ELECTRICAL CONNECTOR

Abstract: An electrical connector for an electrical lead (28) such as a strip heater which has a first conductor (32) and a second conductor (34). The connector has a first component, a conductor-receiving member (38), into which the conductors (32, 34) are inserted, and a second component, a conductor-connecting member (52). The conductor-receiving member (38) and the conductor-connecting member (52) are movable relative to one another between a unique mated configuration and a plurality of demated configurations. The conductor-receiving member (38) is preferably transparent in order to visually determine the correct positioning of the conductors. In a preferred embodiment, the connector is in the form of an electrical plug which is designed to connect the conductors (32, 34) of an electrical lead (28) to an electrical power outlet. The electrical plug contains a signal member (2), e.g. a light, which provides a signal when a fuse (26) is properly inserted and current passes through the plug.

Description: ELECTRICAL CONNECTOR BACKGROUND OF THE INVENTION Field of the Invention This invention relates to electrical connectors for electrical leads, particularly to electrical plugs which are useful for making an electrical connection between an electrical lead and an electrical power outlet. Introduction to the Invention It is often necessary to make an electrical connection to an electrical lead, e.g. to splice two leads together or to attach an electrical plug to a lead in order to apply power. It is also known to insert a light, or other signal, into an electrical circuit so that it is easy to determine whether current is flowing through a heater or other operational electrical device which forms part of the circuit. The light can, for example, be placed in a plug through which the device is connected to a wall outlet in a building or to another power source. It is also known to insert a fuse, circuit breaker, ground fault circuit interrupter (GFCI), or other circuit protection device into an electrical circuit so that if the current exceeds a safe level or otherwise behaves in an abnormal fashion, the protection device is converted from its normal state into an abnormal state in which it disconnects the circuit from the power supply or otherwise prevents maintenance of the abnormal current. The protection device can, for example, be placed in a plug through which a heater or other operational device is connected to a wall outlet in a building or to another power source. When an electrical circuit contains both a signal light and a protection device, absence of the signal light may signify failure of the operational device itself, or failure of the electrical connections to the operational device, or conversion of the protective device into its abnormal state, e.g. failure ("blowing") of the fuse. Self-regulating strip heaters which comprise elongate electrodes connected by a conductive polymer resistive element are well-known. In operation, the thermal output of these strip heaters varies in response to changes in the thermal environment and thus serves to limit the maximum temperature which the heater achieves . Such heaters are often used to provide freeze protection of pipes, such as domestic or commercial water lines, or to maintain a constant temperature for pipes in process industries. A number of measures have been proposed for assisting the safe operation of such heaters. Reference may be made, for example, to U.S. Patent No. 4,436,986 (Carlson) and U.S. Patent No. 4,822,983 (Bremner et al) . SUMMARY OF THE INVENTION I have now realized that when a conductive polymer strip heater is connected to a power supply through an electrical plug which is inserted into a conventional wall outlet and which contains a fuse or other protective device, it is very useful to include, as a part of the plug, a signal device, e.g. a light- emitting diode, which is connected between the two legs of the heater circuit so that it will provide a signal (e.g. will be lit up) only when the power is on and the protective device is in its normal state. In a first aspect, this invention provides an electrical connector for connecting an electrical lead comprising a first conductor and a second conductor, which connector comprises (1) a conductor-receiving member which comprises (a) a first channel in which the first conductor can be placed, and (b) a second channel in which the second conductor can be placed; and (2) a conductor-connecting member which comprises (a) a first conductor-contact section, (b) a first connection-making section, (c) a second conductor-contact section, and (d) a second connection-making section; the conductor-receiving member and the conductor-connecting member being (i) movable relative to each other between a unique mated configuration and a plurality of demated configurations; (ii) such that in at least some of the demated configurations, the first conductor can be placed in the first channel and the second conductor can be placed in the second channel; (iii) such that if the first conductor has been placed in the first channel and the second conductor has been placed in the second Ghannel, the conductor-receiving member with the conductors placed therein and the conductor-connecting member can then be brought into the mated configuration, in which mated configuration the first conductor makes physical and electrical contact with the first conductor-contact section and the second conductor makes physical and electrical contact with the second conductor- contact section; and (iv) such that they cannot be brought into the mated configuration if the first conductor or the second conductor has been placed in direct physical contact with the respective conductor- contact section instead of being placed in the respective channel; and (3) closure means for maintaining the conductor-receiving member and the conductor-connecting member in the mated configuration. In a second aspect, this