Note: Descriptions are shown in the official language in which they were submitted.
WIRE CUTTING ELECTRICAL CONNECTOR
The present invention relates to an electrical
wire connector for simultaneously connecting and severing
electrical wires.
Connectors for terminating electrical wires have
most often required the wire ends to be pushed into
openings in one end of the connector until they contact an
abutment within the connector. Telescoping parts are then
moved together to force the wires into a contact element
to complete the electrical connection. A waterproof
grease is frequently provided between the telescoping
parts to make the final connection water resistant. Such
connectors are disclosed in U.S. Patent Nos. 3,573,723 and
3,656,08~. It has been found that users of such connec-
tors sometimes do not insert the wire ends far enough into
the connectors and electrical connection is not made when
the parts are moved together. Also, it has been found
that occasionally plastic wire insulation stretches suffi-
ciently that it extends beyond the conductor so that even
though the wire end is inserted into the connector against
the abutment only the wire insulation is forced into the
contact element and again the wire connection is not made.
An earlier wire connector disclosed in U.S.
Patent No. 3,202,957 makes good connection to the wires by
; extending the wire openings through the connector body.
-~ 25 The wire ends extend out of the connector prior to connec-
tion and a severing blad cuts the wire at the same time as
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the contact element makes connection to it. However, this
connector suffers from the difficulty that it cannot be
readily waterproofed. Even though a waterproof grease
could be provided within the connector body, when the wire
is severed and the severed end removed from the connector
body a channel is provided to the contact element through
which water could enter the connector and short out the
connection.
The present invention provides a wire connector
having an insulating body, an insulating co`ver and a con-
ductive wire connector element. The body is hollow and
open-topped with a base wall, a pair of generally-parallel
side walls extending generally perpendicularly from the
base wall and an end wall extendiny from the base wall
between the side walls at one end of the body. The upper
edge of at least a portion of the end wall is inclined at
an acute angle to the base wall and the end of the body
opposite the end wall is open for access by at least one
wire. The wire connector element is U-shaped and
resilient with the legs of the U being wide and thin. One
of the legs is formed with at least one wire connecting
slot extending from the top of the leg toward the base of
the V and the second leg is sharpened along its top edge
in alignment with at least one wire connecting slot in the
first leg. The connector element is positioned in the
body with the base of the U on the base wall of the body
and the sharpened second leg abutting and extending above
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_3_ 1113165
the inclined portion of the body end wall. The cover and
body are formed to telescope together. The cover is form-
ed to carry a wire into each connector element slot~and to
cooperate with the sharpened second leg of the connector
element to sever at least one wire extending through the
connector upon telescoping of the cover and body fully
together. The body and cover are formed to seal the end
of the connector adjacent the sharpened second leg of the
connector element when the body and cover are fully tele-
scoped together. They are also formed with complementary
latch members to retain the body and cover in an open
position to permit at least one wire to be inserted into -
the body end that is open for wire access and through said
connector between the body and cover, and to retain the
body and cover in a crimped position with the body and
cover fully telescoped together. }
When the cover and body are telescoped together
the cover forces a wire into each slot in the contact
element and simultaneously forces at least one wire
against the sharpened leg of the contact element which
acts as a cut-off blade to sever the wire end. The
connector end seal closes the end of the body after the
wire end has been severed.
Figure 1 is a perspective view of a first
embodiment of the wire connector of the present invention
in a fully opened position with wires inserted there-
through; Figure 2 is a longitudinal cross-sectional view
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--4--
of the connector of Figure 1 in the fully open position;
Figure 3 is a cross-sectional view taken generally along
line 3-3 of Figure 2; Figure 4 is a cross-sectional view
similar to that of Figure 3 with the cover telescoped into
the body to a precrimped position to hold the wires in
place; Figure 5 is a longitudinal cross-sectional view
similar to that of Figure 2 with the connector in the
fully crimped position; Figure 6 is an end view of the
connector of Figure 1 in the fully crimped position as
viewed from the left end in Figure 5; Figure 7 is a
cross-sectional view taken generally along line 7-7 of
Figure 5; Fig4re 8 is a perspective view of a second
embodiment of the wire connector of the present invention
in a fully open position with wires inserted therethrough;
Figure 9 is a longitudinal cross-sectional view of the
connector of Figure 8 in the fully open position; Figure
10 is an end view of the connector of Figure 8 as viewed
from the left end in Figure 9, with parts broken away;
Figure 11 is a longitudinal cross-sectional view similar
to that of Figure 9 with the connector in the fully
crimped position and the door closed; and Figure 12 is a
transverse cross-sectional view of the connector of Figure
8 as viewed from left to right in Figure 11, at two
depths, one to either side of the vertical break line.
Referring now to the embodiment of Figures 1-7,
; the wire connector of the present invention comprises a
hollow, open-topped, insulating body 10, a U-shaped,
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resilient, conductive wire connector element 12 and an3
insulating cover 14 formed to telescope into the body 10.
