Splice connectors are used to electrically connect an electrical cable to another electrical cable. For a small sized cable, e.g. AWG20GA or AWG22GA, it is difficult to create a reliable and weatherproof connection between cables. Furthermore, known splice connectors for small cables are typically large and thus can obscure the visual impact of a light engine that is powered by the connected cables.
Known connectors are also difficult to use and install and require extra small parts or special tools for field installation. Also, known splice connectors are not staged to allow for a connection of the splice connection to the accompanying wires prior to complete termination of the wires. Furthermore, known splice connectors require proper placement of the wire inside the connector with respect to the terminals so that the proper terminal connects to the proper wire. Also, known connectors are typically not compatible to connect one cable that has one gage of wire to another cable having another gage of wire.
A splice connector includes a first IDC terminal, a second IDC terminal, a body receiving the first and second IDC terminals, and a cover connected to the body such that the cover selectively slides with respect to the body in a first linear direction from a first position to a second position. The body defines a first seat configured to receive an associated first cable and second seat configured to receive an associated second cable that is to be electrically connected to the associated first cable. The first and second IDC terminals each include a portion that extends into a region adjacent a respective wire seat. The cover is configured to cooperate with the body where a portion of the cover engages a portion of the body at a third position between the first position and the second position such that in the third position movement of the cover with respect to the body in a second direction, which is opposite the first, is inhibited.
A method for splicing a first cable to a second cable using a splice connector comprising a body, a first cover, a second cover and IDC terminals disposed in the body includes, among others, the following steps: placing the first cable between the first cover and the body adjacent an end of one of the IDC terminals disposed in the body; placing the second cable between the second cover and the body adjacent an end of one of the IDC terminals disposed the body; linearly displacing one of the body and the first cover towards the other into a staged mechanical connection between the body and the first cover that inhibits movement of the first cover away from the body and inhibits axial movement of the first cable with respect to the body; linearly displacing one of the body and the second cover towards the other into a staged mechanical connection between the body and the second cover that inhibits movement of the second cover away from the body and inhibits axial movement of the second cable with respect to the body; further linearly displacing one of the body and the first cover towards the other such that the end of the IDC terminal adjacent the first cable contacts a wire of the first cable; and further linearly displacing one of the body and the second cover towards the other such that the end of the IDC terminal adjacent the second cable contacts a wire of the second cable.
A splice connector for electrically connecting at least two cables includes a non-conductive body, seven electrically conductive members, a first cover attached to the body, and a second cover attached to the body. The body includes a first seat and a second seat. The first seat is configured to receive an associated first insulated cable. The second seat is configured to receive an associated second insulated cable. Each of the associated cables includes a plurality of wires. The first electrically conductive member is disposed in the body and is configured to pierce insulation to contact a first wire of the first associated cable. The second electrically conductive member is disposed in the body and is configured to pierce insulation to contact a second wire of the first associated cable. A third electrically conductive member is disposed in the body and is configured to pierce insulation to contact a third wire of the associated first cable. The fourth electrically conductive member directly contacts the first electrically conductive member and the third electrically conductive member. A fifth electrically conductive member is disposed in the body and is in electrical communication with the first electrically conductive member. The fifth electrically conductive member is configured to pierce insulation to contact a first wire of the associated second cable. A sixth electrically conductive member is disposed in the body and is in electrical communication with the second electrically conductive member. The sixth electrically conductive member is configured to pierce insulation to contact a second wire of the associated second cable. The seventh electrically conductive member is disposed in the body and in electrical communication with the third electrically conductive member. The sixth electrically conductive member is configured to pierce insulation to contact a third wire of the associated second cable. The first cover is slidably attached to the body and moveable selectively cover at least a portion of the first seat the second cover is slidably attached to the body and moveable to selectively cover at least a portion of the second seat.
With reference to
To splice together the two cables 12 and 14, the cables are inserted into the appropriate location of a connector body 40 as shown by the arrows in
With reference to
As more clearly seen in
In the embodiment depicted, the connector 10 is polarity insensitive. With reference to
The second IDC terminal 70 is spaced from the first IDC terminal 50 and in some locations has an insulating material disposed between the two so that there is no electrical connection between the first IDC terminal 50 and the second IDC terminal 70 (see FIG. 12). The second IDC terminal 70 includes an upper bifurcated end 72 that is configured to engage the central wire 18 of the cable 12 and a lower bifurcated end 74 that is configured to engage the central wire 28 of the lower cable 14.
The IDC terminals 50 and 70 have been described as separate single piece components; however, an IDC connection can be provided in other manners. For example, the first IDC terminal 50 can be replaced with a plurality of electrically interconnected members. For instance, pointed bifurcated ends, similar to bifurcated ends 52, 54, 56 and 58, can be interconnected by an electrically conductive member. The same holds true for the second IDC terminal. Likewise, the bridge portion 66 of the first IDC terminal 50 can be replaced by an electrically conducive member.
With reference to
In the depicted embodiment, the main body 40 is made of a single molded of plastic, or other non-conductive material. The body 40 includes a central platform 80 disposed in the X-Z plane. First and second upper tracks 82, 84 extend upwardly (in the Y-axis) from the central platform 80. The tracks 82 and 84 are spaced from one another along the X-axis and a central pedestal 86 also extends upwardly from the central platform 80 interconnecting the first upper track 82 to the second upper track 84. The central pedestal 86 includes curved upper surfaces 88 that define wire seats for receiving the upper wire 12 (
A forward central pedestal 120 extends into the platform 80 from the central pedestal 86 in a direction that is generally parallel to the Z-axis. A channel 122 is disposed between the forward central pedestal 120 and the central pedestal 86. A shelf 124 is provided at the lower end of channel 122 and the bridge 66 of the first IDC terminal 50 is received inside the channel 122 and rests on the shelf 124.