invention provides an electrical connector which is in the form of an electrical plug for connecting an electrical lead comprising a first conductor and a second conductor to an electrical power outlet. In a third aspect, this invention provides an electrical assemblywhich comprises a plug according to the second aspect and an electrical fuse which is positioned between the first and second contact sections. BRIEF DESCRIPTION OF THE DRAWING Figure 1 is a schematic circuit diagram of an electrical connector of the invention which is in the form of an electrical plug; Figure 2 shows an exploded view of a plug of the invention; and Figure 3 shows a top view of another connector of the invention. PETftl SP PESCRIPTIQN QF THE INVENTION The connector of the invention is useful for connecting- any- type of electrical lead which comprises a first conductor and a second conductor. It is particularly useful when it is in the form of an electrical plug which is used to connect -an electrical lead to an electrical power outlet. The power outlet may be a wall outlet either inside or outside of a bulging, or a * it may be part of a power supply or other suitable souf?ee of -*t power. The outlet may be two-hole for connection to a phase and a neutral wire, or three-hole for connection to a phase, a neutral, and a ground (earth) wire. The electrical lead may ' any electrical component with a first conductor an^i. a second conductor, e.g. an electrical power cord. The plug is particularly useful in making an electrical connection to a strip heater, i.e. an elongate heating element which comprises at least two electrodes. For a connection made with this type of heater, the first conductor is one electrode of the heater and the second conductor is the other electrode of the heater. The strip heater may comprise a conductive polymer, i.e. a composition in which a particulate conductive filler is dispersed or otherwise distributed in a polymeric component. Particularly preferred are self-regulating conductive polymer heaters, i.e. those which exhibit PTC (positive temperature coefficient) behavior. The electrodes of a self-regulating heater are generally elongate metal wires or braid which are parallel and spaced apart. They are attached to or embedded in a resistive element which comprises the conductive polymer and is often in the form of a continuous strip. In order to p ovide environmental protection and electrical insulation, it is common for the resistive element and the electrodes to be covered by a dielectric layer, e.g. a polymeric jacket. A metallic grounding braid is c '.en present over the dielectric layer in order to provide ph y sical reinforcement and a means of electrically grounding the strip heater. The term "PTC behavior" is used in this specification to denote a composition or an electrical device which has an R 14 value of at least 2.5 or an R 100 value of at least 10, and preferably both, and particularly one which has an R 30 value of at least 6, where R 14 is the ratio of the resistivities at the end and the beginning of a 14°C range, R 100 is the ratio of the resistivities at the end and the beginning of a 100°C range, and R 30 is the ratio of the resistivities at the end and the beginning of a 30°C range. Self-regulating conductive polymer heaters which exhibit PTC behavior, and appropriate conductive polymer compositions, are disclosed in U.S. Patents Nos. 3,858,144 (Bedard et al) , 3,861,029 (Smith-Johannsen et al) , 4,188,276 (Lyons et al) , 4,388,607 (Toy et al) , and 4,426,339 (Kamath et al) . The invention is illustrated by the drawings. Figure 1 shows a schematic circuit diagram for an electrical connector in the form of a plug which is designed for insertion into an electrical power outlet. A first contact member 2 comprises a first prong 4 which can be inserted into one socket of the outlet and a first fuse-contact section 6. A second contact member 8 comprises a second fuse-contact section 10 and a first conductor-contact section 12 to which a first conductor of an electrical lead can be physically and electrically connected. A third contact member 14 comprises a second conductor-contact section 16 to which the second conductor of an electrical lead can be physically and electrically connected and a second prong 18 which can be inserted into the other socket of the outlet. A signal member 20 is electrically connected between the second and third contact members. In this embodiment, the signal member 20 is electrically in series with a first resistor 22 and a second resistor 24. When the first and second prongs 4,18 are inserted into the power outlet, the signal member 20 provides a signal if a fuse 26 connects the first and second fuse-contact sections 6,10. No signal is provided if there is no electrical connection between the first and second fuse-contact sections 6,10. The signal member 20 may be a light, e.g. a light emitting diode (LED) which provides a visual signal, a bell or other apparatus which provides an audio signal, or an electrical switch which can generate an alarm signal. Other types of signal members may be appropriate in different circumstances. The first and second fuse-contact sections 6,10 are positioned to receive a fuse 26. The selection of a specific fuse is dependent on the normal operating conditions and the anticipated fault conditions. Particularly preferred when the connection is to be made to a strip heater is a very fast acting fuse, i.e. a fuse which has little, if any intentional delay in the overload region and which "trips" (opens) very-rapidly when the current in the circuit comprising the fuse exceeds the rated value of the fuse. Appropriate fuses are very fast-acting ceramic ferrule fuses with a current rating of 10 amperes and a voltage rating of 125/250 volts. Such fuses are available, for example, from the Bussman Division of Cooper Industries under the name Buss GBB™-10. While it is possible to use one of the measures disclosed in U.S. Patent No. 4,822,983 (Bremner