WO2011047718A1

WO2011047718A1 - Connection mechanism and electrical unit

Info

Publication number: WO2011047718A1
Application number: PCT/EP2009/063808
Authority: WO
Inventors: Thomas Poppe
Original assignee: Inter Ikea Systems BV
Current assignee: Inter Ikea Systems BV
Priority date: 2009-10-21
Filing date: 2009-10-21
Publication date: 2011-04-28
Anticipated expiration: 2012-04-21

Abstract

An electrical connection mechanism (100) for connection of an electrical cable (102) to an electrical unit (104) is disclosed. The connection mechanism (100) comprises a first body (106) and a second body (110) comprising at least one insulation displacement connector (108), wherein the at least one insulation displacement connector (108) is arranged to be electrically connected to electric means of the electrical unit (104), and any of the first and second body (106, 110) comprising at least one wire guide (112) arranged such that a wire (114) of the electric cable (102) applied into the wire guide (112), and such that a conductive part of the wire connects electrically to the at least one insulation displacement connector (108) when the second body (110) mates the first body (106). An electrical unit (104) comprising an electrical cable (102) comprising at least one insulated wire (114) for connecting the electrical unit (104) to a network, electric means for performing the task of the electrical unit (104), and a connector mechanism (100) for connection of the electrical cable (102) to the electric means is also disclosed.

Description

TITLE: CONNECTION MECHANISM AND ELECTRICAL UNIT

Technical field

The present invention relates to an electrical connection mechanism for connection of an electrical cable and an electrical unit, and to an electrical unit comprising an electrical cable, electric means and such a connector mechanism

Background

Assembly of electrical equipment is not only a subject for efficient manufacturing; it is also a subject for secure and reliable electrical connections. The latter has traditionally had an impact on the former, i.e. it is hard to provide efficient manufacturing of electrical equipment since security and reliability put constraints on assembly operations. Traditionally, this has been solved e.g. by producing such equipment where labour costs have been low, or by having high pricing on the products. It is therefore a desire to technically enable efficient manufacturing with high security and reliability for these types of products.

Summary

The present invention is based on the understanding that use of insulation displacement connectors together with the special structure of building elements according to the invention, and their assembly, enable both efficient assembly and high security and reliability of electrical connections.

According to a first aspect, there is provided an electrical connection mechanism for connection of an electrical cable to an electrical unit. The connection mechanism comprises a first body and a second body comprising at least one insulation displacement connector, wherein the at least one insulation displacement connector is arranged to be electrically connected to electric means of the electrical unit, and any of the first and second body comprising at least one wire guide arranged such that a wire of the electric cable applied into the wire guide, and such that a conductive part of the wire connects electrically to the at least one insulation displacement connector when the second body mates the first body.

Any of the first and second body may further comprise a tension relief clip for taking up tension load on the electrical cable. The tension relief clip of the second body may protrude in a first direction to hold the cable in the first direction, and the at least one wire guide may protrude in a second direction perpendicular to the first direction wherein an end of a wire of the cable is arranged in the second direction when an end of the cable is arranged into the second body. The second body may comprise a first part and a second part articulately connected to the first part such that the cable and wire can be fitted into one of the parts and the other part is folded over when mounting the cable into the second body.

The second body may further comprise fastening means for fastening to the first body such that the first and second body are kept in an engaged state when the electrical connection mechanism is assembled.

The mechanism may further comprise a third body arranged to mate the first body such that the second body is arranged between the first and the third body, and the third body may comprise fastening means for fastening the third body to the first body such that the first, second and third body are kept in an engaged state when the electrical connection mechanism is assembled.

The electrical unit may be a lighting device and the first body comprises a lamp socket.

