Electrical connector apparatus and cover therefor

An electrical connector apparatus includes an electrically insulating base, and a conductor extending through the base. The conductor may include a first electrical terminal located on a first side of the base and a second electrical terminal located on a second side of the base. The apparatus further includes at least three spaced apart guides on the first side of the base, all of the spaced apart guides being adjacent the first electrical terminal and being operable to guide a wire terminated to the first electrical terminal to extend in any direction between two adjacent guides. A cover may be applied to the electrical connector, the cover including a housing including joined rigid wall portions configured to extend about a perimeter and over a top of an electrical terminal, at least one of the wall portions having a conductor opening. The cover apparatus further includes a conductor guard having a rigid guide wall extending from at least one of the wall portions, adjacent the conductor opening, to guard a wire terminated to the electrical terminal against small-radius bends near the electrical terminal.

BACKGROUND OF THE INVENTION

1. Field of Invention

This invention relates to electrical connector apparatus and covers therefor.

2. Description of Related Art

Methods for terminating an electrical conductor abound. One common method involves the use of a screw terminal. Various types of screw terminals exist including barrier-type screw terminals that employ a row of screw terminals each of which is separated from an adjacent one by a barrier. The barriers tend to define a particular direction in which a wire or crimp connector may be installed on the screw terminal. Typically they permit a crimp connector or wire to be installed in only two directions, each about 180 degrees apart from the other. This can be limiting, especially where high current DC cables, for example are to be connected to the screw terminal.

Lead acid-type batteries typically have terminals which may include a conductive disk with a threaded stud projecting therefrom. The stud however is susceptible to being broken off due to excessive tightening torque, requiring replacement of the terminal or replacement of the battery. Typically this type of terminal is molded into a battery casing and is not easily removed.

SUMMARY OF THE INVENTION

The present invention provides a way of fastening electrical conductors, particularly relatively high current electrical conductors to a device having an internal printed circuit board, without placing strain on the printed circuit board, while providing an easy way of mounting a connector to the device. The invention need not be employed in this specific application and may be used generally anywhere a connector is required to connect one wire to another, especially on a device, where the two wires may be on opposite sides of a wall, barrier or bulkhead of the device.

In accordance with one aspect of the invention, there is provided an electrical connector apparatus. The electrical connector apparatus includes an electrically insulating base, and a conductor extending through the base. The conductor may include a first electrical terminal located on a first side of the base and a second electrical terminal located on a second side of the base. The apparatus may further include at least three spaced apart guides on the first side of the base, all of the spaced apart guides being adjacent the first electrical terminal and being operable to guide a wire terminated to the first electrical terminal to extend in any direction between two adjacent guides.

The first and second sides of the base may be on opposite sides of the base. The first electrical terminal may include a first threaded opening in the conductor. The second electrical terminal may include a second threaded opening in the conductor. The first and second threaded openings may be coterminous and form a threaded passageway through the conductor. The first and second threaded openings may be coaxial. The base may be molded about the conductor.

The base may include a mounting portion. The mounting portion may include a flat surface on the second side of the base. The flat surface may have threaded inserts disposed therein, for receiving fasteners for fastening the base to a device. The base may include a projection extending from the flat surface. The flat surface may have threaded inserts disposed therein and symmetrically about the projection. The flat surface may have an o-ring groove extending around the projection for receiving an o-ring for sealing the connector against a mounting surface.

The base may include a stage portion on the first side of the base. The spaced apart guides may be disposed about the stage portion. The base may include bridging surface portions extending between the guides, adjacent the stage portion. The base may include a first opening in the stage portion that extends to a cavity in the base. The base may further include a second opening in a distal end of the projection extending to the cavity. The conductor may include a rotation preventer operable to prevent rotation of the conductor relative to the base. The rotation preventer may include a flat surface on the conductor. The rotation preventer may be in the cavity.

The conductor may have first and second end portions with first and second distal surfaces respectively, and a length, measured between the first and second distal surfaces, that is slightly longer than the bore such that the first and second end portions project slightly beyond the distal ends of the projection and the stage portion.

The conductor may have first and second coterminous openings in the first and second distal surfaces respectively, forming a passageway through the conductor. The first and second coterminous openings and the passageway may be coaxial.

The first and second coterminous openings and the passageway may be threaded for receiving first and second bolts in the first and second openings respectively, for securing connectors on respective wires to the first and second electrical terminals respectively.

