Patent Application
20070232137
Embodiments are generally related to electrical connectors. Embodiments are also related to the field of switches utilized in commercial, industrial and consumer applications. Embodiments additionally relate to toggle switches.
A toggle switch is a switch in which a projecting lever with a spring is used to open or to close an electric circuit. Toggle switches of various types have long been utilized to control power in domestic, commercial, industrial, and military applications for operating various electrical devices and equipment.
Known toggle switches typically are manufactured with a housing that contains electrical contacts and is fitted with a manually operable handle to switch power to externally mounted terminals. Common toggle switches are standardized in terms of their mounting configurations such that they can readily be installed in wall-mounted electrical boxes, for example, with only the use of two screws. Typically, screw terminals are positioned on the sides of the switch housing such that connection can be easily made to electrical wires of suitable size to deliver power to electrical devices or equipment.
The process used for attaching a leaded wire to the back of a toggle switch requires attaching the leaded wire with a terminal already crimped on. To make a secure connection, the back of the switch and the wires with the terminal are then potted. The crimped terminals, wires and potting add a significant depth to the back of the toggle switch.
A need thus exists for a cost effective apparatus and method of attaching wires securely to the back of a toggle switch while maintaining a low profile to the housing, which can also eliminate the need for securing the wires by potting.
The following summary is provided to facilitate an understanding of some of the innovative features unique to the embodiments disclosed and is not intended to be a full description. A full appreciation of the various aspects of the embodiments can be gained by taking the entire specification, claims, drawings, and abstract as a whole.
It is, therefore, one aspect to provide for an improved method and apparatus for attaching wires to the back of a toggle switch.
It is another aspect to provide for a method and apparatus for attaching wires to the back of a toggle switch with a lower profile.
The aforementioned aspects and other objectives and advantages can now be achieved as described herein. An electrical connector apparatus is disclosed, which includes an electrically conductive cylinder wherein the electrically conductive cylinder contains an aft end and a forward end. The electrical connector apparatus also incorporates the use of a lateral slot formed from the walls of the forward end of the electrically conductive cylinder. A longitudinal hole can also be formed through and from the electrically conductive cylinder, whereby an electrical wire, with the insulation removed, is insertable into the aft end of the electrically conductive cylinder, and wherein the wire is inserted until the wire conductor of the electrical wire extends beyond the forward end of the electrically conductive cylinder and between the walls of the lateral slot in order to achieve a secure electrical connector apparatus.
In accordance with one embodiment, the electrical connector comprises an electrically conductive cylinder into which a wire conductor is inserted. The connector has a lateral slot cut into it on the forward end which will deform inward to grip the wire conductor when the connector is pressed in a toggle switch screw base. The connector forward end is beveled to allow easier insertion into the toggle switch screw base and also to facilitate the slotted end of the electrical connector to deform around the wire conductor. The act of inserting the connector into the toggle switch base both ensures electrical continuity by completing the electrical connection and secures both the electrical connector to the toggle switch and the wire conductor to the electrical connector by deforming around it.
The slotted forward end of the connector has knurling on the exterior, interfering with the toggle switch screw threads. This plurality of knurls is longitudinal, i.e. parallel to the axis of the longitudinal hole formed in the electrical connector. This interference between the plurality of knurls and the screw threads securely holds the electrical connector in place on the back of the toggle switch. A flange is provided on the connector to facilitate pressing the connector into the screw terminal. The electrical connector may be pressed into place in the toggle switch base by the use of a press.
The combination of providing both a secure connection to the toggle switch base while securely gripping the wire conductor results in a connection that does not require a crimped-on terminal. The electrical potting may also be eliminated, significantly reducing the depth of the back of the toggle switch.
The accompanying figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views and which are incorporated in and form a part of the specification, further illustrate the embodiments and, together with the detailed description, serve to explain the embodiments disclosed herein.
The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope thereof.
The electrical connector apparatus 100 is generally an electrically conductive cylinder with a hole 101 running through it longitudinally. In the preferred embodiment, the cylinder is constructed from a free cutting brass copper alloy, C36000. The electrical connector 100 has a slot 102 cut into the forward end 103. To complete an electrical connection to the base of a toggle switch, a wire is inserted into the aft end 104 of the electrical connector apparatus 100 until the conductor protrudes through the forward end 103 and the wire insulation butts up against the aft end 104 of the electrical connector apparatus 100 as indicated in
The electrical connector apparatus 100 with the protruding conductor is then placed on top of the screw terminal insert of a toggle switch and a press is used to press the electrical connector apparatus 100 into the screw terminal already molded into the back of a toggle switch. A flange 105 is provided on the electrical connector 100 to facilitate pressing the electrical connector apparatus 100 into the screw terminal insert. The forward end 103 of the electrical connector apparatus 100 has a beveled edge 106 to assist in inserting the electrical connector apparatus 100 into a screw terminal insert on the back of a toggle switch. The preferred embodiment is a beveled edge 106 at an angle of 30 degrees.
The electrical connector apparatus 100 has a plurality of longitudinal knurls 107 on the exterior of the forward end 103 as depicted in
Block 706 depicts the beveling of the forward end of the electrical connector, facilitating inserting the electrical connector into a screw terminal insert on the back of a toggle switch. The preferred embodiment is a beveled edge at an angle of 30 degrees. A wire conductor is then inserted in the electrical connector, block 707, with the wire conductor extending beyond the forward end of the electrical connector. Block 708 depicts the step of pressing the entire electrical connector with the wire conductor into a screw terminal. Pressing the electrical connector with the wire conductor inserted into the screw terminal deforms the walls of the cylinder surrounding the lateral slot inward, gripping the wire conductor securely. The plurality of knurls on the exterior causes interference with the screw terminal threads, holding the electrical connector with the wire conductor securely in place.
The combination of providing both a secure connection to the toggle switch base while securely gripping the wire conductor results in a connection that does not require a crimped-on terminal. The electrical potting may also be eliminated, significantly reducing the depth of the back of the toggle switch.
It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
