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
  • H01R4/22—End caps, i.e. of insulating or conductive material for covering or maintaining connections between wires entering the cap from the same end
• • 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
  • H01R4/10—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
  • H01R4/12—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by twisting
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
  • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
  • H01R11/12—End pieces terminating in an eye, hook, or fork

Definitions

• the patent literature also comprises strain relief devices that
• Figure 7 is a side view of the embodiment of Figures 1 , 2 and 6, with the housing in cross-section.
• wires/cables/elements that the unit may connect in a "butt" style connection may connect in a "butt" style connection.
• Figure 23 A is a perspective view of yet another spiral unit, having two cuts spiraling around the tube stock.
• Figures 30 and 31 are perspective and exploded perspective views, respectively, of an alternative embodiment having yet another latch mechanism.
• Figure 32 is a side view of the embodiment of Figures 30 and 31, with the housing in cross-section.
• Figure 33 is a top, cross-sectional view of the embodiment of Figures 30 - 32, viewed along the line 33-33 in Figure 32.
• Figure 39, 39A - C illustrate another, but not the only, embodiment of a double-ended connector, and the preferred method of using the connector in a double- handed twist wherein the two ends are grasped and rotated in opposite directions but the user need not touch the central, main housing.
• the spiral is preferably not formed by wrapping a strip or wire around the wire to be captured, but, instead, is formed from a self-standing (self-supporting) tube/spiral that is inherently biased into a relaxed, loose condition, and yet that may be twisted into a tensioned tightened, smaller-diameter condition (in the direction parallel to the length of the coil of the spiral and generally transverse to the axial length of the spiral). Further, the spiral is preferably not manufactured by mapping a strip or wire around any object that remains in the spiral during its use as a connector.
• latch mechanisms may be used, for example, plunger members, pins members, or other protruding or gripping members that contact or otherwise interfere with the spiral or an attachment fixed to the spiral, to prevent or limit reverse movement of the spiral.
• the latch mechanisms portrayed in the Figures are typically automatic and non-re leasable.
• latch mechanisms may be provided that are manually engaged by the user, and/or releasable/unlatchable by purposeful manual action by a user, for example, by pulling of a plunger or pin member radially outward relative to the spiral and the housing.
• Important features of the preferred embodiments include a large electrical contact surface area, for example, 1/6 - 1 square inch of surface area, in many embodiments, and even more for large cable applications.
• prior art threaded wire connectors have fixed immovable threads, of decreasing diameter, inside a casing, wherein the user threads the threaded wire connector onto a wire and, during this installation, there is no movement of any of the threaded wire connector threads relative to each other.
• the spiral wraps or “coils” move relative to each other during the tightening process (and also during a loosening process, if the embodiment is provided with that option).
• the wraps/coils may start out at the same or substantially the same diameter, but, during the tightening process, they move/slide relative to each other to form a smaller-diameter structure that is typically smaller-diameter, and typically substantially a uniform smaller-diameter, all along the length of the structure.
• the wire is captured and preferably immovable in the spiral and that the terminal end is preferably directly fixed to, or is integral with, the spiral.
• the connector is not adapted or intended to create force on the wire or the terminal end that would cause movement of the wire and/or the terminal end relative to the spiral.
• the connector is not adapted so that electrical current through the wire creates any force on the spiral or terminal end that would cause movement of the spiral or terminal relative to the wire.
• the connector is not a solenoid system for converting electrical energy into axial movement via electromagnetism and/or for converting movement via electromagnetism into electrical current. Preferably, there are no magnets associated with or attached to the connector.
• proximal end 30 of the spiral may not be moveable relative to the housing 12.
• one or more protrusions may be provided in/on the proximal end 30 of the spiral for becoming embedded or otherwise gripping or engaging the material of the housing upon sonic welding, adhesive connection, molding or other fixing of the proximal end to the housing.
• Alternative spiral proximal end configurations may be envisioned by one of skill in the art after viewing this disclosure and the drawings.
• Figures 9 - 1 1 illustrates some, but not the only, possible designs for spiral 14.
• Figure 9 illustrates a spiral version 14', wherein a spiral cut extends transversely, or nearly transversely, across the tube wall from which the spiral is preferably formed.
• Figure 10 illustrates a less-preferred spiral 14 " wherein two cuts or other forming techniques may be used to make the interior surface of the spiral wraps/coils sharp edges.