The guides may have respective flat planar distal end surfaces and the flat planar distal end surfaces may be disposed at a distance from the stage portion. The flat planar distal end surfaces may be coplanar. The guides may have respective threaded inserts in respective flat planar distal end surfaces, the threaded inserts being operable to receive fasteners for fastening a cover to the base.

The apparatus may further include a cover apparatus including a housing including joined rigid wall portions configured to extend about a perimeter and over a top of an electrical terminal, at least one of the wall portions having a conductor opening, the cover apparatus further including a conductor guard comprising a rigid guide wall extending from at least one of the wall portions, adjacent the conductor opening, to guard a wire terminated to the electrical terminal against small-radius bends near the electrical terminal.

In accordance with another aspect of the invention, there is provided a cover apparatus for covering an electrical terminal. The cover apparatus includes a housing including joined rigid wall portions configured to extend about a perimeter and over a top of an electrical terminal, at least one of the wall portions having a conductor opening. The cover apparatus further includes a conductor guard having a rigid guide wall extending from at least one of the wall portions, adjacent the conductor opening, to guard a wire terminated to the electrical terminal against small-radius bends near the electrical terminal.

The rigid guide wall may have an outwardly flared shape.

The wall portions and the rigid guide wall may be embodied in a unitary piece of insulating material.

The insulating material may include plastic.

At least one of the wall portions may have a landing formed therein, the landing having an opening, for receiving a fastener for securing the cover to the electrical terminal.

At least one of the wall portions may be curved and may be configured to extend over the top portion of the electrical terminal.

At least one of the wall portions may be curved and may be positioned opposite the wall portion having a conductor opening.

The wall portion extending over the top portion of the electrical terminal and the wall portion positioned opposite the wall portion having the conductor opening may be joined by an angled wall portion.

At least one of the wall portions may have a test probe opening operable to receive a test probe to permit contacting the test probe with the electrical terminal without requiring removal of the cover from the electrical terminal.

At least one of the wall portions may be curved and may be configured to extend over the top portion of the electrical terminal and may have a test probe opening operable to receive a test probe to permit contacting the test probe with the electrical terminal without requiring removal of the cover from the electrical terminal.

The wall portions configured to extend about a perimeter the electrical terminal may have edges that lie in a common plane. The rigid guide wall may be generally U-shaped and may have first and second leg portions having edges lying in the common plane. The rigid guide wall may include a curved joining portion joining the first and second leg portions, the curved joining portion having a radius of curvature becoming progressively larger progressively farther away from the housing.

DETAILED DESCRIPTION

Referring toFIG. 1, an electrical connector apparatus according to a first embodiment of the invention is shown generally at10. The apparatus includes an electrically insulating base12, a conductor14extending through the base and having a first electrical terminal16located on a first side18of the base. Referring toFIG. 3, the conductor14further includes a second electrical terminal20located on a second side22of the base12, opposite the first side18.

Referring back toFIG. 1, the apparatus10includes at least three spaced apart guides on the first side of the base12and in the embodiment shown there are four spaced apart guides identified as first, second, third and fourth guides30,32,34, and36. All of the spaced apart guides30,32,34,36are adjacent the first electrical terminal16and are operable to guide a wire108terminated to the first electrical terminal16to extend in a sector39between two adjacent guides. Each of the guides30,32,34and36has an outer, distal surface31,33,35and37, and may be fitted with a respective threaded insert51,53,55and57in its respective distal surface. The guides confine the movement of the wire108connected to the first electrical terminal16to cause it to extend from the first electrical terminal in a direction defined between adjacent guides such as guides34and36as shown.

Referring toFIG. 5, the apparatus10may be mounted to an outside of a device40such as an inverter, for example, with fasteners41for holding the apparatus10being installed from an inside area43of the device, so that the fasteners cannot be seen or accessed from the outside of the device.

Referring toFIGS. 1–4, the base12further includes a mounting portion50, a projection52, and a raised stage portion54seen best inFIGS. 1–3. In the embodiment shown, the mounting portion50includes a wall56having a generally rectangular outer perimeter although the outer perimeter may be any suitable shape. The wall56defines the first and second opposite sides18and22of the base12.

On the first side18of the base12, the guides30,32,34,36project from the wall56and the wall has generally coplanar bridging surface portions62,64,66and68that extend between successive guides. The raised stage portion54projects outwardly of the bridging surface portions62,64,66and68by about 1 mm and defines a relatively flat planar area70surrounded by the guides and bridging surface portions62,64,66and68. A first cylindrical opening72is formed in the flat planar area70and extends in a first direction to a cavity71. A second cylindrical opening74in a distal end76of the projection52extends in a second, opposite direction, into the cavity.

