Patent Application
20170003010
The subject matter herein relates generally to multiple cable disconnects.
Electrical systems, such as lighting systems, use power cables to interconnect various electrical components of the system, such as to connect a power supply to an LED driver. Some systems require powering of multiple components, such as multiple LED drivers. For example, in a street light fixture, multiple LED arrays are provided to supply the required lighting. Each LED array is controlled by a corresponding LED driver. Each LED driver needs to be separately connected to the power supply. Typically, the line input from the power supply is split from the 3 wire cable and branched out to each of the LED drivers using a wire splice component such as a wire nut. When connecting multiple branch cables to the line input cable using the wire nut, difficulties arise. For example, one or more of the wires may be improperly terminated, leading to failure of the LED driver associated with such wire. Termination using the wire nut may be time consuming and bulky. Additionally, when one of the LED drivers fails and needs to be replaced, it is not possible to simply remove the one LED driver and associated cable. Rather, all of the wires are uncoupled from the wire nut.
A need remains for a multiple cable disconnect solution that allows wires of multiple power cables to be commoned and that allows the wires to be releasable therefrom for rework.
In one embodiment, a multiple cable disconnect is provided including a housing having a separable mating end for mating with a mating connector and a wire terminating end configured to receive wires of power cables. The housing has a plurality of terminal chambers. Terminals are received in corresponding terminal chambers. The terminals each have a base, a mating contact extending from the base and a wire contact extending from the base. The mating contact has a mating pad defining a separable mating interface for the terminal for mating with a corresponding mating terminal of the mating connector. The wire contact has plural wire interfaces for mating with plural wires such that plural wires are configured to be terminated to and commoned with each terminal. Wire retention springs are received in the housing each having at least one spring arm defining a wire trap with the corresponding wire contact. The spring arms are releasable to release the wires from the housing.
In another embodiment, a cable connector assembly is provided having first and second multiple cable disconnects electrically connected together. The first and second multiple cable disconnects are identical and hermaphroditic and are inverted 180° relative to each other when coupled together. Each of the first and second multiple cable disconnects include a housing having a separable mating end for mating with a mating connector and a wire terminating end configured to receive wires of power cables. The housing has a plurality of terminal chambers. Terminals are received in corresponding terminal chambers. The terminals each have a base, a mating contact extending from the base and a wire contact extending from the base. The mating contact has a mating pad defining a separable mating interface for the terminal for mating with a corresponding mating terminal of the mating connector. The wire contact has plural wire interfaces for mating with plural wires such that plural wires are configured to be terminated to and commoned with each terminal. Wire retention springs are received in the housing each having at least one spring arm defining a wire trap with the corresponding wire contact. The spring arms are releasable to release the wires from the housing.
In a further embodiment, a lighting system is provided including a lamp assembly having plural LED arrays each being powered by a corresponding LED driver having an associated power cable extending therefrom. The lighting system includes a cable connector assembly supplying power to the power cables. The cable connector assembly includes first and second multiple cable disconnects. A plurality of the power cables are terminated to the first multiple cable disconnect. The first multiple cable disconnect includes a housing having a separable mating end for mating with a mating connector and a wire terminating end configured to receive wires of power cables. The housing has a plurality of terminal chambers. Terminals are received in corresponding terminal chambers. The terminals each have a base, a mating contact extending from the base and a wire contact extending from the base. The mating contact has a mating pad defining a separable mating interface for the terminal for mating with a corresponding mating terminal of the mating connector. The wire contact has plural wire interfaces for mating with plural wires such that plural wires are configured to be terminated to and commoned with each terminal. Wire retention springs are received in the housing each having at least one spring arm defining a wire trap with the corresponding wire contact. The spring arms are releasable to release the wires from the housing. The second multiple cable disconnect is identical to the first multiple cable disconnect. The second multiple cable disconnect is coupled to the first multiple cable disconnect. The second multiple cable disconnect is configured to have a power supply cable supply power to terminals of the second multiple cable disconnect to electrically power the terminals of the first multiple cable disconnect at separable interfaces between the terminals of the second multiple cable disconnect and the terminals of the first multiple cable disconnect.
