Abstract:
A compression connector for securing wires therein is disclosed. The compression connector has a first body portion including a first hook and a first ramp extending therefrom to form a first main wire port. The first body portion also has a second hook and a second ramp extending therefrom to form a first tap wire port. The first body portion further has a second tap wire port and a third tap wire port positioned between the first main wire port and the first tap wire port.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims priority to U.S. Provisional Application Ser. No. 60/518,117, filed on Nov. 7, 2003, the entirety of which is hereby incorporated by reference.  
         [0002]     This application is related to U.S. application Ser. No. 10/699,691, filed on Sep. 24, 2003, the entirety of which is hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0003]     The present invention is directed to multi-port compression connectors and, more particularly, to split multi-port compression connectors that can accommodate different size main run and tap wires.  
         [0004]     Examples of multi-port compression connectors can be found in the following U.S. Pat. Nos. 2,956,108; 5,103,068; 5,200,576; 6,452,103; 6,486,403; 6,525,270; 6,538,204; and 6,552,271. However, none of these prior art compression connectors have two small tap wire ports positioned between a main wire port and a large tap wire port.  
       SUMMARY OF THE INVENTION  
       [0005]     It would be desirable to provide a multi-port compression connector having increased wire pullout strength.  
         [0006]     It would also be desirable to provide a multi-port compression connector having improved retention of tap wires before and during the crimping operation.  
         [0007]     It would further be desirable to provide a multi-port compression connector having two small tap wire ports positioned between a main wire port and a large tap wire port.  
         [0008]     A compression connector for securing wires therein is disclosed. The compression connector has a first body portion including a first hook and a first ramp extending therefrom to form a first main wire port. The first body portion also has a second hook and a second ramp extending therefrom to form a first tap wire port. The first body portion further has a second tap wire port and a third tap wire port positioned between the first main wire port and the first tap wire port.  
         [0009]     Preferably, the first tap wire port is larger than the second tap wire port and the third tap wire port, and the second tap wire port is larger than the third tap wire port. Alternatively, the second tap wire port and the third tap wire port are substantially the same size. Moreover, the second tap wire port and the third tap wire port are teardrop-shaped.  
         [0010]     Preferably, the first body portion includes a bump extending from a back side of the second hook. The first body portion further includes a notch and a tab adjacent either the second tap wire port or the third tap wire port. Alternatively, the first body portion includes an aperture adjacent either the second tap wire port or the third tap wire port. Additionally, the second tap wire port or the third tap wire port includes a blend.  
         [0011]     Preferably, the compression connector includes a second body portion connected to the first body portion. The second body portion includes a third hook and a third ramp extending therefrom to form a second main wire port. The second body portion also includes a fourth hook and a fourth ramp extending therefrom to form a fourth tap wire port. Additionally, the second body portion includes a fifth tap wire port and a sixth tap wire port positioned between the second main wire port and the fourth tap wire port.  