On the second side22of the base12, the wall56has a first flat mounting surface58having a central axis60. Threaded inserts61,63,65and67are installed symmetrically about the central axis60in the flat mounting surface58. The projection52has a cylindrical shape and extends outwardly from the first flat mounting surface58and is centered on the central axis60. The flat mounting surface58has an o-ring groove59therein for receiving an o-ring for sealing the connector against a mounting surface of a device such as device40.

In the embodiment shown, the conductor14is provided by a brass member that extends through the base12, from the first side18to the second side22. The conductor14has a section78having a rotation preventer, which in the embodiment shown includes at least one flat surface79that is received in the cavity71to hold it against rotation relative to the base12. The conductor14also has first and second end portions80and82extending in opposite directions from the section78. In the embodiment shown, the section78has a flat surface79to prevent relative rotation between the conductor14and the base12. In general, any method of preventing such relative rotation would work, including simple projections extending from the conductor14into the base12or flat surfaces on portions of the end portions80and82that are embedded within the base, for example. It will be appreciated that the cavity71and openings72and74need not be pre-formed in the base12, but rather may be formed by molding the base around the conductor14. Pre-forming of the cavity71and openings72and74may be required where the base is formed in two halves that are joined together about the conductor14, for example.

The first and second end portions80and82of the conductor14are dimensional to project slightly beyond a distal surface of the raised stage portion54and a distal surface of the projection52. The first and second end portions80and82have first and second generally flat distal surfaces86and88respectively. In the embodiment shown the first and second generally flat distal surfaces86and88have first and second coterminous, coaxial openings90and92respectively forming a passageway94formed along an axis of symmetry96of the conductor14coincident with the central axis60. Referring toFIG. 6, in the embodiment shown, the first and second openings90and92and passageway94are threaded for receiving first and second bolts100and102in the first and second openings90and92respectively, for securing crimp connectors104and106, to which respective external and internal wires108and110may be attached to the opposite ends of the conductor14. The first and second openings90and92and surrounding first and second generally flat distal surfaces86and88respectively act as the first and second electrical terminals16and20respectively.

Referring toFIG. 5, in use, a device40on which the apparatus10is to be used is configured to include a circular opening120having a diameter slightly larger than the diameter of the projection52. Additional openings such as opening122are formed in a wall124of the device40to facilitate receiving fasteners41such as screws therein to permit the fasteners41to engage with the threaded inserts61,63,65and67in the mounting surface58. The apparatus10is mounted to the device40such that the projection52projects inwardly into the device through the opening120and such that the fasteners41are inserted into the openings122from inside the device40. This ensures that the apparatus cannot be easily removed from the device40without opening it up. Referring toFIG. 6, when the apparatus10is mounted to the device40, the o-ring71seals the connector against the wall124of the device, thus making the device usable for both indoor and outdoor applications. A wire110internal to the device, from a circuit such as an inverter circuit inside the device may be connected to the second electrical terminal20by engagement of the second bolt102with a ring of a crimp connector106on the wire and by engagement of the second bolt102with the threads in the second opening92. The conductor14is thus electrically connected to the wire110.

The guides30,32,34and36project outwardly, generally normal to the surface of the wall124of the device40. An external wire108, such as from a battery, for example, may be connected to the first electrical terminal16by engagement of the first bolt100with a ring of a first crimp connector104on the external wire108and engaging the threads on the first bolt with the threads in the first opening90. The external wire108is thus electrically connected to the first electrical terminal16and is connected to the first terminal through the conductor14. As the first bolt100is tightened in the first opening90, the high torque forces involved as the bolt is tightened may have a tendency to rotate the crimp connector104about the central axis60. The guides adjacent the crimp connector104, only one of which is shown at36inFIG. 6, limit the range of rotation of the crimp connector to only a small sector, thus permitting the external wire108to extend from the connector generally radially, in a generally well-defined direction. The raised stage portion54and protruding generally flat distal surface86of the conductor14ensure a good, maximum surface area contact between the crimp connector104and the protruding generally flat distal surface86and provide clearance between the crimp connector104and the bridging surface portions62,64,66and68to avoid deforming the crimp connector104when the first bolt100is fully tightened in the first opening90. A similar advantage is achieved at the second electrical terminal20due to the second end portion82of the conductor14projecting slightly beyond the end of the projection52.

