This invention relates generally to lever type wire connectors and, more specifically, to waterproof lever type wire connectors.
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Numerous types of electrical wire connectors for forming bared ends of electrical wires into a waterproof electrical connection through application of force by the user are known in the art. One type of electrical connector relies on inserting the wires into a sealant located between a terminal block and a terminal screw and then squeezing the bared ends of the wire by rotating the terminal screw. The more the user tightens the terminal screw the greater the squeezing and hence an enhanced electrical connection between the bared wire end and the terminal screw.
Another type of electrical wire connector that depends on the force applied by the user is a twist-on wire connector that can be used to form a waterproof electrical connection through rotation of the electrical wires in a spiral shape housing containing a sealant. In the twist-on wire connector, as well as the terminal connector, the more rotational force applied by the user the greater the compression of the wire ends and hence an enhanced electrical connection between the electrical wires.
Another type of electrical wire connector that depends on the force applied by the user, which is used with unstripped wires, is a cutting connector that uses two blades that slice through the insulation layer of the electrical wire and also cut into the sides of the wire, which is located in a waterproof sealant. In each of these prior connectors the electrical connection can be formed in the presence of a waterproof agent through a user generated force sufficient to negate the presence of a waterproofing and electrically insulating agent located on and between the electrical wires.
If a waterproof connection is required in other types of wire connector the conventional methods of waterproofing such wire connectors is to inject a sealant in the wire connector after the wire has been brought into electrical contact with the electrical conductor and bus strip therein. In still another method of waterproofing other types of wire connectors the entire wire connector with the electrical wires secured therein is inserted into a housing containing a sealant, which allows one to encapsulate the entire wire connector, and thereby waterproof the wire connections therein.
One of the other types of electrical connectors, which can be waterproofed by encapsulation, is the lever type wire connector. This type of connector does not rely on the force imparted by a user since a spring force holds the wires in electrical contact with a bus strip. A lever allows one to release the spring to enable the spring to form electrical contact with the electrical wire. The force of the spring is limited by the spring constant of the spring used in the wire connector. Hence the force on the electrical wire by the spring cannot be increased by the user. Consequently, the user lacks the ability to increase the force on electrical wire and thus enhance the electrical connection through use of additional user force.
Although the enhancement of force by the user cannot be used to enhance an electrical connection in the presence of a sealant the applicants have discovered that one can waterproof connections in lever type wire connectors other than through encapsulation.
A lever push-in wire connector containing a wire displaceable sealant therein to enable the formation of a waterproof electrical connection by axial insertion of the wire into a chamber contained a resilient conductor, a bus strip and a wire displaceable sealant to form a protective waterproof covering over the contact regions between conductors and releasing the lever to bring the resilient conductor into electrical contact with the wire in the presence of the sealant.
In one example a displaceable sealant is placed in the chamber in an uncured state yet when cured the wire displaceable sealant can flex sufficiently so as not to impair axial insertion of the electrical wire or the formation of an electrical connection between the wire engaging members of the lever push-in wire connector.
In another example a viscous displaceable sealant is inserted into the lever push-in wire connector.
In contrast,
In joining two wires into an electrical connection in the lever push-in wire connector 10a first bared wire end is axially inserted into the socket 11b and into engagement with a common bus strip therein to form electrical contact with the bus strip and a second bared wire end, which is to be electrically joined to the first wire, is axially inserted into the wire socket 12b and into engagement with the common bus strip in the push-in connector 10. If needed a third wire can be inserted into wire socket 13b and into engagement with the common bus strip in the push-in connector 10.
The lever push-in wire connector 10 allows one form a waterproof electrical connection in a two step process by axially inserting a wire into electrical contact with an electrical conductor in the presence of a wire displaceable sealant 20, which is also an electrical insulator, and moving the associated lever to the down position to release the spring from its compressed condition. In the example of the invention shown a wire displaceable sealant located in the chamber 19 waterproofs the resilient conductors in the chamber 19 so that the moving the lever to the down position allows the end of the resilient spring 21b to contact the electrical wire therein so an electrical connection can be made in the presence of the sealant 20 to thereby in situ form a waterproof electrical connection therein.
If desired the wire ports of connector 10 may be covered with a pierceable one-piece cover such as a pierceable film which extends over the socket to protect the sealant in the push-in wire connector 10 from accidentally contacting other items during shipping and handling.
To illustrate the operation of the lever push-in wire connector reference should be made to
The sealant 20, which is a waterproof sealant, is located in the lever push-in wire connector is characterized as a displaceable sealant that can be forcibly displaced yet remain in a water proofing condition. A wire and spring displaceable sealant is sufficiently viscous so as to be normally retainable within the lever push-in wire connector during handling and storage of the lever push-in wire connector, yet yieldable and self healing to form a waterproof covering over a wire inserted therein. An example of a type of sealant that may be used is a gel sealant although still other types of sealants such as silicone sealants that may be used.