     
    
     BRIEF DESCRIPTION OF FIGURES  
       [0012]      FIG. 1  is a left front perspective view of a compression connector according to a first embodiment of the present invention, shown secured around main line wires after crimping three different sized tap wires;  
         [0013]      FIG. 2  is a left front perspective view of the compression connector of  FIG. 1 ;  
         [0014]      FIG. 3  is a right side perspective view of the compression connector of  FIG. 1 ;  
         [0015]      FIG. 4  is a front view of the compression connector of  FIG. 1 ;  
         [0016]      FIG. 5  is a right side view of the compression connector of  FIG. 1 ;  
         [0017]      FIG. 6  is a left side view of the compression connector of  FIG. 1 ;  
         [0018]      FIG. 7  is a cross-sectional view taken along lines  7 - 7  of  FIG. 6 ;  
         [0019]      FIG. 8  is a front view of the compression connector of  FIG. 1 , after crimping three different sized tap wires;  
         [0020]      FIG. 9  is a left front perspective view of a compression connector according to a second embodiment of the present invention;  
         [0021]      FIG. 10  is a right side perspective view of the compression connector of  FIG. 9 ;  
         [0022]      FIG. 11  is a left side view of the compression connector of  FIG. 9 ;  
         [0023]      FIG. 12  is a cross-sectional view taken along lines  12 - 12  of  FIG. 11 ;  
         [0024]      FIG. 13  is a left front perspective view of a compression connector according to a third embodiment of the present invention;  
         [0025]      FIG. 14  is a right side perspective view of the compression connector of  FIG. 13 ;  
         [0026]      FIG. 15  is a left side view of the compression connector of  FIG. 13 ;  
         [0027]      FIG. 16  is a cross-sectional view taken along lines  16 - 16  of  FIG. 15 ;  
         [0028]      FIG. 17  is a left front perspective view of a compression connector according to a fourth embodiment of the present invention;  
         [0029]      FIG. 18  is a right side perspective view of the compression connector of  FIG. 17 ;  
         [0030]      FIG. 19  is a left side view of the compression connector of  FIG. 17 ;  
         [0031]      FIG. 20  is a cross-sectional view taken along lines  20 - 20  of  FIG. 19 ;  
         [0032]      FIG. 21  is a left front perspective view of a compression connector according to a fifth embodiment of the present invention;  
         [0033]      FIG. 22  is a right side perspective view of the compression connector of  FIG. 21 ;  
         [0034]      FIG. 23  is a left side view of the compression connector of  FIG. 21 ;  
         [0035]      FIG. 24  is a cross-sectional view taken along lines  24 - 24  of  FIG. 23 ;  
         [0036]      FIG. 25  is a left front perspective view of a compression connector according to a sixth embodiment of the present invention;  
         [0037]      FIG. 26  is a right side perspective view of the compression connector of  FIG. 25 ;  
         [0038]      FIG. 27  is a left side view of the compression connector of  FIG. 25 ;  
         [0039]      FIG. 28  is a cross-sectional view taken along lines  28 - 28  of  FIG. 27 ;  
         [0040]      FIG. 29  is a left front perspective view of a compression connector according to a seventh embodiment of the present invention;  
         [0041]      FIG. 30  is a right side perspective view of the compression connector of  FIG. 29 ;  
         [0042]      FIG. 31  is a left side view of the compression connector of  FIG. 29 ;  
         [0043]      FIG. 32  is a cross-sectional view taken along lines  32 - 32  of  FIG. 31 ;  
         [0044]      FIG. 33  is a left front perspective view of a compression connector according to an eighth embodiment of the present invention, shown secured around main line wires after crimping two different sized tap wires;  
         [0045]      FIG. 34  is a left front perspective view of the compression connector of  FIG. 33 ;  
         [0046]      FIG. 35  is a right side perspective view of the compression connector of  FIG. 33 ;  
         [0047]      FIG. 36  is a front view of the compression connector of  FIG. 33 ;  
         [0048]      FIG. 37  is a right side view of the compression connector of  FIG. 33 ;  
         [0049]      FIG. 38  is a left side view of the compression connector of  FIG. 33 ;  
         [0050]      FIG. 39  is a cross-sectional view taken along lines  39 - 39  of  FIG. 38 ;  
         [0051]      FIG. 40  is a front view of the compression connector of  FIG. 33 , after crimping two different sizes tap wires;  
         [0052]      FIG. 41  is a left front perspective view of a compression connector according to a ninth embodiment of the present invention;  
         [0053]      FIG. 42  is a right side perspective view of the compression connector of  FIG. 41 ;  
         [0054]      FIG. 43  is a left side view of the compression connector of  FIG. 41 ; and  
         [0055]      FIG. 44  is a cross-sectional view taken along lines  44 - 44  of  FIG. 43 . 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0056]     The illustrated embodiments of the invention are directed to split multi-port compression connectors having range-taking ports for multiple wires, usually main run wires and two or more tap wires. Each of the compression connector ports accepts a range of wire sizes falling within certain limits, and the range may be different for each port.  FIGS. 1-8  are directed to compression connector  50 ,  FIGS. 9-12  are directed to compression connector  150 ,  FIGS. 13-16  are directed to compression connector  250 ,  FIGS. 17-20  are directed to compression connector  350 ,  FIGS. 21-24  are directed to compression connector  450 ,  FIGS. 25-28  are directed to compression connector  550 ,  FIGS. 29-32  are directed to compression connector  650 ,  FIGS. 33-40  are directed to compression connector  750 , and  FIGS. 41-44  are directed to compression connector  850 .  
