Waterproof wire connectors

Abstract: A waterproof and fire retardant connector having a rotatable wire connector with an end cap attached thereto with the wire connector filled with a sealant to permit the user to simultaneously compress the junctions ends of electrical wires into low resistance electrical contact while forming a waterproof covering and spark inhibiting compound surrounding the twisted junction end of the wires. The process includes inserting the junction ends of electrical leads into a wire connector, which is filled with a waterproof and fire retardant sealant, and then either crimping or rotating the wire connector to simultaneously form an electrical connection and waterproof and spark inhibiting seal around the twisted junction ends of the wires.

Description: FIELD OF THE INVENTION This invention relates generally to waterproof and fire retardant connectors and, more specifically, to waterproof wire connectors that can in one operation permit the user to simultaneously compress the junction ends of electrical wires into low resistance electrical contact while forming a waterproof covering around the junction ends of the electrical wires. BACKGROUND OF THE INVENTION The concept of wire connectors for connecting the junction of two or more wires together by twisting a cap on the wires is old in the art. Wire connectors are well known in the art and generally comprise an outer housing with a tapered threaded interior to permit a user to insert wires into the tapered opening. Typical examples of prior art wire connectors are shown in U.S. patents 3,497,607; 3,875,324; and 4,691,079. To use a wire connector, the user inserts the twisted ends of electrical wires into a cavity on the inside of the wire connector. The user then holds the wire in one hand and with the other hand twists the wire connector. The twisting action pulls the junction ends of the wires into a low resistance electrical contact. If the connector is located in a wet location it is necessary to place a waterproof sealant around the connector. In order to prevent water or moisture from entering the connector and forming an oxidation layer over the ends of the wire the user inserts the wire connector and the wire into some type of a waterproof potting compound. The compound may be either a non hardening or a hardening compound. In either case the compound creates a waterproof capsule over the wire connector and the junction ends of the electrical wires. The prior art process is time consuming because it involves two separate steps as well as the nuisance of having separate potting compounds and containers to hold the potting compound. The present invention provides an improved wire connector that permits the user in one continuous action to simultaneously form the junction ends of wire leads into a low resistance electrical connection that is surrounded by a waterproof sealant to form a waterproof covering around the junction ends of the wire leads. DESCRIPTION OF THE PRIOR ART The Viersen U.S. patent 1,297,614 shows a process where twisted wire ends are potted in a solder. The Nicolazzo U.S. patent 2,416,943 shows a wire connector that squeezes the ends of the wires between an outer housing and an inner housing. The Bird U.S. patent 3,083,260 shows a cup shaped body that has a metal cement or putty located around the twisted ends of two electrical leads. The Swanson U.S. patent 3,497,607 shows a wire connector that has a spring in the cavity of the connector that cuts through the insulation on the wires. The Smith U.S. patent 4,039,742 shows a waterproof splice that uses an enclosed tube containing a sealant that covers the electrical connection between the wires. The Erixon U.S. patent 4,107,453 shows a wire connector with an inner and an outer housing with the ends of the wires located between the inner and the outer housing. Twisting the outer housing while holding the inner housing twists the wires into electrical contact. The Dauser U.S. patents 4,295,004 and 4,446,332 show a solderless wire connector where a cap is squeezed over the ends of the wires to provide an electrical connection. The Eaton U.S. patent 4,751,350 shows a cap containing a sealant and retentions to engage the end of a wire inserted into the cap to provide a sealing device around the end of the wire. The Ustin U. S. patent 2,870,239 shows a wire connector with a splice cap that is permanently crimped to the conductors to hold the conductors in mechanical and electrical contact. The Vogel U.S. patent 3,109,051 shows an electrical wire connector that includes parallel spaced surfaces to insert the ends of the twisted wires in. The Krup U.S. patent 3,483,310 shows a connector that has a sleeve that contracts to prevent the sleeve from being withdrawn from the connector. The Anderson U.S. patent 3,550,765 shows a sleeve that contains a viscous or flowable substance such as an uncured cement that is hardened to hold the electrical leads in the connector. The Waddington U.S. patent 3,875,324 shows a wire connector as defined in the preamble of the appended claim 1, in particular with a tapered spring located in the connector. The Caviar U.S. patent 4,491,686 shows an electrical connector with coverings that can be pierced by inserting a sharply pointed object. A potting compound is then placed around the wires. The U.S. patent 4,691,079 shows a screw on wire connector with a shell that is easier to manufacture. The Netherlands patent 56183 shows a hook on the side of some type of a connector. The Bumpsted U.S. patent 3,937,870 shows a connector including a potting cement to cement the wires in a solid mass. The Penfield U.S. patent 3,597,528 shows an an electrical wire connector with an insertable plastic plug that contains a plastic bonding agent. The Smith U.S. patent 3,934,076 shows an electrical connector with a pre filled and premixed sealant for encapsulating the ends of the wires. The Smith U.S. patent 4,314, 094 shows a container for spliced cables. The Smith U.S. patent 4,053,704 shows a key for forming an enclosure for two or more wire cables together. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 shows a cross sectional view of our waterproof wire connector; Fig 2. shows a cross sectional view of our waterproof and fire retardant connector with the junction ends of two wire leads partially inserted into our connector; Fig. 3 shows a cross sectional view of our waterproof and fire retardant connector with the junction ends of two wire leads twisted into the cavity in the connector; Fig. 4 shows a user rotating one end of our waterproof wire connector while holding the other end stationary; Fig. 5 is an end view of our waterproof and fire retardant connector taken along lines 5 of Fig. 4; Fig. 6 shows a cross sectional view of another embodiment of our invention. Fig. 7 shows an end view of an alternate embodiment of the invention; Fig. 8 shows a pictorial view of the wire connector of Fig. 7; Fig. 9 shows a cross sectional view of the wire connector of Fig. 7 taken along lines A-A of Fig. 7; Fig. 10 shows a further alternate embodiment of an end cap in a wire connector; and Fig. 11 shows a perspective view of the end cap of the wire connector of Fig. 9. SUMMARY OF THE INVENTION Briefly, the present invention is mainly defined in claims 1 and 9 and comprises an improvement to a wire connector by providing a wire connector with an end cap to hold a sealant in the wire connector. In one embodiment the user inserts the twisted wires through the end cap into the sealant in the wire connector. While holding the wires the user twists the wire connector to simultaneously form an electrical connection between the wires and to place a waterproof and spark inhibiting coating over the twisted electrical leads to produce a waterproof and fire retardant wire connector. In another embodiment the end cap comprises a sleeve rotatably mounted on the end of the wire connector with the sleeve containing a waterproof sealant to permit a user to insert the twisted junction ends of electrical leads into the wire connector by inserting the junction ends into the waterproof sealant located in the sleeve and the wire connector. The user then holds the wire and sleeve and rotates the wire connector to simultaneously form the junction ends of the electrical leads into a low resistance electrical connection protected by the waterproof sealant. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to Fig. 1 reference numeral 10 generally identifies our waterproof and fire retardant wire connector for simultaneously forming a waterproof, spark inhibiting, low resistance electrical connection between the junction ends of electrical leads. Wire connector 10 includes a general cylindrical electrical insulated housing 11 having a cylindrical opening 16 for rotatively engaging an end cap comprising a closed end cylindrical tube or sleeve 12. Located on the closed end of housing 11 is an electrical conducting collar 40 having a first cylindrical interior surface 13 and a converging or tapered wire coil forming a spiral surface 14. The drawing shows collar 40 as a one-piece wire coil, however if desired collar 40 could be made in two pieces. Collar 40 is rigidly mounted in housing 11 so that one can twist housing 11 and collar 40 about the twisted ends of electrical leads to provide a low resistance electrical connection therebetween. Housing 11 is virtually identical to existing wire connectors except for a cylindrical surface 16 to rotatively support a sleeve 12 and an annular opening 18 located in the cylindrical surface 16 to prevent axial displacement of sleeve 12 in housing 18. While our connector is shown with an electrical conducting collar 40 having a wire coil forming a spiral surface in some applications the wire coil is replaced with a nonconducting collar having a surface for twisting on electrical leads. Rotatively connected to the open end of housing 11 is cylindrical tube or sleeve 12. The cylindrical tube 12 has an exterior cylindrical surface 34 with an annular cylindrical retaining bead 17 extending radially outward from tube 12. Located on the interior cylindrical surface 16 of housing 11 is a cylindrical recess 18 that extends completely around surface 16. The bead 17 engages cylindrical recess 18 to prevent axial withdrawal of tube 12 from housing 11 but permits rotational movement of housing 11 with respect to sleeve 12. While bead 17 is shown as annular, bead 17 need only be sufficiently long so as to hold end cap 12 in rotatable position in wire connector 11. The cylindrical surface 34 engages a portion of cylindrical recess 16 in a close mating relationship that provides a tortuous path for escape of sealant. That is, the annular path between the two surfaces and the combination of a bead 17 and annular recess 18 effectively prevent the sealant from leaking out of my connector during storage and handling. Waterproof and fire retardant connector 10 includes interior compartments 21,22, 23, and 25 that are partially filled with a viscous sealant 29. Typically sealant 29 can be a silicone base material or the like, a potting compound, greases, or any other waterproofing and fire retardant compounds. A viscous sealant that remains in the connector due to its inherent non-flowability is preferred since the sealant will not run out when our waterproof wire connectors are stored for use or during use. However, other materials could also be used, for example potting compounds that set after exposure to the air. Typical of materials