The body 10 has a base wall 15, a pair of
generally paralle~l side walls 16 that extend generally
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perpendicularly from the base wall and an end wall 17
extending from the base wall 15 between the side walls 16
at one end of the body. The upper edge 18 of the body end
wall 17 is inclined at an acute angle to the base wall 15.
The end of the body 10 opposite the end wall 17-is open
for access by insulated wires 20. Adjacent the open end
of the body 10 two trans erse rows of dividers 21 and 22
extend from the base wall 15 in lines transverse of the
body to define three parallel wire access passageways that
are slightly narr ~er than the insulated wires 20.
The legs 24 and 25 of the U-shaped wire connec-
tor element 12 are wide and thin. One leg 24 is formed
with three wire connecting slots 27 extending from the top
of the leg 24 toward the base of the U. The second leg 25 -
is sharpened along its top edge. The connector element 12
is positioned in the body 10 with the base of the U on the
base wall 15 of the body, the sharpened leg 25 abutting
and extending above the body end wall 17 and the wire con-
necting slots 27 aligned with the passageways defined by
the dividers 21 and 22. A waterproof grease 28 fills the
body cavity between dividers 22 and end wall 17 including
the space within the U of the connector element 12.
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The cover 14 is formed to telescope into the
body 10 between the body side wall 16. The cover is form-
ed with a pair of parallel transverse slots 29 and 30 to
receive the legs 24 and 25, respectively, of the connector
element 12. It is also formed with three longitudinal
wire support channels 32 aligned with the slots 27 in the
wire connector element 12 to carry wires 20 into the slots
27 upon telescoping of the cover 14 fully into the body.
The end of the cover 14 over the inclined edge 18 of the
body end wall 17 is formed with a sharp corner 34 to con-
tact the inclined edge 18. The corner 34 contacts the
inclined body edge 18 when the cover 14 is fully tele-
scoped into the body 10 to close the end of the connector.
The body 10 and cover 14 are formed with comple-
mentary latch members defined by longitudinal ribs 36 and
37 on the interior of both body side walls 16 and ribs 38
and 39 on the exterior of both cover side walls. In the
fully open position of the connector, illustrated in
Figures 1, 2 and 3, the lower ribs 39 on the cover fit
between the ribs 36 and 37 on the body. In this position
the wires 20 may be slid between the body 10 and cover 14
in the wire support channels 32.
~he cover may then be telescoped into the body
to the precrimped position illustrated in Figure 4 by
finger pressure on the cover. This moves the cover to a
position where its latching ribs 38 and 39 lie on either
side of the body ribs 36 and 37 and its channels 32 press
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-7_ ~131~5
the insulated wires 20 against the top of the connector
element 12 to frictionally retain the wires in their
position in the connector.
The cover is fully crimped into the body to the
; 5 position illustrated in Figures 5, 6 and 7 by a pliers
type tool which telescopes the cover 14 into the body 1~
until its upper ribs 38 lie between the ribs 36 and 37 on
the bbdy. As the cover is moved to its fully crimped posi-
tion the channels 32 carry the wires 20 into the dividers
21 and 22, into the slots 27 in the connector element 12,
and against the sharpened cut-off leg 25 of the connector
element. In the dividers 21 and 22 the insulation on the
wire 20 is indented to provide strain relief. In the
slots 27 the insulation is pierced and connection is made
- 15 to the conductor as the cover forces the wire ends against
the sharpened leg 2S to cut off thè wire ends. The in-
cline on the upper edge 18 of the body end wall 17 causes
the wire ends to be expelled from the connector as they
are severed. As the cover 14 is being moved from the
precrimped to the fully crimped position the grease 28 is
extruded around the wire connections. The wire ends are
severed and expelled before the cover reaches the fully
crimped position and thereafter grease is extruded into
and fills the area vacated by the severed wire ends to
make the connection reliably water resistant.
Referring now to the embodiment of the present
invention illustrated in Figures 8-12, this embodiment --
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also comprises a hollow, open-topped insulating body 50, a
U-shaped, resilient, conductive wire connector element 52
and an insulating cover 54. The parts in this embodiment
are esstentially inverted from those of the first embodi-
ment and the body 50 telescopes into the cover 54 instead
of the cover telescoping into the body.
The body 50 has a base wall 55, a pair of
generally parallel side walls 56 that extend generally
perpendicularly from the base wall and an end wall 57
extending from the base wall 55 between the side walls 56
at one end of the body. The upper edge 58 of the body end
wall 57 is inclined at an acute angle to the base wall 55
across the width thereof spanning the wire positions
; through the connector. The end of the body 50 opposite
the end wall 57 is open for access by insulated wires 60.
Adjacent the open end of the body 50 two transverse rows
of dividers 61 and 62 extend from the base wall 55 in
lines transverse of the body to define three parallel wire
passageways that are slightly narrower than the insulated
wires 60.
The legs 64 and 65 of the U-shaped wire connec-
tor element 52 are wide and thin. One leg 64 is formed
with three wire connecting slots 67 extending from the top~
of the leg 64 toward the base of the U. The second leg 65
is sharpened along its top edge in alignment with the wire
connecting slots 67 in the first leg 64. Four stabilizing
posts 66 formed with barbed ends extend from the top edge
.