         [0057]      FIG. 1  shows a split multi-port compression connector  50  secured around main line wires  52  and tap wires  54 ,  56 ,  58 , after crimping. Preferably, compression connector  50  is a one-piece member made of electrically conductive material, such as copper. However, it is likewise contemplated that compression connector  50  may be made of any suitable materials or elements that will withstand a crimping operation.  
         [0058]     As shown in  FIGS. 2-7 , compression connector  50  has a first section  60  and a second section  62 . As best seen in  FIG. 4 , first section  60  includes body portion  64  having a hook  66  and a ramp  68  extending therefrom to form main wire port  70  in which main line wires  52  can be placed. Preferably, hook  66  is C-shaped. As shown in  FIG. 8 , when the crimping dies close on compression connector  50 , hook  66  wraps around main line wires  52  and against the outside of ramp  68 , to provide a continuous contact surface along substantially the entire circumference of main line wires  52 . Although  FIG. 8  shows compression connector  50  crimped with hook  66  locking against the outside of ramp  68 , it is likewise contemplated that compression connector  50  may be crimped with hook  66  locking against the inside of ramp  68 .  
         [0059]     As best seen in  FIG. 4 , first section  60  has a tap wire port  72  extending from body portion  64 . Preferably, tap wire port  72  is substantially oval, with one end slightly narrower than the other. Narrow end  74  nests tap wires  54  before crimping and is pointed inward and towards the top of compression connector  50 . Ramp  76  extends from narrower end  74  toward the bottom of compression connector  50 . The wider end of tap wire port  72  is pointed downward and is enclosed by hook  78  that comprises the bottom of compression connector  50 . Hooks  66 ,  78  provide two contact points with the crimping dies (not shown) prior to crimping. Bump  80  extends from the back of hook  78 , but does not come into contact with the crimping dies prior to crimping. Bump  80  provides an additional pressure point during the later phase of the crimping process, which results in less distortion of the crimped wires than in prior art compression connectors.  
         [0060]     As best seen in  FIG. 4 , first section  60  has two non-planar and non-parallel sides, each comprising one or more curved segments and separated by slots  82 ,  84  extending from tap wire ports  86 ,  88 , respectively. The compression connector sides are both curved, slightly offset, and tilted with respect to one another, such that the configuration compensates for connector distortion during the crimping process and, thus, results in less shape irregularities in the crimped connector. Preferably, tap wire ports  86 ,  88  are teardrop or diamond shaped and are located at the middle portion of compression connector  50 . Although, as shown in  FIGS. 1-8 , tap wire ports  86 ,  88  are different sizes, it is likewise contemplated that tap wire ports  86 ,  88  can be the same size.  
         [0061]     Second section  62  is identical to first section  60 . Accordingly, the same numerals utilized to describe first section  60  will be utilized to describe second section  62 , with the addition of the prime (′) notation. As best seen in  FIG. 7 , second section  62  includes body portion  64 ′ having a hook  66 ′ and a ramp  68 ′ extending therefrom to form main wire port  70 ′ in which main line wires  52  can be placed. Preferably, hook  66 ′ is C-shaped. As shown in  FIG. 1 , when the crimping dies close on compression connector  50 , hook  66 ′ wraps around main line wires  52  and against the outside of ramp  68 ′, to provide a continuous contact surface along substantially the entire circumference of main line wires  52 . Although  FIG. 1  shows compression connector  50  crimped with hook  66 ′ locking against the outside of ramp  68 ′, it is likewise contemplated that compression connector  50  may be crimped with hook  66 ′ locking against the inside of ramp  68 ′.  