The insulation displacement connector may comprise a conductor jaw arranged to cut through insulation of the wire to provide electrical contact with a conductor of the wire. The insulation displacement connector may comprise twin jaws. The jaw of the insulation displacement connector may be arranged with its open end towards the direction facing the second body when the second body mates the first body such that the jaw will cut through insulation of the wire to provide electrical contact with the conductor of the wire when the first and second bodies are assembled. Alternatively, the jaw of the insulation

displacement connector may be arranged to be engaged with the wire when the second body has mated the first body to cut through insulation of the wire to provide electrical contact with the conductor of the wire.

According to a second aspect, there is provided an electrical unit comprising an electrical cable comprising at least one insulated wire for connecting the electrical unit to a network, electric means for performing the task of the electrical unit, and a connector mechanism according to the first aspect for connection of the electrical cable to the electric means.

The unit may comprise a luminaire, wherein the electric means comprises an electric light source, and the network is an electric power network. An advantage of an embodiment is that both manual assembly is facilitated, and machine operated assembly is enabled.

An advantage of an embodiment is that both electrical contact and mechanical features to be achieved, such as providing means for taking up tension load on the electrical cable, are provided in one operation.

An advantage of an embodiment is that both assembly of parts and provision of electrical contact is provided in one operation.

An advantage of an embodiment is that assembly requires only a limited set of tools, and/or operations.

A particular advantage is, especially when automated machine operated assembly is used for the connection mechanism, is that in practise zero fault production is enabled. A very high yield can thus be provided in production. This is also particularly beneficial when high voltage connections are provided due to product safety. Thus, both cost and quality advantages can be achieved.

Brief description of drawings

Fig. 1 illustrates a connection mechanism for connection of an electrical cable to an electrical unit.

Figs 2a and 2b illustrate a second body of the connection mechanism according to an embodiment.

Figs 3a and 3b illustrate examples of insulator displacement connectors.

Detailed description

Fig. 1 illustrates a connection mechanism 100 of an electrical cable 102 to an electrical unit 104. The electrical cable 102 can for example be for power supply, and the electrical unit 104 can for example be a luminaire with a light source, such as a light emitting diode arrangement, a fluorescent lighting element or a light bulb. The electrical unit 104 can be a lighting device to which a lighting element is connectable, e.g. comprising a lamp socket such as of the Edison type, pin type, bayonet type, or other type of sockets. The electrical unit 104 can also be any other electric or electronic device with a need to be connected to a network. Thus, the connection mechanism is for permanently mounting a cable to an electrical unit, and is not to be considered as a connector that is plugged and unplugged repeatedly as a contact pin plug. On the other hand, the connection mechanism 100 can be used to permanently mount a cable to a contact pin plug, which then is considered as the electrical unit 104.

A first body 106 related to the electrical unit 106, such as integrated with or mechanically and electrically joined with the electrical unit 106, comprises an insulation displacement connector (IDC) 108, i.e. connectors that are designed to be connected to the conductor of an insulated wire by a connection process which forces a blade or blades through the insulation, removing the need to strip the wire before connecting. The connector blade then connects, and may even cold- weld, to the wire, making a highly reliable and mostly gas-tight connection. The IDC 108 is electrically connected to circuitry of the electrical unit 104

To enable the connection, there is provided a second body 1 10

comprising a wire guide 112 in which an insulated wire 114 of the electrical cable 102 is kept in place for interacting with the IDC 108 when the mechanism 100 is assembled. The second body can also comprise means for relieving strain on the cable by engaging with the cover of the cable. This can be a tension relief clip 1 16 arranged to pinch the part of the cable 102 still having the cover over the wires. The force to pinch the cable 102 can be provided by the mating of the first and second bodies 106, 1 10.