for use with our invention are waterproof and fire retardant greases, potting compounds, or the like. Not only is the sealant useful in preventing the electrical leads from oxidation which results in a poor electrical connection, but it also helps to keep the wires from working loose in the wire connector. In addition, the sealant is also useful in inhibiting sparks that could ignite volatile gases and other flammable material since the sealant encapsulates the exposed portions of the electrical leads. Located on the end of tube 12 is a flexure cover that comprises a plurality of pie shaped resilient segments 26 that converge toward the pointed end 26a of the segments. (Fig. 5) The segments slightly overlap each other to form a closure to hold sealant 29 within connector 10 during the handling and transportation of our waterproof connectors. Prior to use the waterproof and fire retardant connectors are loosely stored in a box. With the end of the tube covered by the overlapping segments it prevents one from accidently getting the sealant onto other connectors. If one uses a waterproof sealant that sets when exposed to the air one could use a continuous foil instead of segments 26. With a foil one would pierce the foil with the end of the wires as the wire ends are inserted into the tube. Fig. 5 shows how the segment ends 26a flex inward to permit the wires 30 and 31 to be inserted into our waterproof connector. Thus the segments permit a wire to be inserted therethrough while at the same time flexing into a position to close off and seal around the wires. When one inserts a twisted wire pair into the cylindrical tube the resilient segments 26 flex inward around the wire to permit the wire to be inserted into the cylindrical cavity 21 while also providing a self forming opening that automatically conforms to the size and shape of the electrical wires. As Fig. 3 illustrates sealant 29 expands to fill the cavity as the wires are inserted into the connector and displace sealant 29. In order to understand the operation of our invention reference should be made to Fig. 2, Fig. 3 and Fig. 4. Fig. 2 shows an installer inserting a twisted junction 33 formed from wires 30 and 31 into the sealant filled cavity 25. Wire 30 has an electrical insulating covering 30a surrounding a metal wire 30b. Similarly, wire 31 has an electrical insulating covering 31a surrounding metal wire 31b. Fig.3 shows the wire junction inserted into the cavity 21 with the twisted wire junction 33 contacting the inside surface 13 of collar 40. Fig. 4 illustrates how a user can simultaneously form a waterproof, spark inhibiting, low resistance electrical connection between the electrical leads with our waterproof connector. To simultaneously form the electrical connection and the waterproof and spark inhibiting covering the operator grasps wires 30 and 31 and the outside surface 34 of tube 12 in one hand and axially inserts the twisted ends of wires 30 and 31 into the chambers 21 and 22 of housing 11. Once the junction ends of the wires are inserted into chambers 21 and 22 the installer takes the other hand and grasps exterior surface 19 on housing 11. The installer then rotates housing 11 while holding the wires and the sleeve to firmly twist the wire junction 33 into contact with the metal collar 40. At the same time the viscous sealant 29 located in the interior cavities 21, 22, 23, and 25 forms a waterproof and spark inhibiting protective covering over junction end 33 of wires to make the connector both waterproof and fire retardant. The use of the sealant in conjunction with a twist on connector permits the installer to simultaneously connect and seal the junction in housing 11 to prevent water and moisture from entering housing 11 which could cause oxidation of the wires resulting in a poor electrical connection. Although the sealant is present in cavities 21 and 22 it has been found that the sealant does not prevent one from rotating housing 11 to twist the junction ends of electrical leads into a low resistance electrical connection. In the embodiment of figure 1 we show sleeve 12 rotatively connected to wire connector 11. In certain embodiments one could fixedly connect sleeve 12 to wire connector 11. For example if the sealant was flowable it would flow around the wires as the sleeve is rotated about the wires. If the sealant is flowable one could use a flowable air hardened material such as an epoxy to form the waterproof covering over the twisted ends in the wire connector. In order to maintain the sealant within the rigid connector one can use segments with a spiral configuration that will flex laterally and inwardly around the wire as the wire connector is rotated. Another variation of my invention is to have the flexible segments that permit the end seal to rotate with respect to the sleeve. For example, flexure segments 26 could have an annular base region 28 that is rotatably mounted in an annular recess in sleeve 12. Referring to Fig. 6 an alternate embodiment of our invention is shown with reference numeral 50 identifying the invention. Connector 50 is identical to connector 10 except the connector 50 includes a first resilient wire clip 54 located on one side of housing 12 and an identical resilient wire clip 53 located on the opposite side of housing 12. Identical parts in Fig. 6 and Figs. 1-5 and are identified with identical numbers. Resilient clip 54 compress a forward extending member that has a curved section 55 terminating in an end 62 that is slightly angled to permit sliding a wire between clip 55 and surface 34. Likewise clip 53 includes a curved surface 56 and an angled end 61. Fig. 6 illustrates that wire 51 extends through opening in the end of sleeve 12 and around clip 54 and then back in the