The body 40 also includes first and second lower tracks 132 and 134 that depend downwardly from the platform 80 in the direction that is generally parallel to the Y-axis. The lower tracks 132 and 134 are similarly shaped to the upper tracks 82 and 84 of the main body 40. Curved surfaces 136 that define a wire seat are interposed between the tracks 132 and 134 and are shaped to receive the lower cable 14 (
With reference back to
An IDC terminal cover 180 attaches to the body 40 to secure the IDC terminals 50 and 70 to the body. In the depicted embodiment, the IDC cover 180 sandwiches a portion of each terminal 50 and 70 against the platform 80 of the base 40 (see
The IDC cover 180 includes a generally rectangular base 194. The rectangular base 194 is shaped to cover at least a majority of the central platform 80 of the main body 40. A ramped protuberance 196 extends from the rectangular base 194 and is configured to be received inside the opening 192 in the central wall 188 that extends upwardly from the central platform 80 of the body 40 when the IDC connector 180 is attached to the main body 40. The IDC cover 180 also includes an upwardly extending pedestal portion 198 that includes curved surfaces 202 that define portions of a wire seat. The curved portions 202 align with the curved portions 88 of the central pedestal 86 when IDC cover 180 is attached to the main body 40. A channel 204 formed in the upwardly extending pedestal portion 198 aligned with the Y-axis is formed in the rear of the pedestal 198 and is configured to receive the central forward pedestal 120 in the upper portion of the second terminal 70 when the IDC cover attaches to the main body 40.
The base 194 of the IDC terminal cover 180 also includes a first recessed surface 206 formed in the Y-Z plane and a second recessed surface 208 formed in the Y-Z plane spaced from the first recessed surface along the X-axis. The recessed surfaces 206 and 208 align with the tracks to facilitate movement of the upper and lower covers 42 and 44. The IDC cover 180 also includes a curved upper surface 212 that can facilitate attachment of the IDC cover 180 to the main body 40. The curved upper surface 212 directs the rotationally directed force of pliers toward the centerline, along the Y-axis, of the IDC cover 180. Similar to the curved upper surface 212, the base 40 includes a curved lower surface 214 (
The upper cover 42 and the lower cover 44 attach to the main body 40 in such a manner that each can slide linearly along the Y-axis with respect to the main body. In the depicted embodiment, the upper cover 42 and the lower cover 44 are identical which eases assembly of the splice connector 10 as well as reducing manufacturing costs by limiting the number of different components that are to be molded. Accordingly, portions of each of the upper cover and lower cover will be described with reference to each cover where visible and only one cover where the portion is not visible on the other cover.
Each cover includes a longer appendage 220 and a shorter appendage 222 that each extend from a base 224. The appendages 220 and 222 are configured to be received in the tracks 82, 84, 132 and 134 of the main body 40. More specifically, the longer appendage 220 of the upper cover 42 is received in the second track 84 and the shorter appendage 222 of the upper cover 42 is received in the first track 82. Similarly, the longer track 20 of the lower cover 44 is received in the second lower track 134 and the shorter appendage 222 of the lower cover 44 received in the first track 132. Each appendage includes flanged edges that run along the Y-axis that are configured to be received in the channels of the respective tracks. For example, the longer appendages 220 include side flanges 226 and 228. For the upper cover the edge flanges 226 and 228 are received by the channels 96 and 98 respectively. Likewise, the flanges 226 and 228 are received by the channels 142 and 144 respectively (
The longer appendage includes three openings: a proximal opening 240, an intermediate opening 242, and a distal opening 244. The openings are rectangular in configuration and are configured to cooperate with the ramped protuberance 116 and 158 (
The shorter appendage 222 includes two openings: a proximal opening 246 and a distal opening 248. These openings are also rectangular in configuration. The proximal opening 246 is aligned with the proximal opening 240 as defined by a plane that is parallel to the X-Z plane. Likewise, the distal opening 248 and the intermediate opening 242 also reside in a plane that is parallel to the X-Z plane offset from the proximal openings.
Each cover also includes a wire seat 252 that comprises a plurality of curved surfaces that are configured to receive the cables 12 and 14 (
Each cover 42 and 44 (only visible in
The splice connector 10 as shown in the figures allows for a staged connection between two wires. With reference back to
With reference to
The aforementioned connector 10 includes two ratchet action sliding covers 42 and 44. As described above, the covers 42 and 44 include the female portion of the connection between the body 40 and the respective covers and the body includes the male portion of the connection. Alternatively, the male portion of the connection can be provided on the cover, e.g. the cover can include a ramped protuberance that is received in separate openings formed in the body.
As mentioned above, the splice connector 10 is polarity insensitive. Typically for a series/parallel electrical configuration, three wires are provided: a positive wire, a negative wire, and a neutral wire. As seen in
The splice connector 10 can achieve polarity insensitivity in other manners than providing only two IDC connectors 50 and 70 that have been described above. For example, the bifurcated ends 52, 54, 56, 58, 72 and 74 can be separate electrically conductive members that are in electrical communication with one another in a similar manner to the aforementioned IDC connectors. Similarly, the bridge 66 can be provided as a separate electrically conductive member that contacts two separate IDC connectors to provide an electrical connection between the two.
A splice connector has been described with reference to one embodiment and alternatives of that embodiment have also been disclosed. Nevertheless, the invention is not limited to the disclosed embodiment and the disclosed alternatives. Instead, the invention is to be broadly construed to include all embodiments covered the appended claims and the equivalents thereof.
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Number | Date | Country |
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WO 02097770 | Dec 2002 | WO |