Additional wires may be connected to the first electrical terminal16by overlaying crimp connectors connected to respective such wires so that respective rings of the crimp connectors are axially aligned to receive the first bolt100, and by securing the bolt with the crimp connectors thereon to the first opening90. Respective wires may be arranged to extend between respective pairs of guides30,32,34and36such that each wire extends generally radially from the opening in a sector determined by the spacing of the respective pair of guides and the width (diameter) of the crimp portion of the respective crimp connector.

Referring toFIG. 7, in accordance with another aspect of the invention, there is provided a cover apparatus150, in accordance with one embodiment of the invention, for covering an electrical connector apparatus such as the one described above. In the embodiment shown the cover apparatus150includes a main housing151comprised of first152, second154, third156, fourth158, fifth160and sixth162joined rigid wall portions configured to extend about the perimeter and top of the base of the electrical connector apparatus10described above. The first, second, third and fourth wall portions152,154,156and158have respective edges172,174,176and178each having an edge surface lying in a common plane. In use, when the cover apparatus150is installed on the connector apparatus10, the common plane would be coincident with a mounting surface on a wall such as wall124the device40, or spaced apart slightly therefrom.

At least one of the wall portions has a conductor opening180and in the embodiment shown, the conductor opening is in the third wall portion156. The cover apparatus150further includes a conductor guard190comprising a rigid guide wall192extending outwardly of the third wall portion156, adjacent the conductor opening180, to guard a wire terminated to the connector apparatus10described above against small-radius bends near the connector apparatus.

In the embodiment shown, the wall portions152,154,156,158,160and162and the rigid guide wall192are embodied in a unitary piece of electrically insulating material such as hard plastic.

The first and second side wall portions152and154are generally flat. The third wall portion156is generally flat with the rigid guide wall192extending therefrom. The fourth wall portion158, disposed opposite the third wall portion156is convexly curved. Thus, the wall portion on a side of the cover opposite to the side from which the rigid guide wall extends is convexly curved.

The sixth wall portion162extending over the top portion of the electrical terminal is curved and joins the first, second and third side wall portions152,154and156. The fifth wall portion160extends between the fourth wall portion158and the fifth wall portion160and joins each of these wall portions such that it extends at an angle relative to the common plane in which the edges172,174,176and178lie.

At least one of the wall portions has a test probe opening179operable to receive a test probe to permit the test probe to contact the electrical terminal without requiring removal of the cover therefrom. In the embodiment shown, the test probe opening179is in the sixth wall portion162.

In the embodiment shown, the rigid guide wall192is generally U-shaped having first and second leg portions194and196and a curved joining portion197joining the first and second leg portions194and196. The first and second leg portions194and196are terminated in respective coplanar edges198and200that are coplanar with the edges172,174,176, and178of the main housing151. The first and second leg portions194and196also have distal portions202and204terminated in a single continuous distal edge206that defines an access opening208through which a wire connected to the connector apparatus10housed by the cover apparatus150may extend. The rigid guide wall192is configured such that the first and second leg portions194and196become progressively longer, progressively farther away from the third wall portion156, and such that the radius of curvature of the joining portion197becomes progressively larger such that the access opening208is slightly larger than the conductor opening180in the third wall portion156. The rigid guide wall192thus has an outwardly flared shape. This reduces any chance of cutting insulation on a wire extending into the housing due to rubbing of the insulation on the distal edge206.

In the embodiment shown, the first and second wall portions152and154have first and second landings220and222formed at right angles therein, to align with corresponding fastener openings in an electrical connector with which the cover apparatus150is to be used. In the embodiment shown, the first and second landings220and222align with corresponding threaded inserts51,53,55and57in the guides30,32,34and36of the connector apparatus10described above. The landings220and222have first and second openings224and226respectively therein for receiving a fastener (not shown) for fastening the cover apparatus150to the connector apparatus10. The sixth wall portion162has first and second recessed areas228and230adjacent the first and second landings220and222respectively, facilitating application of a tool such as a screw driver to fasteners received in the first and second openings224and226. In the embodiment shown, the threaded inserts51,53,55and57in the guides30,32,34and36are arranged symmetrically at a common distance from the central axis60. Similarly, the first and second landings220and222and first and second openings224and226are arranged symmetrically about an axis of the cover at distances similar to those of the threaded inserts. Consequently, the cover apparatus150may be placed on the connector apparatus10at one of four orientations, allowing the cover apparatus to permit a wire connected to the connector apparatus to extend in any of four directions from the connector apparatus. Similar symmetrical connector and cover arrangements could be made with other connectors having three or more guides and correspondingly shaped covers.

Different cover apparatuses of the type described may be colored red and black, for example and used on positive and negative terminals on the device40, for example.