The present invention relates to an insulation displacement contact with expanded wire range capacity. In particular, the invention relates to an insulation displacement contact which can terminate one or more magnet wires of the same type and size therein, and the magnet wire size can be from a large range of available sizes.
As the number of electrical appliances increases, the need to manufacture and assemble small electrical motors in an efficient manner greatly increases. The motors are typically incorporated into appliances such as vacuum cleaners, kitchen appliances, and any other power accessory used in home or business. One electrical contact that is particularly useful for automated assembly is TE Connectivity's Mag-Mate Interconnection System. Contacts of this type enable insulation displacement-style contact techniques to be applied to magnet wire terminations, thereby eliminating the need for pre-stripping the magnet wire.
While the insulation displacement-style contact techniques applied to magnet wire terminations are effective in many applications, thereby existing a need to provide a magnet wire insulation displacement contact which can effectively terminal magnet wires of different gauges and/or more than one magnet wire.
It would, therefore, be beneficial to provide a magnet wire insulation displacement contact which is configured to allow for the termination of more than one magnet wire of the same type and gauge therein and to allow for the termination of a broad range of gauges.
An embodiment is directed to an insulation displacement contact with insulation displacement arms. The insulation displacement arms define a conductor or wire receiving slot. The insulation displacement arms have insulation peeling or stripping sections, weakened sections and base sections. The weakened sections have weakened section widths which are less than insulation stripping section widths of the insulation stripping sections and less than base section widths of the base section. The wire receiving slot is configured to receive one or more insulated conductors therein. The wire receiving slot has an insulation stripping zone and a wire termination zone. The insulation stripping zone is adjacent to the insulation stripping sections of the insulation displacement arms. The wire termination zone is adjacent to the weakened sections of the insulation displacement arms. The insulation stripping zone width of the insulation stripping zone is greater than the wire termination zone width of the wire termination zone. The weakened sections are resiliently deformed upon the one or more insulated conductors engaging the insulation stripping sections of the insulation displacement arms as the one or two insulated conductors are inserted into the insulation stripping zone of the wire receiving slot, allowing the insulation displacement contact to accommodate the one or more insulated conductors of different gauges.
An embodiment is directed to an insulation displacement contact with insulation displacement arms which define a conductor or wire receiving slot. The insulation displacement arms have insulation stripping sections, weakened sections and base sections. The wire receiving slot is configured to receive one or more insulated conductors therein. The wire receiving slot has an insulation stripping zone and a wire termination zone. The insulation stripping zone is adjacent to the insulation stripping sections of the insulation displacement arms. The wire termination zone is adjacent to the weakened sections of the insulation displacement arms. Relief slots are provided proximate the weakened sections of the insulation displacement arms. The slots extend from sides of the weakened sections which are opposite the wire receiving slot. The relief slots reduce width of the weakened sections to allow the weakened sections to be resiliently deformed more easily than the base sections and the insulation stripping sections. The weakened sections are resiliently deformed upon the one or more insulated conductors engaging the insulation stripping sections of the insulation displacement arms as the one or more insulated conductors are inserted into the insulation stripping zone of the wire receiving slot, allowing the insulation displacement contact to accommodate the one or more insulated conductors of the same type and gauge chosen from a broad range of gauges.
Other features and advantages of the present invention will be apparent from the following more detailed description of the illustrative embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.
Moreover, the features and benefits of the invention are illustrated by reference to the preferred embodiments. Accordingly, the invention expressly should not be limited to such embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features, the scope of the invention being defined by the claims appended hereto.
With reference to
As shown in
The first insulation displacement member 20 has insulation displacement arms 30, 32 which are mirror images of each other. The insulation displacement arms 30, 32 extend from a free end 34 of the contact 10 to proximate a fixed end 36. The insulation displacement arms 30, 32 define a conductor or wire receiving slot 38. The wire receiving slot 38 is configured to receive one or more insulated conductors or wires 80, such as, but not limited to, magnet wires, therein.