• This Figure 10 embodiment is less preferred relative to embodiments wherein the internal surfaces of the wraps/coils are generally flat and broad and thus maximize contact with the wire.
• Figure 11 illustrates an alternative spiral 14"' wherein the cut that creates the wraps/coils is slanted so that interior surfaces of the wraps/coils have acutely-angled edges E. Twisting of the spiral 14"' of Figure 1 1 may create some slight overlap of the wraps/coils and, thus, a sturdier, more rigid structure around the wire.
• This fixing may be done by sonic welding, as described above for the embodiment of Figures 1 and 2 and the central region 120 and central sleeve 123, wherein material from the interior surfaces of the sleeves 121, 122 flows into, and then re-hardens, in recesses 156, 158.
• the fingers 250 upon release of the twisting motion, and/or any reverse force, the fingers 250 will fall into and become lodged in, or otherwise engage, the notches or recesses 252 or otherwise engage to limit, and preferably prevent, reverse motion of the spiral 214.
• this cooperation of the fingers 250 with the distal end 240 acts as a latch or lock for retaining the spiral in the tightened configuration.
• Fingers 250 may alternatively be formed of plastic to create plastic-metal cooperation if desired.
• FIG. 28 and 29 portray an alternative, double-ended comiector 300.
• Major differences between this connector 300 and the connector 100 of Figures 12 and 13 include the following:
• the central sleeve 323 is fixed to the central region 320 of the spiral unit 314 by welding, adhesive, or other methods that result in sleeve 323 not being movable relative to the spiral unit 314.
• Said central sleeve 323 does not extend to cover, and does not cooperate with, the notches/recesses 332, 342 provided at the inner end of each spiral 316, 318 (each of which may also be called a "spiral portion" of spiral unit 314).
• Figures 36, 36A, 36B, 37, 37A, and 37B illustrate some, but not the only, embodiments of invented flat- sheet-cutting or -stamping methods and conductive spiral portions formed thereby.
• the structure for the spiral may be stamped, cut, or otherwise formed from a flat or generally flat metal or other conductive sheet.
• Figures 36 and 36A many flat shapes 600 are cut/stamped from a single flat sheet, wherein the terminal end T is connected to, and distanced from, band Bl by a long, diagonal portion D.
• Each flat shape 600 is separated from the adjacent flat shapes and/or extra metal, and then rolled/curled/bent into the generally tubular shape (spiral unit 600'), by methods that will be understood by those of skill in the metal arts.
• Bands Bl and B2 are similarly roller/curled/bent and their outer edges may be fixed together to assist in strengthening the spiral unit 600', for example, by spot-welding or other techniques.
• the resulting spiral unit 600' as shown in Figure 36B, has opening O through which wire(s) may be inserted so that stripped/exposed metal of the wires may extend deep into the spiral to be contacted by the spiral wraps.
• Figures 37 and 37B show flat shape 700, which is cut/stamped from a flat sheet to allow formation of a double-ended connector spiral unit 700' .
• End E 1 and center CE are connected by, and distanced apart by, a long, diagonal portion Dl.
• Center CE and end E2 are connected by, and distanced apart by, a long, diagonal portion D2.
• the diagonal portions Dl and D2 may each have a longitudinal cut C through them, whereby both the strips of material SI, S2 on both sides of cut C each form a spiral wrap, similar, for example, to the multiple-cut spiral shown in Figure 23 A.
• two separate electric cables 22, 22' extending from different equipment/devices have their ends stripped of insulation, and all of the resulting stripped strands 20 from both cables are inserted side-by-side in the same direction into a single spiral unit 814 rather than into two spirals.
• the strands optionally may be twisted together if desired before insertion into the spiral, but this is not typically necessary, as the end of the housing having the opening preferably has a large funnel-shaped interior surface (large relative to the combined diameter of the strand bundle) and the spiral, as discussed previously is significantly larger than said combined diameter. This way, the strands, which tend to be at least somewhat flexible, will enter the connector easily by sliding into the housing opening, along the slanted inside of the funnel, and into the spiral.
• the user would twist housing portion 812 so that the top wing W in Figure 38E would come out away from the paper and would twist housing portion 813 toward the paper, as suggesting by the arrows in Figure 38E.
• the spirals of the preferred embodiments may be manufactured in the reverse direction, which would result in twisting/rotation in opposite direction being operable to tighten the spirals.
• the latching system comprising ratchet bars 850 and teeth 853, is illustrated to best advantage in Figures 38A and B.
• said latching/locking comprises engagement of cooperating ratchet members provided on the spiral unit (on or adjacent funnel-opening ends 912) and interior end surfaces of the housing 913, in a manner similar to the ratchet bars 850 and teeth 853 of connector 800.
• Figure 39A and B illustrate to best advantage how separate cables, with stripped/stripped strands ends may be slid into the funnel-opening ends 912 and deep into the spiral unit 914.