The tension relief clip 1 16 can be arranged to apply forces to the cable 102 from two sides, i.e. by only pinching, to enable taking up forces along the cable 102. Alternatively, the tension relief clip 1 16 can be wedged or conical to apply forces on further sides of the cable 102 for enhancing the force the clip 1 16 is able to take up along the cable 102, or to relief the demands on pinching force. The tension relief clip 1 16 can be provided with ridges or other pattern to enhance the ability to take up forces along the cable 102 when the cable is applied into the tension relief clip 1 16. The tension relief clip can be actively applied, as when folding or moving members as will be demonstrated below, or automatically actuated when the cable is applied. In Figs 4 to 6 below, different variants of tension relief clips 416, 516, 616 are schematically illustrated.

Thus, both electrical connection and mechanical strain relief is provided by one mounting action.

Figs 2a and 2b illustrate an embodiment of the second body 1 10. The second body 1 10 can be formed as a first part 118 and a second part 120 connected by e.g. a hinge such that the cable 102 with its wire(s) 114 can be easily fitted into one of the parts, in the state illustrated in Fig. 2a, and the other part is folded over, as illustrated in Fig. 2b, to arrange the wire(s) 1 14 in the wire guide(s) 1 12, and optionally the covered cable in the tension relief clip 1 16. The second body 1 10 can then be mated with the first body 106 such that the IDC connects electrically. The first body 106 can comprise for example lugs for keeping the folded second body 1 10 closed when pushed in between the lugs, and there can also be provided engagement means, e.g. a snap lock 122, keeping the first and second bodies 106, 1 10 together when mated. The snap lock 122 can for example snap into recesses of the lugs when the second body 1 10 is pushed towards the first body 106. The lugs can alternatively comprise the snap lock such that it can snap into recesses of the second body 1 10 when the second body 1 10 is pushed towards the first body 106.

There can also be provided a third body 124 arranged to mate the first body 104 such that the second body 1 10 is arranged between the first and third bodies 104, 124. The third body 124 has fastening means 126 for fastening the third body 124 to the first body 106, e.g. by snap hooks 126 arranged to snap into recesses 128 of the first body, or by a threaded joint. In Fig. 1 , the snap hooks 126 are on the third body 124 and the recesses 128 are on the first body 106, but they can of course be arranged oppositely, i.e. the snap hooks 126 on the first body 106 and the recesses 128 on the third body 124. The third body 124 can have at least one of the functions covering the electrical connection, providing a cover which can be subject to visual design of the product, providing

strengthened mechanical connection between the first and second bodies 106, 1 10, and providing a tension relief clip 1 16' in case this is not provided by the second body 1 10.

The IDC 108 comprises, for each electrical connection to be made, one or more blade arranged to cut through the insulation of the wire and connect to the conductor of the wire. For example, two blades can be arranged to form a jaw 130, as illustrated in Fig. 3a, in which the wire is arranged to be pressed for making the connection. Alternatively, a twin jaw arrangement comprising a first jaw 130' and a second jaw 130", as illustrated in Fig. 3b, can be provided. A twin jaw arrangement can have the advantage of increasing the certainty of electrical connection, and also be able to provide an electrical contact that is able to carry higher currents.

The jaw arrangement can be arranged on the first body 106 such that the jaw or jaws 130, 130', 130" are directed towards the mating second body 1 10, i.e. the direction of movement when assembling the first and second bodies 106, 1 10. Thus, the insulation displacement and contact operation is performed by the mating movement between the first and second bodies when assembling.

Alternatively, for example if the wire guide 1 12 of the second body is arranged to direct the wire(s) 1 14 in another direction than illustrated in Fig. 1 , the jaws 130, 130', 130" can be arranged to be displaced after assembly of the first and second bodies 106, 110 in a direction towards the wire(s) to perform the insulation displacement and contact operation. For example, this displacement can be provided by the third body 124 pushing the jaw arrangement(s) when arranging the third body 124 to the assembly, or be provided as a separate operation.

Fig. 4 illustrates an alternative connection mechanism 400 of an electrical cable 402. The features and benefits are similar to what is demonstrated with reference to Figs 1 to 3, and for the sake of conciseness, only features differing from what is already disclosed will be demonstrated here.

