Patent Application
20130105033
Assemblies for tapping into electrical wires are generally known. By way of example, U.S. Pat. No. 6,159,035 describes a connector assembly for penetrating the insulation and establishing an electrical connection with insulated electrical wires or conductors, thereby eliminating the need to strip the insulation away from the insulated wires. U.S. Pat. No. 3,594,703 describes an electrical tapoff connector having an insulation-piercing screw means which, when tightened onto an insulated line cable, pierces the insulation of the cable and mechanically and electrically engages the conductor thereof. U.S. Pat. No. 5,141,449 describes a snap-on light socket having sharply pointed portions which function to pierce the insulation of a wire to effect an electrical connection. U.S. Pat. No. 5,611,709 describes an assembly for electrically and mechanically connecting one or more flexible conductive members with one or more insulated wires using one or more insulation piercing terminals.
While such assemblies generally work for their intended purpose, a need exists for an improved assembly, particular one which may be used in connection with low voltage DC power systems.
Described hereinafter are improved connector assemblies useful, for example, to provide a means to connect various DC devices (e.g., LED light fixtures, alarm systems, cameras, sensors, etc.) to a low voltage DC power source. More particularly, in these DC applications there is always a positive (+) and negative (−) wire for the DC voltage. The pair of wires are most often in an outer jacket but can be a pair of wires running together that are not in a jacket. The subject connector assemblies provide a relatively simpler method for attaching DC powered devices to such wires.
By way of example only, the connector assembly may include a “run” side connector that is releasably matable with a “tap” side connector. The “run” side connector is adapted to be mechanically and electrically coupled to the pair of wires through the use of insulation piercing contacts. While insulation piercing contacts are provided on the “run” side connector, the pair of wires to which the “run” side connector is to be mated may have an outer jacket or may not and may be twisted or not twisted without limitation. The “tap” side connector is then adapted to receive a further pair of wires, e.g., a pair of wires used to provide DC power to one or more DC devices. In this regard, the “tap” side connector may also utilize insulation piercing contacts whereby the further pair of wires need not be stripped in order to make a connection therewith. The “tap” side connector could alternatively utilize push-in connectors, weld connectors, or other connectors as required without limitation. The “tap” side connector, in cooperation with the “run” side connector, thus allows a user to tapoff of the “run” also using a twisted pair or untwisted 2-conductor wire with or without an outer jacket.
While one described embodiment utilizes a “run” connector and a “tap” connector that are adapted to be releasably matable using, for example, a spring contact in each of the “run” connector and the “tap” connector which are also arranged to be engaged, in other embodiment the “run” connector and the “tap” connector are integrated into an integrated housing assembly. In both embodiments, however, the connector assembly is designed to be press-fit over the wires where only a pair of pliers or the like need be used to compress the insulation piercing connectors onto the wires.
While the foregoing provides a general description of the subject connector assemblies, a better understanding of the objects, advantages, features, properties, and relationships of the subject connector assemblies will be obtained from the following detailed description and accompanying drawings which set forth illustrative embodiments and which are indicative of the various ways in which the principles of the invention may be employed.
