Patent Application
20080085625
With reference to
The main body 10 includes a connecting portion 40 including wire receiving slots 42 of substantially circular geometry, in which conductors 12, 14 of the first and second cables 16, 18 are arranged. The connecting portion 40 retains and aligns the corresponding wires to be connected. Nubs 44 assist in retaining the conductors 12, 14. As explained in detail below, a first hinging portion or section 46 including substantially circular wire slots 48 and a hinge 50 mechanically snaps onto the first cable 16. A second hinging portion or section 52 including substantially circular wire slots 54 and a hinge 56 mechanically snaps onto the second cable 18 so that corresponding pairs of wires 24, 30; 26, 32; 28, 34 make electrical contact.
With continuing reference to
Each prong 62, 64, 66, 68, 82, 84 includes a corresponding bifurcated or V-shaped end 90, 92, 94, 96, 98, 100 which extends out of the corresponding terminal 60, 80 toward the wire receiving slots 42. The first hinging portion 46 snaps onto the connecting portion 40 with the conductors 12 of the first cable 16 arranged in the wire receiving slots 42. The ends 90, 92, 98 of the prongs 62, 64, 82 push the conductors 12, puncture the insulating material layer 38 of the conductors 12 and electrically contact the wires 24, 26, 28. The snapping connection includes an engagement of a first engaging member or clip 110 of the first hinging section 46 with a matching recess or void 112 of the connecting portion 40 to secure the first hinging section 46 onto the connecting portion 40. Likewise, the second hinging portion 52 snaps onto the connecting portion 40 with the conductors 14 of the second cable 18 arranged in the wire receiving slots 42. The ends 94, 96, 100 of the prongs 66, 68, 84 push the conductors 14, puncture the insulating material layer 38 of the conductors 14 of the second cable 18 and electrically contact the wires 30, 32, 34. The snapping connection includes an engagement of a second engaging member or clip 114 of the second hinging section 52 with a recess or void (not shown) of the connecting portion 40 to secure the second hinging section 52 onto the connecting portion 40. As a result, the first positive prongs 62, 66 provide the electrical connection between the first positive wires 24, 30, the second positive prongs 64, 68 provide the electrical connection between the second positive wires 26, 32, and the negative prongs 82, 84 provide an electrical connection between the negative wires 28, 34 of the first and second cables 16, 18. Of course, it is contemplated that a different number of terminals and/or prongs can be used. For example, the illustrated embodiment can have two positive terminals and one negative terminal to achieve the polarity insensitive design.
In one embodiment, each bifurcated end 90, 92, 94, 96, 98, 100 defines a gap 120 sized to receive the respective conductor 12,14 of one of the first and second cable 16, 18. In one embodiment, each conductor 12, 14 includes multiple strands of wire surrounded by the insulation layer 38. The wire compressively squeezes into the gap 120 of the end 90, 92, 94, 96, 98, 100 of one of the prongs 62, 64, 66, 68, 82, 84 when the first or second hinging section 46, 52 is snapped in place onto the connecting portion 40.
In this manner, a miniature robust IDC connector is provided which includes a body having two living hinges and two terminals. The living hinges push the wires into the static terminal creating IDC connection. Such miniature connector can be assembled without special tools and, for example, placed in a tight spot or connect a miniature LED light.
With reference to
Each prong 62, 64, 66, 68, 82, 84 includes a corresponding bifurcated or V-shaped end 90, 92, 94, 96, 98, 100 which extends out of the corresponding terminal 60, 80 toward the receiving slots 42. The electrical connection between corresponding wires of the first and second cables 16, 18 is achieved by squeezing the first and second terminal holders 200, 202 toward one another onto the main body 10. The squeezing of the first and second terminal holders 200, 202 results in bifurcating the ends connecting to the conductors 12, 14 of the corresponding first and second cables 16, 18 thus connecting respective pairs of wires. The terminal holders 200, 202 retain the terminals 60, 80 and interface to the main body to provide proper alignment and retention of the terminals to the main body. The terminal holders 200, 202 can also have features to position the wire during termination and have voids to retain the gel for moisture protection. The connector is scalable for the size of the wires, the number of conductors to be connected, and which wires are to be connected. The end result is a small compact IDC splice connection usable with miniature LED lights, for example, that is placed over the wires to be connected and is terminated by squeezing the connection with a standard pair of pliers.
Optionally, the main body 10 includes multiple voids to be filled with a dielectric gel that provides moisture resistance to the critical areas where the terminals connect to the wire and to each other.
The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