The connection mechanism 400 comprises a first body 404 which comprises an IDC 408 and a wire guide 412. When the cable is inserted in the first body 404, the wire guide 412 provides for insulated wire(s) 414 of the electrical cable 402 is kept in place for interacting with the IDC 408. A second body 410 is slidably or hingedly arranged with the first body 404 such that when moved from a first position to a second position, the second body 410 applies a force to the cable 402 such that a conductor of the insulated wire(s) is connected by a connection process which forces a blade or blades of the IDC 408 through the insulation, and the connector blade connects, and may even cold-weld, to the wire, making a highly reliable and mostly gas-tight connection. The movement of the bodies 404, 410 in relation to each other can also provide force for pinching the cable 402 to provide the strain relief feature, as demonstrated above.

Alternatively or additionally, the IDC 408 ' can be arranged with the second body 410 and the process of arranging and connecting the wire is provided in a similar way, but the IDC 408 ' moves with the second body 410.

Fig. 5 illustrates a further alternative connection mechanism 500 of an electrical cable 502. The features and benefits are similar to what is demonstrated with reference to Figs 1 to 3, and for the sake of conciseness, only features differing from what is already disclosed will be demonstrated here.

The connection mechanism 500 comprises a first body 504 provided with a wire guide 512 and a second body 510 provided with an IDC 508. At mounting, the wire 502 is arranged in the wire guide 512 and the two bodies 504, 510 are mated wherein the connection process as demonstrated above is performed when the bodies 504, 510 are pushed together. The bodies 504, 510 can be kept together by a snap mechanism or other means keeping the bodies together, e.g. by insertion into a third member such as a body of the electrical unit to be

connected.

Fig. 6 illustrates an alternative arrangement of the components of the connection mechanism demonstrated with reference to Fig. 5. Here, a wire guide 612 and an IDC 608 is provided on a first body 604, and a second body 610 is mated with the first body to provide the connection process as demonstrated above.

The different features of the tension relief clip as demonstrated with reference to Fig. 1 are applicable to any of the embodiments demonstrated herein, independently on the arranging of the first and second bodies, the IDC, and the wire guide. The different features for keeping the elements together demonstrated herein are also applicable to any of the embodiments independently on the different arranging of the elements.

The term "comprise" is here to be interpreted openly, i.e. as "including at least". Wherever "a(n)" element is indicated in this disclosure, the interpretation should be as "at least one", i.e. one or more of the elements can be in question. For example, where "a wire of the cable" is expressed, the number of wires are at least one, and the number is determined on the number of connections needed, e.g. two for an AC network or DC supply connection, three for an AC network connection with ground, or more for controlling/supplying further functions such as selecting different colours of light etc. The terms "first", "second", "one", "another", "further", etc. are to distinguish between different elements, and are not to be construed as any ranking, timing, or other interrelation constraints between the elements, unless expressly pointed out.

Claims

1. An electrical connection mechanism (100, 400, 500, 600) for connection of an electrical cable (102, 402, 502, 602) to an electrical unit (104), the connection mechanism (100, 400, 500, 600) comprising

a first body (106, 404, 410, 504, 604); and

a second body (1 10, 410, 404, 510, 610),

wherein the first body comprises at least one insulation displacement connector (108, 408, 408 ' 508, 608), wherein the at least one insulation displacement connector (108, 408, 408 ', 508, 608) is arranged to be electrically connected to electric means of the electrical unit (104), and

any of the first and second body comprises at least one wire guide (1 12, 412, 512, 612) arranged such that a wire (1 14, 414, 514, 614) of the electric cable (102, 402, 502, 602) applied into the wire guide (1 12, 412, 512, 612), and such that a conductive part of the wire connects electrically to the at least one insulation displacement connector (108, 408, 408 ', 508, 608) when the second body (1 10, 404, 410, 510, 604) mates the first body (106, 404, 410, 504, 610).