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of leg 65, one post 66 to each side of the wlre positions
through the connector element 52. The connector element
52 is positioned in the body 50 with the base of the U on
the base wall 55 of the body, the sharpened leg 65 abutt-
ing and extending above the body end wall 57 and the wire
connecting slot 67 aligned with the wire pass,,ageways
defined by the dividers 61 and 62. A waterproof grease 68
fills the body cavity between the dividers 62 and end wall
57 including the space within the U of the connector
element 52.
The cover 54 is hollow and open topped to tele-
scopically receive the body 50. The cover is formed with
parallel transverse slots 69 and 70 to receive the legs 64
and 65, respectively, of the connector element 52 and four
wells 71 are formed to receive the posts 66 extending from
the sharpened leg 65 of the connector element 52. Narrow
ribs 72 extend across the slot 69 in alignment with each
of the three wire connecting slots 67 to prwide support
for the wires 60 for,insertion into the slots 67 upon tele-
scoping of the body 50 into the cover 54. Similar ribs 73
provide for inserting of the wires 60 between the dividers
61 and 62. At the end of the cover 54 adjacent the wire
access end of the body 50 the cover is formed with three
wire insertion ports 75 aligned with the wire passageways
between the dividers 61 and 62 and the wire slots 67 in
the connector element 52 to aid in insertion and guiding
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of the wires 60 through the connector between the body 50
and the cover 54 in their fully open positionO
The body 50 and the cover 54 are formed with
complementary latch members defined by longitudinal ribs
76 and 77 on the exterior of both body side walls 56 and
ribs 78 and 70 on the interior of both cover side walls.
~n the fully open position of the connector, illustrated
in Figures 8-10 the lower ribs 77 on the body fit between
the ribs 78 and 70 on the cover. In this position the
wires 60 may be slid into the wire insertion posts 75 and
¦ through the connector between the body 50 and the cover
54.
~ The body 50 may then be telescoped into the
¦ cover 54 by finger pressure to the precrimped position in
¦ 15 which the body latching ribs 76 and 77 lie on either side
¦ of the cover ribs 78 and 79. In this position the body 50
i and cover S4 frictionally engage the wires 60 between
them. The barbed ends of the stabilizing posts 66 on the
connector element 52 bite into the sidewalls of the wells
71 in the cover to aid in retaining the body and cover in
¦ this position.
¦ The body is fully crimped into the cover to the
position illustrated in Figures 11 and 12 by a pliers-type
tool which telescopes the body 50 into the cover 54 until
its upper ribs 76 lie between the ribs 78 and 79 on the
cover. As the body is moved to its fully crimped position
the wire insertion ribs 73 carry the wires into the divid-
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13i~5
ers 61 and 62, the wire insertion ribs 72 carry the wires
60 into the connector element slots 67 and the sharpened
cut-off leg 65 cuts through the~wires and moves into slot
70. In the dividers 61 and 62 insulation on the wire 60
is indented to provide strain relief. In the slots 67 the
insulation is pierced and connection is made to the
conductor as the cover forces the wire ends against the
sharpened leg 65 to cut off the wire ends. The stabiliz-
ing posts 66 prevent deflection of the sharpened cut-off
leg 65 by the wires and the barbed ends thereof bite into
the sidewalls of the wells 71 in the cover to aid in
~ retaining the body and cover in the fully crimped posi-
! tion. The incline on the upper edge 58 of the body end
~ wall 57 causes the wire ends to be expelled from the
¦ 15 connector as they are severed. As the body 50 is moved
! from the precrimped to the fully crimped position the
¦ grease 68 is extruded around the wire connections. The
wire ends are severed and expelled before the cover
¦ reaches the fully crimped position and thereafter grease
is extruded into and fills the area vacated by the severed
~ wire ends.
¦ In the embodiment of Figures 8 through 12 the
¦ inclined wall 58 on the body 50 does not make contact withany portion of the cover 54 in the fully crimped position.
I 25 The end of the connector is thus not fully closed in the
same manner as in the first embodiment. For this reason,
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-12- ~13~65
a hinged door 81 extends from the end of the cover 54.
When the body 50 is ful~y crimped into the cover 54 the
door 81 may be pivoted to close the end of the connector
adjacent the cut-off leg 65 of the connector element.
Wedge shaped latching projections 83 extending from the
edges of the door 81 adjacent the end thereof fit into
latching recesses 84 in the edge walls of the cover 54 to
retain the door in the closed position sealing the end of
the connector.
Many other variations of the present invention
will be apparent to those skilled in the art. For
example, a two wire connector may be constructed for
receiving one wire from each end by forming each leg of
the connector element with a wire receiving slot and a
cut-off edge, the cut-off edge being aligned with the slot
in the other leg, and by providing an inclined end wall
and a sealing door at the portion of each end adjacent the
nearest cut-off edge. ~s another example, a two wire tap
connector may be constructed in which the through wire
enters from the side of the connector in its fully open
position and only the position for the terminated wire has
a cut-off edge, an inclined end wall and means such as a
door to seal the end of the connector adjacent the cut-off
edge.
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