Patent Application
20230096491
This disclosure relates generally to gel filled electrical connectors. The gel filled connectors are used to splice or connect wires used, for example, in recreational vehicles and trailers. Crimp-type electrical terminals and connectors come in several varieties. Sizes/gauge ranges may be denoted by their color. Such connectors are suitable for any job where soldering is not needed or desired. Ring terminals would commonly be used in situations where you need a more secure connection than a fork terminal. The fork terminal is typically used in situations where ease of removal is more important than a secure connection. The fork terminals are typically bound with a screw or threaded post and a nut. Quick disconnect terminals come in both male and female varieties. They can be used together to create a connection. They can connect to existing connectors such as car audio speakers which often have male quick disconnect terminals. The gel filling provides protection for the wires and electrical connection against moisture intrusion and ultra violet damage.
The invention disclosed and claimed herein is a gel filled electrical connector 10 for wires 20, 30, having a diameter of about 2.59 mm or greater, corresponding to 10-gauge or larger-diameter wire. The sizes of wires 20, 30 are estimated by devices, also called gauges, which consist of plates of circular or oblong form having notches of different widths around their edges to receive wire and sheet metals of different thicknesses. Each notch is stamped with a number, and the wire or sheet, which fits a given notch, is stated to be of, say, No. 10, 11, 12, etc., of the wire gauge. One such wire gauge and current table is as follows:
In some applications, wire sizes are specified as the cross sectional area of the wire, usually in square millimeters (mm2). Advantages of this system include the ability to readily calculate the physical dimensions or weight of wire, ability to take account of non-circular wire, and ease of calculation of electrical properties.
The gel connector 10 comprises a base 40 configured to house a gel fill insulating material 50, and to receive 10-gauge or larger diameter wires 20, 30. A top cover 60 is provided. Base 40 and cover 60 may be formed from any suitable material such as Nylon, polycarbonate, plastic, resin, etc. as is known in the art. Wire connectors 70a-c are mounted to the top cover 60 positioned to allow wire connectors 70a-c to engage wires 20, 30 so as to remove the insulating cover of the wires 20, 30 without damaging the conductive material in wires 20, 30. When the wires 20, 30 are inserted into the base 40, the top cover 60 is secured to the base 40 so that the wire connectors 70a-c pierce the plastic insulating cover 80 of the wires 20, 30 to be connected thereby providing a conductive connection between the two wires 20, 30. The top cover 60 is securely connected to the base 40 once the wires 20, 30 are inserted into the base 40 and secured to the wire connector 70.
The present invention provides an environmentally protected electrical connector. To protect the connector 10 from moisture and other corrosion, the connector assembly is filled with an environmental sealant 50. The environmental sealant 50 is preferably a hydrophobic dielectric to eliminate moisture and insulate wires 20, 30 and contacts wire connectors 70a-c. Gels 50 are preferred and most preferred are silicone gels. The gel 50 requires sufficient adhesion and forms an acceptable seal around the wire connectors 70a-c, wires 20, 30, and other parts of the connector 10 in the need for environmental protection. Various suitable gels are known to those of skill in the art. The gel sealant 50 should have sufficient hardness to provide lasting protection against environmental pollutants. The gel sealant 50 should be soft enough to be displaced by the connectors 70a-c and properly seal it according to the shape of the connector 10.
The devices and methods disclosed include one or more of the features, structures, methods, or combination thereof described. For example, a device or method may be implemented to include one or more of the features and/or processes described herein. Such device or method need not include all the features and/or processes described but may be implemented to include selected features and/or processes that provide useful structures and/or functionality. Various modifications and additions can be made to the disclosed embodiments. The scope of the present disclosure is not limited by the embodiments described but is defined by the claims set forth below and equivalents thereof.
Referring to
A hydrophilic gel is dispersed within cavity 130 of base 40 to provide moisture resistance two wires, 20, 30, including the electrical connection between wires 20, 30. The hydrophobic gel can be your various kinds known in the field. Suitable hydrophobic gels include: Dynatex and Super Lube. Any other type of hydrophobic gel such as silicone or similar products may be used within the scope of the disclosed invention. Top the top cover 60 and base 40 may be made from flame retardant nylon, polycarbonate, or any other material that ensures good connectivity and good conductivity for the wires 20, 30 to prevent corrosion and or UV deterioration.
The present application claims priority to U.S. provisional patent application No. 63/084,192, filed Sep. 28, 2020, titled “Gel Filled Connector for Large Gauge Wires.” The entire content of the identified provisional patent application is incorporated herein by reference.