same direction. The purpose of clip 54 is to ensure that the wire 51 is not accidentally pulled out of wire connector 11 during handling of the wires. Fig. 6 also illustrates that wire 52 extends through opening in the end of sleeve 12 and around clip 53 and then back in the same direction. Likewise the purpose of clip 53 is to ensure that the wire 52 is not accidentally pulled out of wire connector 11 during the handling of the wires. While only two wires are shown in my invention one can use either of our inventions with either one wire or with multiple wires. Also although two clips are shown one clip is sufficient to hold two or more wires from accidentally being pulled out of housing 12. Referring to figure 8 reference numeral 70 identifies a conventional wire connector having a cylindrical tapered body or housing 73 with a first flange 71 and a second flange 72. Extending outward form wire connector 70 are a first wire 80 and a second wire 81. The purposes of the flanges are to provide better gripping surfaces to enable a user to twist a wire connector around a pair of twisted wires such as wires 80 and 81. Figure 7 shows an end view of the wire connector 70 with the end cap comprising a cylindrical threaded insert 74 for holding the waterproof sealant within wire connector 70. End cap 74 comprises an outer support ring 75 with a plurality of flexible pie shaped segments 76 extending in an overlaping arrangement toward the center of the end cap 74 to provide a flexure cover closure to the end cap of wire connector 70. Figure 11 shows end cap 74 in a pictorial view revealing annular support ring 77 containing male threads 77 for engaging with female threads located on the inside of a conventional wire connector. The flexible segments are identified by reference numeral 76. Figure 9 illustrates end cap 74 located in the end portion of wire connector 70. Wire connector 70 includes a first set of conical female threads 91 for engaging conical male threads 91a on the outside of a metal insert 92 and conical shaped female threads 93 on the inside for engaging electrical leads. Located in contact with insert 92 are the twisted ends of wires 80 and 81. Wires 80 and 81 extend through the flexible segments 76 which flex around the wires to form a barrier to prevent the sealant 110 in wire connector 70 from flowing out the end of the wire connector 70. Depending on the frictional resistance between female threads 90 and male threads 77, insert 74 may or may not rotate as the user twists the wire connector about the ends of electrical leads 80 and 81. In either case the resilient flexible segments retain the sealant in the connector. The advantage of end cap 74 is that one can quickly convert a standard wire connector with an internal female thread into the present invention of a water resistant wire connector by merely screwing insert 74 into the female threads 90 located on the inside of wire connector 70. Alterantly one could make a longer wire nut to hold more sealant. If the resilient flexible segments 76 are sufficiently flexible one can hold wires 80 and 81 in one hand and rotate wire connector 70 about the wires. The resilient flexible segments 76 not only flex inward but also flex sideways as the wire connector 70 and end cap 74 are rotated about the stationary wires to hold the sealant in the wire connector as the wires are twisted into electrical contact with the metal insert 92 in wire connector 70 Typically, flexible segments can be made from a polymer plastic or the like. Fig. 10 shows an alternate embodiment wherein the end cap comprises a non-rotateable insert 102 that contains an extended cylindrical section or sleeve 100 that projects outward beyond the end of wire connector 70. The advantage of wire connector connector of fig. 10 is that more sealant 110 can be located in the wire connector sleeve 102. End cap 102 includes a first end 103 having male threads 104 for engaging the female threads 90 in wire connector 70. The end of wire connector 70 includes a shoulder 105 for abutting and securing connector 70 against an annular surface 105a on end cap 102. The advantage of the embodiment of Figure 9 is that a conventional wire connector can be converted into a water proof connector with a reservoir of sealant for ensuring that the twisted bare ends of the electrical connections remain covered with the sealant. While end cap 74 is shown as being threaded into connector 70 other means of fastening such as adhesives or mechanical interlocks could be used to fasten the end cap to the connector to produce a compartment for holing a sealant. Although end cap 74 is shown fitting on the interior of wire connector 70 end cap 74 could be adapted to include an external collar to perm the end cap to fasten to the exterior of the wire connector rather than the interior of the wire connector. With both the embodiments of Figure 7-11 it is apparent that one can readily adapt a wire connector containing female threads to a closed container for holding a viscous electrical waterproof material. While the embodiments shown have been pre-filled with a sealant, one could also inject sealant into the compartment formed by the end cap and the wire connector. For example, a flexible tube dispenser could be used to inject sealant around the junction of the wire leads in the wire connector. In certain applications one may not need an end cap to hold the sealant in place. For example, if the sealant sets upon ageing the sealant itself could form it's own cap. Where technical features mentioned in any claim are-followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly, such reference signs do not have any limiting effect on the scope of each element identified by way of example by such reference signs.

