claveté à l'intérieur de l'élément extérieur, entre des parties de l'insert électriquement conducteur, mettant en contact les fils d'alimentation et de prise. L'invention concerne aussi des réalisations destinées à connecter électriquement les fils d'alimentation et de source qui comprennent des conducteurs isolés et non isolés.
PCT/GB2000/004172 1999-11-01 2000-10-30 Connecteur de cables electriques et insert associe WO2001033670A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU11542/01A AU1154201A (en) 1999-11-01 2000-10-30 Electrical cable connector and insert therefor

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US16279899P 1999-11-01 1999-11-01
US60/162,798 1999-11-01

Publications (1)

Publication Number Publication Date
WO2001033670A1 true WO2001033670A1 (fr) 2001-05-10

Family

ID=22587175

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2000/004172 WO2001033670A1 (fr) 1999-11-01 2000-10-30 Connecteur de cables electriques et insert associe

Country Status (2)

Country Link
AU (1) AU1154201A (fr)
WO (1) WO2001033670A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0810688A1 (fr) * 1996-05-31 1997-12-03 Framatome Connectors International Connecteur électrique pour la connexion de conducteurs électriques
US5868588A (en) * 1997-04-23 1999-02-09 Framatome Connectors Usa, Inc. Electrical wedge connector with collapsible rear extension
WO1999041806A1 (fr) * 1998-02-16 1999-08-19 Framatome Connectors International Connecteur a coin de serrage dote d'un dispositif de perforation d'isolation
WO2000001035A2 (fr) * 1998-06-30 2000-01-06 The Whitaker Corporation Connecteur de cable electrique et insert prevu pour ce dernier
US6152786A (en) * 1999-04-23 2000-11-28 The Whitaker Corporation One-piece insulation piercing insert

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0810688A1 (fr) * 1996-05-31 1997-12-03 Framatome Connectors International Connecteur électrique pour la connexion de conducteurs électriques
US5868588A (en) * 1997-04-23 1999-02-09 Framatome Connectors Usa, Inc. Electrical wedge connector with collapsible rear extension
WO1999041806A1 (fr) * 1998-02-16 1999-08-19 Framatome Connectors International Connecteur a coin de serrage dote d'un dispositif de perforation d'isolation
WO2000001035A2 (fr) * 1998-06-30 2000-01-06 The Whitaker Corporation Connecteur de cable electrique et insert prevu pour ce dernier
US6152786A (en) * 1999-04-23 2000-11-28 The Whitaker Corporation One-piece insulation piercing insert

Also Published As

Publication number Publication date
AU1154201A (en) 2001-05-14

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