         [0062]     As best seen in  FIG. 7 , second section  62  has a tap wire port  72 ′ extending from body portion  64 ′. Preferably, tap wire port  72 ′ is substantially oval, with one end slightly narrower than the other. Narrow end  74 ′ nests tap wires  54  before crimping and is pointed inward and toward the top of compression connector  50 . Ramp  76 ′ extends from narrower end  74 ′ toward the bottom of compression connector  50 . The wider end of tap wire port  72 ′ is pointed downward and is enclosed by hook  78 ′ that comprises the bottom of compression connector  50 . Hooks  66 ′,  78 ′ provide two contact points with the crimping dies (not shown) prior to crimping. Bump  80 ′ extends from the back of hook  78 ′, but does not come in contact with the crimping dies prior to crimping. Bump  80 ′ provides an additional pressure point during the later phase of the crimping process, which results in less distortion of the crimped wires than in prior art compression connectors.  
         [0063]     As best seen in  FIG. 7 , second section  62  has two non-planar and non-parallel sides, each comprising one or more curved segments and separated by slots  82 ′,  84 ′ extending from tap wire ports  86 ′,  88 ′, respectively. The compression connector sides are both curved, slightly offset, and tilted with respect to one another, such that the configuration compensates for connector distortion during the crimping process and, thus, results in less shape irregularities in the crimped connector. Preferably, tap wire ports  86 ′,  88 ′ are located at the middle portion of compression connector  50 . Although, as shown in  FIGS. 1-8 , tap wire ports  86 ′,  88 ′ are different sizes, it is likewise contemplated that tap wire ports  86 ′,  88 ′ can be the same size. As shown in  FIGS. 5 and 6 , central body portion  90  connects body portion  64  and body portion  64 ′.  
         [0064]     As best seen in  FIGS. 5 and 6 , compression connector  50  includes four slots  92 ,  94 ,  96 ,  98  cut through compression connector  50 . Slots  92 ,  94 ,  96 ,  98  provide space to loop a cable tie (not shown) to secure main line wires  52  and tap wires  54 ,  56 ,  58  to compression connector  50  before crimping, as disclosed in co-pending U.S. Ser. No. 10/668,847, the disclosure of which is incorporated by reference in its entirety. Although  FIGS. 1-8  show compression connector  50  having slots  92 ,  94 ,  96 ,  98 , it is likewise contemplated that compression connector  50  may not have any slots.  
         [0065]     A second embodiment of the present invention is illustrated in  FIGS. 9-12 . As shown in  FIGS. 9-12 , a split multi-port compression connector  150  is substantially the same as compression connector  50  illustrated in  FIGS. 1-8 , except that hooks  66 ,  78  are facing opposite sides of compression connector  150 . Likewise, hooks  66 ′,  78 ′ are facing opposite sides of compression connector  150 . As a result, tap wire ports  86 ,  88  are on opposite sides of compression connector  150 . Likewise, tap wire ports  86 ′,  88 ′ are on opposite sides of compression connector  150 . However, compression connector  150  functions similarly to compression connector  50  illustrated in  FIGS. 1-8 .  
         [0066]     A third embodiment of the present invention is illustrated in  FIGS. 13-16 . As shown in  FIGS. 13-16 , a split multi-tap compression connector  250  is substantially the same as compression connector  150  illustrated in  FIGS. 9-12 , with the addition of a notch  252  and a tab  254  at the smallest wire port entrance. The addition of notch  252  and tab  254  increases the pullout force of extremely small wires crimped in one of the range-taking ports. Upon crimping, tab  254  yields under the pressure exerted by the opposite sides of the wire port entrance and is pushed into notch  252  with little resistance and, thus, results in a tighter collapse of the entire wire port. Although notch  252  and tab  254  are shown below the smallest port entrance, it is likewise contemplated that notch  252  and tab  254  may be positioned above the smallest port entrance.  