Claims: A waterproof and fire retardant connector (10;50;70) for connection of electrical leads comprising: a housing (11;73) having a first open end for insertion of the electrical leads therethrough and a second closed end; and a collar (40;92) for engaging the electrical leads located in the housing to permit a user to rotate the housing with the collar about the ends of electrical leads (30a,31a;51b,52b;80,81) to thereby provide an electrical connection of the ends of the electrical leads; the connector being characterized in that it further comprises a sealant (29;110) located inside said housing to permit a user to first insert the electrical leads through the first open end of the housing and into the inside of the housing which contains the sealant and then to grasp and hold the electrical leads in one hand while rotating said housing about the electrical lead located in said housing with another hand to thereby simultaneously form a low resistance electrical connection of the electrical leads and a waterproof connection of the electrical leads with the sealant located around said electrical leads. A connector according to claim 1, wherein said collar comprises an electrical conducting collar (40) with a first cylindrical interior surface (13) and a second spiral surface (14). A connector according to claim 1, wherein said collar comprises a metal insert (92) with female threads (93) for engaging the electrical leads inserted in the housing. A connector according to one or more of the preceding claims, further comprising an end cap (26;74;102) connected to said first open end of said housing for sealing of the sealant inside said housing and simultaneously for allowing insertion of the electrical lead inside the housing through the end cap. A connector according to claim 4, wherein said end cap comprises a flexure cover having segments (26) that flex inward in response to insertion of the electrical leads therethrough A connector according to one or more of claims 4 and 5, wherein said end cap comprises a threaded surface (77;104) for engaging a threaded surface (90) of the first end of said housing. A connector according to one or more of the preceding claims, wherein said sealant comprises a viscous and spark inhibiting sealant that does not flow out of the waterproof connector under normal storage conditions with said viscous sealant substantially filing the cavity in said housing when the electrical leads are located in said waterproof connector to thereby provide a waterproof and spark inhibiting substance surrounding the wires located in said waterproof connector to thereby make said waterproof connector fire retardant. A connector according to one or more of the preceding claims, including a clip (53,54) located on the housing to permit a user to hook electrical leads about the clip to prevent the electrical leads from being accidentally pulled free of said connector. A method of simultaneously forming a waterproof connection and a low resistance electrical connection between electrical leads, comprising the steps of: inserting a sealant (29;110) inside a housing (11;73), the housing having a first open end and a second closed end, and an electrical leads engaging collar (40;92) located therein; inserting electrical leads (30,31;51,52;80,81) through the first open end of the housing and into the inside of the housing which contains the sealant such that the end of the electrical leads is arranged near the engaging collar; and grasping and holding the electrical leads in one hand while rotating said housing about the electrical leads located in said housing with another hand to thereby simultaneously form a low resistance electrical connection of the electrical leads and a waterproof connection of the electrical leads with the sealant located around said electrical leads. A method according to claim 9, wherein the step of inserting the electrical leads through the first open end comprises inserting the electrical leads through an end cap (26;74;102) which is connected at the first open end of the housing and which allows for simultaneous sealing of the sealant inside said housing and insertion of the electrical lead therethrough and inside the housing. A method according to claim 10, including inserting the electrical leads through flexible segments (26). A method according to one or more of the preceding claims 9 to 11, wherein the step of inserting electrical leads through the first open end of the housing and into the inside of the housing comprises inserting ends of wire leads which are twisted together in the form of a twisted junction into the housing.

Inventors: KING LLOYD HERBERT JR, KING THOMAS A, KING, LLOYD HERBERT, JR., KING, THOMAS A.
Applicants: KING TECHNOLOGY INC, KING TECHNOLOGY OF MISSOURI, INC.
Application year: 1990
Main classification: H01R4
IPC codes: H01R4, H02G15, H01R13