The electrical system 100 may be used in various applications. For example, in an exemplary embodiment, the electrical system 100 is a lighting system and may be referred to hereinafter as lighting system 100. The lighting system 100 includes a lamp assembly 130 used as part of a lighting application. For example, the lamp assembly 130 may be a street light fixture or another type of lighting fixture. The electrical system 100 is not limited to a lighting system. For example, the electrical system 100 may be an HVAC unit where AC power enters the unit and may be split by the multiple cable disconnect 120 to run multiple devices of the unit, such as a fan, a control board, a humidifier, and the like. The electrical system may be another device, such as an appliance where AC power enters the appliance (for example, a washing machine) and is then split by the multiple cable disconnect to power other components, such as a motor, a control board, and the like.
The lamp assembly 130 may include one or more lighting devices, such as LED arrays 132. The LED arrays 132 are controlled by LED drivers 134. The LED arrays 132 and LED drivers 134 define various electrical components 106 of the electrical system 100 in the illustrated embodiment. The power cables 112 are electrically connected between the multiple cable disconnect 122 and the LED drivers 134. The LED drivers 134 may include circuit boards or other components. Optionally, the LED arrays 132 and LED drivers 134 may be part of a common circuit board. Alternatively, other cables or wires may extend between the LED drivers 134 and the LED arrays 132.
The lighting system 100 may be powered by a power supply 136. For example, the power cable 110 may be electrically connected between the power supply 136 and the multiple cable disconnect 120. The power supply 136 may be an AC power supply, such as from a circuit breaker. The power supply 136 may define one of the electrical components 104. The multiple cable disconnects 120, 122 may splice the power from the power supply 136 into multiple lines to multiple LED drivers 134.
Other electrical components 104, 106 may be provided in the lighting system 100 in alternative embodiments. Optionally, other power cables 110 may be electrically connected to the multiple cable disconnect 120. For example, other power cables 110 may extend from the multiple cable disconnect 120 to an LED driver or other electrical component. As such, the multiple cable disconnect 120 may operate as a splicer or pigtail connector.
In an exemplary embodiment, the multiple cable disconnects 120, 122 are hermaphroditic and oriented 180 degrees relative to each other for coupling thereto. In the description below, components or features may be described with respect to the multiple cable disconnect 120 or the multiple cable disconnect 122, however such components or features may be applicable to the other multiple cable disconnect 120, 122.
The multiple cable disconnect 120 includes a housing 140 having a separable mating end 142 for mating with a mating connector, such as the multiple cable disconnect 122. The housing 140 has a wire terminating end 144 configured to receive the wires 114 of the one or more power cables 110. Terminals 150 (
In an exemplary embodiment, the multiple cable disconnect 120 includes a latch 152 extending from a first end 154 of the housing 140 at or near the separable mating end 142. The housing 140 includes a catch 156 extending from a second end 158 opposite the first end 154 at or near the separable mating end 142. In the illustrated embodiment, the first end 154 defines a bottom end of the multiple cable disconnect 120 and the second end 158 defines a top end of the multiple cable disconnect 120, while the first end 154 defines a top end of the second multiple cable disconnect 122 and the second end 158 defines a bottom end of the second multiple cable disconnect 122. Optionally, the latch 152 may include a latch release 160 for releasing the latch 152 from the catch 156 of the multiple cable disconnect 122. The latch 152 is deflectable to release and uncouple the multiple cable disconnects 120, 122. The latch 152 may have a ramped lead-in surface to guide mating of the latch 152 with the catch 156 of the other multiple cable disconnect 122.