For a better understanding of the hereinafter described connector assemblies, reference may be had to the following drawings in which:
Turning now to the Figures, illustrated are various embodiments of a connector assembly useful, for example, to provide a means to connect various DC devices (e.g., LED light fixtures, alarm systems, cameras, sensors, etc.) to a low voltage DC power source. By way of first example, shown in
For mechanically and electrically coupling the “run” side connector assembly 12 to the first wire pair 16, the “run” side connector assembly 12 comprises a first housing section 20 which is moveably engaged with and lockable with respect to a second housing section 22, as particularly illustrated in
To electrically and mechanically engage the first wire pair 16 when the “run” side connector 12 is compressed upon the first wire pair 16, the second housing component 22 is provided with a pair of insulation piercing contacts 28 having at one end thereof a piercing tine 30 having one or more piercing tips and having at the second end thereof a spring disconnect interface 32 which is provided to engage with a corresponding spring disconnect interface provided to contacts within the “tap” side connector 14 as described hereinafter. When the insulation piercing contacts 28 are arranged within the second housing component 22, the disconnect interface 32 of each contact 28 will be positioned within a male housing extension 34 (over which female housing extensions of the “run” side connector 14 are to be positioned) while the tines 30 of the contacts 28 will be positioned so as to extend into a wire receiving chamber formed between the two housing component 20 and 22, e.g., an area that is formed between opposed surfaces of the housing components 20 and 22. In this manner, when the first housing component 20 and the second housing component 22 are compressed upon the first wire pair 16, for example via use of pliers or the like, the first wire pair 16 will be forced upon the tines 30 of the contacts 28 and the tines 30 will be caused to pierce the outer jacket (if any) of the wires, the insulation of the wires, and the wires themselves to thereby provide an electrical connection therewith. To support the wires of the first wire pair 16 within the wire receiving chamber, one or both of the first housing component 20 and second housing component 22 may be provided with a rib 36 which is to be positioned on the surfaces forming the wire receiving chamber along a line that generally separates the wires in the first wires pair 16. The second housing component 22 may also be provided with a first half of a latching component 38 which is adapted to releasably engage with a corresponding second half of a latching component that is to be provided to the “tap” side connector 14. Furthermore, the contacts 28 may be provided with barbs 40 or the like engageable with like components formed in the second housing component 22 to thereby lock the contacts 28 in place when the contacts 28 are inserted into the second housing component 22.
For mechanically and electrically coupling the “tap” side connector assembly 14 to the second wire pair 18, the “tap” side connector assembly 14 likewise comprises a first housing section 42 which is moveably engaged with and lockable with respect to a second housing section 44, as particularly illustrated in
To electrically and mechanically engage the second wire pair 18 when the “tap” side connector 14 is compressed upon the second wire pair 18, the first housing component 42 is provided with a pair of insulation piercing contacts 52 having at one end thereof a piercing tine 54 having one or more piercing tips and having at the second end thereof a spring disconnect interface 56 which is provided to engage with the corresponding spring disconnect interface 32 provided to the contacts 28 within the “run” side connector 12 as described above. When the insulation piercing contacts 52 are arranged within the first housing component 42, the disconnect interface 56 of each contacts 52 will be positioned within a female housing extension (into which the male housing extensions of the “run” side connector 12 are to be positioned) while the tines 54 of the contacts 52 will be positioned so as to extend into a wire receiving chamber formed between the two housing component 42 and 44, e.g., an area that is formed between opposed surfaces of the housing components 42 and 44. In this manner, when the first housing component 42 and the second housing component 44 are compressed upon the second wire pair 18, for example via use of pliers or the like, the second wire pair 18 will be forced upon the times 54 of the contacts 52 and the tines 54 will be caused to pierce the outer jacket (if any) of the wires, the insulation of the wires, and the wires themselves to thereby provide an electrical connection therewith. To support the wires of the second wire pair 18 within the wire receiving chamber, one or both of the first housing component 42 and second housing component 44 may be provided with a rib 58 which is to be positioned on the surfaces forming the wire receiving chamber along a line that generally separates the wires in the second wires pair 18. The first housing component 42 may also be provided with a second half of a latching component 60 which is adapted to releasably engage with a corresponding first half of a latching component 38 that is to be provided to the “run” side connector 12 as above described and as illustrated in
While the contacts 52 are illustrated and described as being insulation piercing contacts, it will be appreciated that, in other embodiments, the contacts may include other mechanisms for engaging with the wires of the second wire pair 18.