         [0067]     Moreover, as best seen in  FIG. 13 , a blend  256  is added to the smallest wire port to improve the overall quality of the wire crimp. Rounded edges on both sides of compression connector  250  prevent nicking of the crimped wires by sharp edges in the port, which is advantageous for ports that accept extremely small wire sizes. However, compression connector  250  functions similarly to compression connector  150  illustrated in  FIGS. 9-12 .  
         [0068]     A fourth embodiment of the present invention is illustrated in  FIGS. 17-20 . As shown in  FIGS. 17-20 , a split multi-tap compression connector  350  is substantially the same as compression connector  250  illustrated in  FIGS. 13-16 , except that hole  352  has replaced notch  252  and tab  254 . When compression connector  350  is crimped, hole  352  collapses under pressure exerted by the opposite sides of the wire port entrance. Thus, the entire port collapses tighter on the crimped wire and holds the wire more securely. However, compression connector  350  functions similarly to compression connector  250  illustrated in  FIGS. 13-16 .  
         [0069]     A fifth embodiment of the present invention is illustrated in  FIGS. 21-24 . As shown in  FIGS. 21-24 , a split multi-tap compression connector  450  is substantially the same as compression connector  50  illustrated in  FIGS. 1-8 , except that tap wire ports  88 ,  88 ′ are opposite tap wire ports  86 ,  86 ′. Moreover, notch  452  and tab  454  have been positioned above tap wire port  88 . However, compression connector  450  functions similarly to compression connector  50  illustrated in  FIGS. 1-8 .  
         [0070]     A sixth embodiment of the present invention is illustrated in  FIGS. 25-28 . As shown in  FIGS. 25-28 , a split multi-tap compression connector  550  is substantially the same as compression connector  50  illustrated in  FIGS. 1-8 , except that tap wire ports  88 ,  88 ′ are positioned below tap wire ports  86 ,  86 ′. However, compression connector  550  functions similarly to compression connector  50  illustrated in  FIGS. 1-8 .  
         [0071]     A seventh embodiment of the present invention is illustrated in  FIGS. 29-32 . As shown in  FIGS. 29-32 , a split multi-tap compression connector  650  is substantially the same as compression connector  550  illustrated in  FIGS. 25-28 , except that tap wire ports  86 ,  86 ′,  88 ,  88 ′ are on the opposite side of the compression connector. However, compression connector  650  functions similarly to compression connector  550  illustrated in  FIGS. 25-28 .  
         [0072]     An eighth embodiment of the present invention is illustrated in  FIGS. 33-40 . As shown in  FIGS. 33-40 , a split multi-tap compression connector  750  is substantially the same as compression connector  50  illustrated in  FIGS. 1-8 , except that tap wire ports  88 ,  88 ′ have been removed from compression connector  50 . Compression connector  750  is utilized to accommodate large size wires. However, compression connector  750  functions similarly to compression connector  50  illustrated in  FIGS. 1-8 .  
         [0073]     A ninth embodiment of the present invention is illustrated in  FIGS. 41-44 . As shown in  FIGS. 41-44 , a split multi-tap compression connector  850  is substantially the same as compression connector  750  illustrated in  FIGS. 33-40 , except that tap wire ports  86 ,  86 ′ have been positioned on the opposite side of the compression connector. However, compression connector  850  functions similarly to compression connector  750  illustrated in  FIGS. 33-40 .  
         [0074]     The disclosed invention provides split multi-port compression connectors having improved retention of tap wires before and during the crimping operation. It should be noted that the above-described illustrated embodiments and preferred embodiments of the invention are not an exhaustive listing of the form such a compression connector in accordance with the invention might take; rather, they serve as exemplary and illustrative of embodiments of the invention as presently understood. By way of example, and without limitation, a compression connector having more than three tap wire ports is contemplated to be within the scope of the invention. Many other forms of the invention are believed to exist.