Optionally, the multiple cable disconnect 120 may have keying features 162, 164 for keyed mating of the multiple cable disconnect 120 with the multiple cable disconnect 122. For example, in the illustrated embodiment, the keying feature 162 is a slot and the keying feature 164 is a tab or protrusion configured to be received in the keying feature 162. Other types of keying features may be provided in alternative embodiments. Other multiple cable disconnects may have keying features in other locations for keyed mating with the corresponding multiple cable disconnect.
The front housing 170 has a plurality of terminal chambers 174 that receive corresponding terminals 150. The terminal chambers 174 may be open at the rear end of the front housing 170 and the terminals 150 may be loaded into the terminal chambers 174 through the open rear end. Separating walls 176 separate the terminal chambers 174. The separating walls 176 may electrically isolate the terminals 150 from each other. The separating walls 176 may define a mounting structure for the terminals 150 to mount and secure the terminals 150 in the front housing 170.
The wire holder 172 includes a base 180 that may be coupled to the front housing 170. The wire holder 172 includes a plurality of wire bores 182 extending therethough. The wire bores 182 are configured to receive corresponding wires 114 and may guide the wires 114 into electrical connection with the corresponding terminals 150 when the wires 114 are poked in to the wire bores 182.
The terminals 150 each have a base 200, a mating contact 202 extending from the base 200 and a wire contact 204 extending from the base 200 opposite the mating contact 202. In the illustrated embodiment, the mating contact 202 is oriented generally horizontally extending forward of the base 200. The mating contact 202 has a mating pad 206 defining a separable mating interface 208 for the terminal 150 for mating with the corresponding mating terminal 150 of the multiple cable disconnect 122 (shown in
The wire contact 204 has plural wire interfaces 212 for mating with plural wires 114 of different power cables 110, 112 such that plural wires 114 are configured to be terminated to and commoned with each terminal 150. Optionally, the wire contact 204 may include one or more tabs 214, each defining one or more wire interfaces 212. Optionally, the tabs 214 may be bent in different directions. In the illustrated embodiment, the tabs 214 of the wire contacts 204 are oriented vertically and are configured to be loaded into corresponding terminal chambers 174 for mating with the wires 114. As such, the wire contacts 204 of the terminals 150 are arranged vertically and are stacked within the housing 140. Each terminal 150 is configured to be electrically connected to a different wire 114 of each of the power cables 110 (or 112) poked in to the wire terminating end 144 of the housing 140. The wire interfaces 212 are arranged at different vertical heights along the wire contact 204 for electrical connection to different wires 114 of different power cables 110 (or 112). For example, the wire interfaces 212 may be aligned with corresponding wire bores 182 at different vertical heights along the wire contact 204.
In an exemplary embodiment, the multiple cable disconnect 120 includes wire retention springs 220 configured to be received in the front housing 170. The wire retention spring 220 are used in association with corresponding terminals 150. The wire retention springs 220 and the terminals 150 define wire traps for trapping corresponding wires 114 in the multiple cable disconnect 120. For example, the wires 114 may be poked in to corresponding wire bores 182 and pinched or sandwiched between the wire retention spring 220 and the corresponding terminal 150 to create an electrical connection between the wire 114 and the terminal 150.
In the illustrated embodiment, the wire retention spring 220 is a separate component from the terminal 150 and includes a base 222 and one or more spring arms 224. Alternatively, the wire retention spring 220 may be integral with the terminal 150, such as being stamped and formed from the terminal 150. In the illustrated embodiment, each wire retention spring 220 includes a plurality of spring arms 224, with each spring arm 224 being associated with a corresponding wire bore 182 and configured to receive a different wire 114. Alternatively, multiple wire retention springs may be provided and associated with each terminal 150, where each wire retention spring includes a single spring arm. Having the wire retentions springs 220 separate from the terminal 150 allows the wire retention spring 220 to be manufactured from a different type of material as compared to the terminal 150. For example, the terminal 150 may be manufactured from a material having characteristics of good electrical conductivity, such as copper, whereas the wire retention spring 220 may be manufactured from a material having a characteristic of good mechanical integrity or spring force, such as stainless steel. The spring arms 224 include edges 226 that are used to pinch the wire 114 and hold the wire 114 in the multiple cable disconnect 120. A wire trap may be defined between the edge 226 of the spring arm 224 and the wire interface 212 of the wire contact 204.