In a second embodiment, illustrated in
For mechanically and electrically coupling the “run” side connector portion to the first wire pair 16, the first housing section 70 is moveably engaged with and lockable with respect to the second housing section 72, as particularly illustrated in
To electrically and mechanically engage the first wire pair 16 when the “run” side connector portion is compressed upon the first wire pair 16, the second housing component 72 is provided with a pair of insulation piercing contacts 76 having at one end thereof a piercing tine 80 having one or more piercing tips and having at the second end thereof a further piercing time 82 having one or more piercing tips. As will be described further below, the piercing tine 82 is provided to engage with the second wire pair 18 as part of the “tap” side connector portion of the assembly 10′. Thus, in the event that different gauge wires are used within the first wire pair 16 and the second wire pair 18, the contacts 76 may be provided with a bend or the like 84 to thereby allow the tines to be aligned as required. The contacts 76 may also include a curved portion 86 which will engage with a corresponding surface provided within the second housing 72 to thereby bias or force the tines 82 towards the third housing component 74 when the contacts 76 are inserted into the second housing component 72. When so inserted, the tines 80 of the contacts 76 will be positioned so as to extend into a wire receiving chamber formed between the two housing component 70 and 72, e.g., an area that is formed between opposed surfaces of the housing components 70 and 72, while the tines 82 of the contacts 76 will be positioned so as to extend into a wire receiving chamber formed between the two housing components 74 and 72, e.g., an area that is formed between opposed surfaces of the housing components 74 and 72. Furthermore, the contacts 76 may be provided with barbs 88 or the like engageable with like components formed in the second housing component 72 to thereby lock the contacts 76 in place when the contacts 76 are inserted into the second housing component 72. With this arrangement, when the first housing component 70 and the second housing component 72 are compressed upon the first wire pair 16, for example via use of pliers or the like, the first wire pair 16 will be forced upon the times 80 of the contacts 76 and the tines 80 will be caused to pierce the outer jacket (if any) of the wires, the insulation of the wires, and the wires themselves to thereby provide an electrical connection therewith. To support the wires of the first wire pair 16 within the wire receiving chamber, one or both of the first housing component 70 and second housing component 72 may be provided with a rib 98 which is to be positioned on the surfaces forming the wire receiving chamber along a line that generally separates the wires in the first wires pair 16.
For mechanically and electrically coupling the “tap” side connector portion to the second wire pair 18, the third housing section 74 is moveably engaged with and lockable with respect to a second housing section 74. To provide the movable engagement between the third housing section 74 and the second housing section 72, the third housing section 74 and the second housing section 72 may include cooperating tabs and grooves as described previously. As before, other arrangements for slidably connecting, hingedly connecting, or the like the two housing components 74 and 72 for the purpose of allowing the second wire pair 18 to be disposed therebetween and to then allow the two housing components 74 and 72 to be moved together to thereby trap and engage the second wire pair 18 within the “tap” side connector portion are also contemplated. To lock the third housing section 74 and the second housing section 72 together once the housing sections 74 and 72 have been brought together upon the second wire pair 18, cooperating movement inhibiting mechanisms, such as bumps 90 or the like, may be provided to each of the third and second housing components 74 and 72. Thus, when the third housing component 74 and the second housing component 72 are compressed upon the second wire pair 18, for example via use of pliers or the like, the second wire pair 18 will be forced upon the times 82 of the contacts 76 and the tines 82 will be caused to pierce the outer jacket (if any) of the wires, the insulation of the wires, and the wires themselves to thereby provide an electrical connection therewith. To support the wires of the second wire pair 18 within the wire receiving chamber, one or both of the third housing component 74 and second housing component 72 may be provided with a rib 99 which is to be positioned on the surfaces forming the wire receiving chamber along a line that generally separates the wires in the second wires pair 18.
While the second end of the contacts 76 are illustrated and described as being insulation piercing contacts having tines 82, it will be appreciated that, in other embodiments, the second end of the contacts 76 may include other mechanisms for engaging with the wires of the second wire pair 18.
In a yet further embodiment, illustrated in
While specific embodiments of the subject invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of this disclosure. For example, it will be appreciated that the “run” portion of the connector assemblies can be at the power supply, e.g., the power supply is provided with a disconnect interface as described above to which the “tap” portion may be releasably engaged. Still further, while the “run” and “tap” portions of the connector assemblies are shown as generally being in-line, it will be appreciated that the “run” and “tap” portions of the connector assemblies can be off-line, e.g., oriented at an angle with respect to one another. It will therefore be appreciated that features described with respect to the various embodiments are not to be limited to any particular embodiment but may be freely used across embodiments where applicable. Additionally, it will be appreciate that the size, shape, arrangement, and/or number of components illustrated and described can be changed as necessary to meet a given need. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any equivalents thereof.
This application claims the benefit of U.S. Provisional Application No. 61/480,605, filed on Apr. 29, 2011, the disclosure of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61480605 | Apr 2011 | US |