2. The mechanism according to claim 1 , wherein any of the first and the second body further comprises a tension relief clip (1 16) for taking up tension load on the electrical cable (102, 402, 502, 602).

3. The mechanism according to claim 2, wherein the tension relief clip (116) is arranged on the second body (110) and protrudes in a first direction to hold the electrical cable (102) in the first direction, and the at least one wire guide (112) protrudes in a second direction perpendicular to the first direction wherein an end of the wire (1 14) of the electrical cable (102) is arranged in the second direction when an end of the cable (102) is arranged into the second body (110).

4. The mechanism according to claim 3, wherein the second body (110) comprises a first part (118) and a second part (120) articulately connected to the first part (118) such that the electrical cable (102) and wire (1 14) can be fitted into one of the parts (1 18) and the other part (120) is folded over when mounting the electrical cable (102) into the second body (1 10).

5. The mechanism according to any of claims 1 to 4, wherein the second body (1 10) further comprises fastening means (122) for fastening to the first body (106) such that the first and second body (106, 1 10) are kept in an engaged state when the electrical connection mechanism (100) is assembled.

6. The mechanism according to any of claims 1 to 5, further comprising a third body (124) arranged to mate the first body (106) such that the second body (110) is arranged between the first and the third body (106, 124), and comprising fastening means (126, 128) for fastening the third body (124) to the first body (106) such that the first, second and third bodies (106, 110, 124) are kept in an engaged state when the electrical connection mechanism (100) is assembled.

7. The mechanism according to claim 1 or 2, wherein the first body (404, 604) comprises the wire guide (412, 612), and the second body (410, 610) is arranged with relation to the first body (404, 604) such that when moved from a first position to a second position to mate the first body, the second body (410, 610) applies a force to the cable (402, 602) such that the conductive part of the wire connects to the insulation displacement connector (408, 608).

8. The mechanism according to claim 1 or 2, wherein the second body (404, 504) comprises the wire guide (412, 512), and the first body (410, 510) is arranged with relation to the second body (404, 504) such that when moved from a first position to a second position to mate the second body, the second body (410, 510) applies a force to the cable (402, 502) such that the conductive part of the wire connects to the insulation displacement connector (408 ', 508).

9. The mechanism according to claim 7 or 8, wherein the second body (404) is slidably or hingedly arranged with the first body (410).

10. The mechanism according to any of claims 1 to 9, wherein the electrical unit (104) is a lighting device and the first body comprises a lamp socket.

11. The mechanism according to any of claims 1 to 10, wherein the insulation displacement connector (108, 408, 408 ', 508, 608) comprises a conductor jaw (130, 130', 130") arranged to cut through insulation of the wire (114, 414, 514, 614) to provide electrical contact with the conductive part of the wire.

12. The mechanism according to claim 11 , wherein the insulation displacement connector (108, 408, 408 ', 508, 608) comprises twin jaws (130', 130").

13. The mechanism according to claim 11 or 12, wherein the jaw (130, 130', 130") of the insulation displacement connector ( 108, 408, 408 ', 508, 608) is arranged with its open end towards the direction facing the second body (110, 410, 404, 504, 610) when the second body mates the first body (106, 404, 410, 504, 610) such that the jaw (130, 130', 130") will cut through insulation of the wire (114, 414, 514, 614) to provide electrical contact with the conductor of the wire when the first and second bodies are assembled.

14. An electrical unit (104) comprising

an electrical cable (102, 402, 502, 602) comprising at least one insulated wire (114, 414, 5 14, 614) for connecting the electrical unit (104) to a network; electric means for performing the task of the electrical unit (104); and a connector mechanism (100, 400, 500, 600) according to any of claims 1 to 13 for connection of the electrical cable (102, 402, 502, 602) to the electric means.

15. The unit according to claim 14, comprising a luminaire, wherein the means comprises an electric light source, and the network is an electric power network.