The wire receiving slot 38 extends from the free end 34 of the contact 10 to proximate the fixed end 36. The wire receiving slot 38 has a wire lead in zone or section 40, an insulation stripping zone or section 42 and a wire termination zone or section 44. The wire lead in section 40 is positioned proximate the free end 34 and has width D1 which is greater than the width D2 of the insulation stripping section 42. The insulation stripping section 42 extends from the wire lead in section 40 to the wire termination section 44. The insulation stripping section 42 extends from the wire lead in area 40 to the wire termination section 44. The width D2 of the insulation stripping section 42 is greater than the width D3 of the wire termination section 44. The wire termination section 44 extends from the insulation stripping section 42 to proximate the free end 36. The width D1 of the wire lead in area 40 is greater than the width of the wire 80 to be inserted therein. The width D2 of the insulation stripping section 42 is less than the width of the wire 80 to be inserted therein, but essentially equal to or slightly larger than the width of the inner core 82 of the wire 80. The width D3 of the wire termination section 44 is less than the width of the inner core 82 of the wire. The core 80 can be a single wire or a plurality of wires combined to form a strand.
The insulation displacement arms 30, 32 have wire lead in sections 50, insulation stripping sections 52, weakened sections 54 and base sections 56. The wire lead in sections 50 are positioned proximate the free end 34. The wire lead in sections 50 have wire receiving surfaces 58 proximate the free end 34. The wire receiving surfaces 58 are sloped to form a substantially V-shaped configuration to facilitate an introduction or guide a conductor or wire into the wire receiving slot 38. The wire receiving surfaces 58 define the wire lead in section 40 of the wire receiving slot 38.
The insulation stripping sections 52 of the insulation displacement arms 30, 32 extend from the wire lead in sections 50 to the weakened sections 54. The insulation stripping sections 52 have stamped areas 60 which form cutting edges 62. The cutting edges 62 are configured to penetrate the insulation or coating which is provided on the wire. The cutting edges 62 define the insulation stripping section 42 of the wire receiving slot 38. In the illustrative embodiment shown, the length of the cutting edges 62 in the direction of insertion of the wires is greater than two times the diameter of a wire, thereby allowing two wires to be positioned between the cutting edges 62 at the same time. However, the length of the cutting edges 62 may vary without departing from the scope of the invention.
The weakened sections 54 of the insulation displacement arms 30, 32 extend from the insulation stripping sections 52 to the base 56. The weakened sections 54 have core engagement edges 64 which are configured to engage the core of the wire after the insulation or coating has been removed by the cutting edges 62 of the insulation stripping sections. The core engagement edges 64 extend from the weakened sections 54 to the base 56. The core engagement edges 64 define the wire termination section 44 of the wire receiving slot 38. In the illustrative embodiment shown, the length of the core engagement edges 64 in the direction of insertion of the wires is greater than two times the diameter of a wire, thereby allowing two wires to be positioned between the core engagement edges 64 at the same time. However, the length of the core engagement edges 64 may vary without departing from the scope of the invention.
The core engagement edges 64 do not have to be as sharp as the cutting edges 62 of the insulation stripping sections. In various embodiments, the core engagement edges 64 have a rounded or even flat shape to provide a greater contact area between the core engagement edges 64 of the weakened sections 54 with the core of the wire.
As shown in
The base 56 has securing projections 68 which engage walls of the contact receiving cavity of the housing (not shown). The projections 68 are configured to displace material of the housing to retain the insulation displacement contact 10 in the housing. The insulation displacement contact 10 may secured in the housing by other methods or devices without departing from the scope of the invention. An opening 70 is provided in the base 56 at the end of the wire receiving slot 38. The opening 70 is provided to facilitate the control movement of the insulation displacement arms 30, 32 relative to each other.