• the two spirals twist/rotate along with the ends 912 to tighten on their respective stripped/un-insulated strands.
• the stripped/im-insulated wires may abut into structure at the distal end of the spiral such as a portion of the terminal end or such as a plug (not shown) inserted into the spiral distal end that does not interfere with tightening of the spiral.
• the stripped/un-insulated wires may slightly protrude (preferably, less than 1 cm) from the distal end of the spiral to be seen by the user.
• the user may ship the wire a predetermined amount and be able to judge proper insertion by knowing how much stripped wire extends from the insulation and, hence, how far to insert the wire(s).
• a stop or limiting structure may be provided (not shown) at or near the center of the double- ended spiral units, but the plug should be chosen and installed so that it does not interfere with spiral tightening.
• the preferred embodiments may provide flexibility in the type and diameter of wire(s) that can be inserted and tightened into the connector.
• a connector according to the invention may be designed to optimally capture a single diameter/gauge of wire
• many of the connectors according to the invention will have a structure capable of receiving and tightening to capture a range of diameters/gauges of wire.
• many connectors and their spirals may tighten to capture at least two gauge sizes, for example, 2 gauge (American Wire Gauge) and 4 gauge, or 6 and 8 gauge, or 10 and 12 gauge.
• a connector capable of reducing the spiral diameter by 50 percent would operate with 2 gauge wire but also with smaller wire diameters such as those represented by 4 gauge, 6 gauge, and 8 gauge (or sizes in-between). Or, with said 50 percent reduction, a connector working well with 8 gauge wire could also operate with 10 gauge, 12 gauge, and 16 gauge (or sizes in-between).
• a single connector may be used for a variety of wires and cables, and the electrician, auto mechanic, computer technician, and especially the "do-it-yourselfer," may not have to use different connectors for each different size or gauge of wire.
• the electrically-conductive parts of the preferred connectors may be selected from many commonly-available conductive materials available in industry, and from materials to be made available in the future.
• many metal and metal alloy tubular materials and flat sheet materials are known in the electrical arts, including but not limited to copper and copper alloys, and those of skill in the art will understand how to select materials from these commercially-available stock materials.
• some embodiments of the invented connector may be described as consisting essentially of, or consisting only of, a spiral unit, a single housing portion, and a terminal end, wherein one or more wires with stripped ends are inserted into and tightened in the spiral.
• Other embodiments of the invented connector may be described as consisting essentially of, or consisting only of, a spiral unit, and two housing portions that may be twisted relative to each other, wherein multiple wires with stripped ends are inserted into and tightened in the spiral.
• FIG. 40 through 43 A - E there is shown an especially- preferred embodiment of butt-style connector 1000, which is similar to the butt-style connector shown in Figures 39A - C, but with modified housing 1013 and ends 1012, 1012 ' .
• the housing 1013 may also be called the "main housing body” or “central housing portion”, and ends 1012, 1012' may also be called “end caps” or “housing end portions”, as both housing 1013 and ends 1012, 1012' may be considered portions of one housing that generally surrounds and insulates the conductive spiral and the conductive wires.
• the housing 1013 is fixed to a central region of the spiral 1014, midway or generally midway between the two end of the spiral 1014, and the two ends of the spiral are fixed to their respective ends 1012, 1012', so that twisting of the ends 1012, 1012' relative to the housing 1013 tightens the spirals to grip wires inserted therein.
• the latch interaction between the housing 1013 and ends 1012, 1012 ' comprises curved latch arms 1050 with teeth 1051 that engage cooperating end cap teeth 1052 on the inside circumferential surface of a generally cylindrical skirt 1056.
• portions of the housing 1013 comprising said latch arms 1050 extend into an annular space in each end 1012, 1012 ' , and the shirt 1056 extends outside of, and axially along, the portions of the housing 1013 comprising the latch arms 1050.
• the latch arms 1050 are preferably inherently biased to press outward against said end cap teeth 1052 to mate with teeth 1052.

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• Details Of Connecting Devices For Male And Female Coupling (AREA)
• Connections By Means Of Piercing Elements, Nuts, Or Screws (AREA)
• Coupling Device And Connection With Printed Circuit (AREA)

Priority Applications (2)

Applications Claiming Priority (2)

Publications (2)

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ID=43970732

Family Applications (1)

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Cited By (2)

Citations (18)

Family Cites Families (6)

• 2010
  • 2010-11-03 CA CA2779248A patent/CA2779248C/en not_active Expired - Fee Related
  • 2010-11-03 EP EP10829047.9A patent/EP2497158A4/de not_active Withdrawn
  • 2010-11-03 WO PCT/US2010/055337 patent/WO2011056901A2/en active Application Filing

Patent Citations (18)

Non-Patent Citations (1)

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