Gel sealants are commercially available in liquid form i.e. an uncured state and are often used for vibration damping. The gel sealant, when in the liquid or uncured state, is poured or placed into the chamber 19 in the push-in connector 10 containing moveable parts such as the resilient conductor 21 and lever 11. Since the sealant is in liquid form with low viscosity the sealant 20 flows around any movable parts. Once in position the sealant sets or cures to form a waterproof sealant that has sufficient cohesiveness so as to retain itself within the housing 15 in a ready to use condition. Once cured the gel sealant is capable of yielding in response to conductor or spring movement as well as axial insertion of a wire into engagement with the conductor as well as being self healing to form a waterproof covering over an electrical connection between an electrical wire inserted between the resilient conductor and the bus strip in the lever push-in wire connector.
If one wants to ensure that no pockets of air are retained in the chamber in the lever push-in wire connector the air can be removed from the chamber 19 before injecting the sealant in the chamber 19. As an alternate method, an opening can be placed in the top portion of the housing 15 so that air is forced out as the sealant is injected therein. A further option is to have the ports extending upward as the sealant is directed into the chamber in the lever push-in wire connector so air can be forced out of the chamber as sealant is introduced therein. Sealants that can be placed in lever push-in wire connector, for example in assembled lever push-in wire connectors, can be either in liquid form or in viscous form. An example of a sealant in liquid form is a curable gel that is commercially available and generally comprises two parts that may either be mixed in the wire connector chamber or before placing the curable gel in the chamber of the lever push-in wire connector. The use of a curable gel in liquid form allows the gel, while still in the liquid state, to flow around and encapsulate or protect the wire contacting surfaces components in the chamber including the moving part or parts of the lever push-in wire connector.
Another method for introducing the sealant into an assembled or partially assembled lever push-in wire connector is to force or inject a viscous sealant into one of the ports until the sealant begins to appear in the other ports. It has been found that as the sealant 20 flows from one port to another port through the chamber the sealant flows around the wire connecting surfaces in the lever push-in wire connector. Also, in flowing from port to port air can be forced from the chambers to provide a waterproof covering around the wire connecting surfaces that contact a wire inserted therein. The method of port injection can also be used if the lever push-in wire connector contains multiple ports, in such a case the sealant may be injected or forced into one or more of the ports.
While the introduction of sealant into the lever push-in wire connector may be stopped based on a visual indication, such as the sealant becoming visible in another port, it also may be stopped based on a known volume of sealant injected into the lever push-in wire connector. Also, the amount of sealant injected into the lever push-in wire connector may vary depending on the wiring application. For example, in some applications it may be desired that sealant not extend outside the ports of the lever push-in wire connector and in other applications one may want the sealant to extend outside the ports of the lever push-in wire connectors and onto the housing. Thus one example of the invention is a lever waterproof lever push-in wire connector comprising a housing 15 having a chamber 19 therein and a pivotable lever 11 with a resilient conductor 21 located in the chamber 19 with the resilient conductor having a wire engaging edge 21c extending at least partially across a wire port 11b in the housing 15 when the wire connector is in an unlatched condition; and a wire displaceable sealant 20 located in the chamber 19 with the wire displaceable sealant waterproofing the resilient conductor 21 in the chamber so that axial insertion of a wire into the wire port 11b can extend into the sealant 20 and through an opening 21d in the resilient conductor 21 so that when the pivotable lever 11 is brought to the latched position the wire engaging edge 21c of the resilient connector 21 is brought into electrical engagement in presence of the displaceable sealant 20 to form a waterproof electrical connection between the wire and the resilient conductor 21. As can be seen in
Thus the invention includes the method of making a waterproof lever push-in wire connector without encapsulation of the entire connector and without requiring increased pressure from the user by forming a lever push-in wire connector housing having a first port 11b and a second port 12b connected to a chamber 19, placing wire connecting surfaces 21c and 22 with at least one of the wire connecting surfaces comprising a moving part in the chamber to form a lever push-in wire connector and directing a sealant 20 into the first port 11b or the second port 12b until the sealant 20 forms a protective covering over the wire connecting surfaces in the chamber.
In the method of prefilling the connector with waterproofing material one can stop directing the sealant 20 into the first port 11 prior to the sealant being forced from the second port 12 or by injecting a known volume of sealant into the first port. In an alternate method one can the forming a lever push-in wire connector by directing a liquid sealant into the first port and allowing the liquid sealant to cure therein.
This application claims priority from provisional application Ser. No. 61/135,102 filed Jul. 16, 2008 titled Lever Waterproof Wire Connector.
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Number | Date | Country | |
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Number | Date | Country | |
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61135102 | Jul 2008 | US |