A stabilization member 72 extends from the second insulation displacement member 22. The stabilization member 72 has a free end 74 and a mounting end 78. As best shown in
Referring to
The continued insertion of the wire 80 into the wire receiving slot 38 causes the wire 80 to move into the insulation stripping section 42 of the wire receiving slot 38. As this occurs, the insulation or protective coating 84 of the wire 80 engages the cutting edges 62 of the insulation stripping sections 52 of the of the insulation displacement arms 30, 32. As the width D2 of the insulation stripping section 42 is less than the width of the wire 80 to be inserted therein, but essentially equal to the width of the inner core 82 of the wire 80, the cutting edges 62 of the insulation stripping sections 52 will cut, remove or strip the insulation or protective coating 84 of the wire 80 to expose the core 82 in that region. As the wire 80 is of a small diameter or high gauge, the weakened sections 54 of the insulation displacement arms 30, 32 are moved only a small distance in the directions of arrows A in
The continued insertion of the wire 80 into the wire receiving slot 38 causes the wire 80 to move into the wire termination section 44 of the wire receiving slot 38. As this occurs, the inner core 82 which was exposed in the insulation stripping sections 52 of the of the insulation displacement arms 30, 32 mechanically and electrically engages the core engagement edges 64 of the weakened sections 54 of the insulation displacement arms 30, 32. As the width D3 of the wire termination section 44 is less than the width of the inner core 82 of the wire 80, the core engagement edges 64 of the weakened sections 54 will frictionally engage the core 82 in that region. As the wire 80 is of a small diameter or high gauge, the weakened sections 54 of the insulation displacement arms 30, 32 are moved only a small distance in the directions of arrows A in
Referring to
The continued insertion of the wire 180 into the wire receiving slot 38 causes the wire 180 to move into the insulation stripping section 42 of the wire receiving slot 38. As this occurs, the insulation or protective coating 184 of the wire 180 engages the cutting edges 62 of the insulation stripping sections 52 of the of the insulation displacement arms 30, 32. As the width D2 of the insulation stripping section 42 is less than the width of the wire 180 to be inserted therein, and less than the width of the inner core 182 of the wire 180, the cutting edges 62 of the insulation stripping sections 52 will cut, remove or strip the insulation or protective coating 184 of the wire 180 to expose the core 182 in that region. As shown in
The continued insertion of the wire 180 into the wire receiving slot 38 causes the wire 180 to move into the wire termination section 44 of the wire receiving slot 38. As this occurs, the inner core 182 which was exposed in the insulation stripping sections 52 of the insulation displacement arms 30, 32 mechanically and electrically engages the core engagement edges 64 of the weakened sections 54 of the insulation displacement arms 30, 32. As the width D3 of the wire termination section 44 is less than the width of the inner core 182 of the wire 180, the core engagement edges 64 of the weakened sections 54 will frictionally engage and compress the core 182 in that region. As the wire 180 is of a large diameter or small gauge, the weakened sections 54 of the insulation displacement arms 30, 32 is moved a greater distance in the directions of arrows A (
Referring to
The continued insertion of the wires 280 into the wire receiving slot 38 causes the wire 280 to move into the insulation stripping section 42 of the wire receiving slot 38. As this occurs, the insulation or protective coating 84 of the wire 280 engage the cutting edges 62 of the insulation stripping sections 52 of the of the insulation displacement arms 30, 32. As the width D2 of the insulation stripping section 42 is less than the width of the wires 280 to be inserted therein, and less than the width of the inner cores 282 of the wires 280, the cutting edges 62 of the insulation stripping sections 52 will cut, remove or strip the insulation or protective coating 284 of the wires 280 to expose the cores 282 in that region. As shown in
The continued insertion of the wires 280 into the wire receiving slot 38 causes the wires 280 to move into the wire termination section 44 of the wire receiving slot 38. As this occurs, the inner cores 282 which was exposed in the insulation stripping sections 52 of the of the insulation displacement arms 30, 32 mechanically and electrically engage the core engagement edges 64 of the weakened sections 54 of the insulation displacement arms 30, 32. As the width D3 of the wire termination section 44 is less than the width of the inner cores 282 of the wires 280, the core engagement edges 64 of the weakened sections 54 will frictionally engage and compress the cores 282 in that region. As the wires 280 are of a large diameter or small gauge, the weakened sections 54 of the insulation displacement arms 30, 32 is moved a greater distance in the directions of arrows A (
The insulation displacement contact 10 of the present invention allows for the termination of more than one wire or magnet wire therein and accommodates wires or magnet wires of different sizes of gauges, thereby eliminating the need for different part and part numbers for wires of different sizes of gauges.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the spirit and scope of the invention as defined in the accompanying claims. One skilled in the art will appreciate that the invention may be used with many modifications of structure, arrangement, proportions, sizes, materials and components and otherwise used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being defined by the appended claims, and not limited to the foregoing description or embodiments.