With additional reference back to
The contact holders 240 each have a front end 244, sides 246, 248 extending rearward from the front end 244, an outer end 250 extending rearward from the front end 244 between the sides 246, 248 and an inner end 252 opposite the outer end 250. The inner end 252 faces the corresponding hood 242. The inner end 252 may have an opening and the mating pad 206 may be exposed within the opening at the inner end 252. Gaps 254 are provided between adjacent contact holders 240. The sides 246, 248 face each other across the gaps 254.
The hoods 242 have a plurality of walls defining pockets 260. The pockets 260 are sized, shaped, and positioned to receive the contact holders 240 of the second multiple cable disconnect 122 when the multiple cable disconnects 120, 122 are coupled together. For example, the pockets 260 may have a volume slightly larger than a volume of the contact holders 240 (e.g. height, length, width). The pocket 260 is defined by side walls 262 extending rearward from a front end 264 of the hood 242. The hood 242 has an outer end 266 extending between the side walls 262 opposite the contact holder 240. The hood 242 is open along the inner end to expose the mating contact 202. In an exemplary embodiment, the side walls 262 are aligned with the gaps 254 and the contact holder 240 are aligned with the pockets 260. For example, in the illustrated embodiment, the contact holders 240 are positioned below the pockets 260 of the corresponding hoods 242.
The second multiple cable disconnect 122 is inverted 180 degrees such that the contact holders 240 of the second multiple cable disconnect 122 are positioned above the hoods 242 and corresponding pockets 260. When the second multiple cable disconnect 122 is coupled to the first multiple cable disconnect 120, the pockets 260 of the hoods 242 receive corresponding contact holders 240 and the mating contacts 202 of the terminals 150 are electrically connected together.
The multiple cable disconnects 120, 122 have a hermaphroditic mating interface defined by the contact holders 240 and the hoods 242. Optionally, the contact holders 240 and the hoods 242 at the front ends 244, 264 may be chamfered or have lead-in surfaces for guiding mating of the multiple cable disconnects 120, 122. The keying features 162, 164 are provided on the hoods 242 and contact holder 240 respectively.
The spring arms 210 of the mating contacts 202 engage the contact holders 240 to spring bias the mating pads 206 outward toward each other to spring bias the terminals 150 of the multiple cable disconnects 120, 122 into electrical engagement with each other. Optionally, the spring arms 210 may be at least partially compressed or deflected when mated to ensure that the mating pads 206 are spring biased against each other.
In an exemplary embodiment, the wires 114 are releasable from the multiple cable disconnect 120, such as to rework or rewire the multiple cable disconnect 120. In an exemplary embodiment, the wire holder 172 includes wire release slots 270 that may receive a tool to release the wires 114 from the wire bores 182 and the wire traps inside the multiple cable disconnect 120. Optionally, each wire 114 may be individually released, and as such, some of the wires 114 may be unreleased while other wires 114 are released for rework or rewiring.
The wire 114 is prepared for connection to the multiple cable disconnect 120 by stripping the end of the wire and removing a portion of a jacket 280 of the wire 114 to expose a conductor 282 of the wire 114. The conductor 282 may be a solid conductor or may be a stranded conductor. The wire bore 182 is sized to receive the conductor 282 and may be sized to receive the jacket 280. The wire bore 182 may include a wire guide 290 for guiding the wire 114 into the multiple cable disconnect 120.
The wire 114 is loaded into the wire bore 182 (
The wire 114 may be released (
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. §112(f), unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