et al) in conjunction with this invention, I have found that, when a fuse as just described is employed, excellent results can be obtained without using a sensor conductor as disclosed irf-that patent. A switch or other component may be used in place of the fuse for some applications. Figure 2 shows an exploded view of one specific embodiment of a connector in the form of a plug which is designed to connect the conductors of a first electrical lead 28 to an - electrical power outlet. In this figure the electrical lead 28 is a strip heater which comprises a resistive element 30, and embedded therein, a first conductor 32 and a second conductor 34. The heater is surrounded by a metallic grounding braid 36. Both the first conductor 32 and the second conductor 34 have been stripped of the conductive polymer which comprises the resistive element 30 to allow easy insertion into the conductor- receiving member 38. For other types of leads, e.g. insulated wires, it may not be desirable to remove the polymeric insulation or jacketing material. The conductor-receiving member 38 comprises a first channel 40, a second channel 42, and a third channel 44, designed for insertion of the first conductor 32, the second conductor 34, and the grounding lead 36, respectively. Each channel is a tunnel which has a frusto- conical opening, both features sized so that the conductors inserted in them can be held by frictional forces. The walls of the channels serve to prevent contact between the conductors . A radial opening 46,48,50 is cut through each tunnel to allow electrical connection of the inserted conductor to the conductor-contact sections. Once the conductors are inserted into the conductor-receiving member 38, it is mated to the conductor-connecting member 52. As a result of the design of the conductor-receiving member, which may include positioning pins or other design elements which are not shown, there is a unique mated configuration. When the two pieces are mated, the first conductor 32 is in physical and electrical contact with the first conductor-contact section 12, the second conductor 34 is in physical and electrical contact with the second conductor- contact section 16, and the grounding lead 36 is in physical and electrical contact with the grounding contact section 54. The first and second conductor-contact sections 12, 16 and the grounding contact section 54 may comprise insulation-piercing means for use when the conductors are insulated with a polymeric jacket. The conductor-connecting member further comprises first and second fuse-contact sections 6, 10 designed to receive a fuse. The first connection-making section 4 corresponds to the first prong of Figure 1 and the second connection-making section 18 corresponds to the second prong. A ground-connection-making section 56 is also present to connect to the ground in the outlet. The embodiment shown also comprises a base 58 for the conductor-connecting member 52 which can be welded, glued, or snapped into place. A signal port 60 is positioned so that the signal member 20 will be visible. Figure 2B shows the bottom of the conductor-connecting member 52 with the base 58 removed. The signal member 20, an LED, and first and second resistors 22,24 are visible. It is apparent that the first fuse-contact section 6 and the first connection-making section 4 are made from a single piece of metal, e.g. brass. In this embodiment, the second conductor-contact section 16 and the second connection-making section 18 are also made from a single piece of metal, as are the second fuse-contact section 10 and the fuse conductor-contact section 12. The conductor-receiving member 38 is preferably made from an insulating material, e.g. a polymer. It is particularly- preferred that it be made from a transparent polymer, e.g. polycarbonate, so that there is a visual indication that the conductors are properly positioned. The conductor-receiving member 38 and the conductor-connecting member 52 are maintained in position by a closure means 62, e.g. a screw or a clamp. When mated properly, the plug provides adequate strain relief to the electrical lead. A minimum pull force of 20 pounds on the electrical lead is achieved. (The "pull force" or "pullout force" measures the amount of force required to pull the electrical lead 0.125 inch (0.318 cm) out of the plug. This procedure is described in U.S. Patent No. 4,883,945 (Bautista) ) . Proper mating of the conductor-receiving member 38 and the conductor-connecting member 52 cannot be achieved if either the first conductor 32 or the second conductor 34 has been directly connected to the respective conductor-contact section 12,16. When the fuse 26 is in place but no conductors are inserted into the conductor-receiving member, the plug may be used to determine whether wall outlets are properly wired and/or live. If the fuse is electrically intact and there is no signal when the plug is placed into the outlet, that is an indication that the outlet is defective. Additional signal members can be incorporated into the plug to signal whether the phase and neutral wires are wired correctly. When there is a ground connection to the plug, additional signal members will indicate whether there is actually a ground. Figure 3 illustrates a connector 64 which is designed to connect a first electrical lead 28 comprising first and second conductors 32,34 and a second electrical lead 66 comprising third and fourth conductors 68,70. In this connector 64, there are two conductor-receiving members 38,72. The second conductor-receiving member 72 comprises two channels 74,76 for insertion of the third and fourth conductors 66,68. A second closure means 78 maintains the second conductor-receiving member 72 in the mated configuration. In the mated configuration, the third conductor 68 makes physical and electrical contact with the first connection-making section 4 and the fourth conductor 70 makes physical and electrical contact with the second connection-making section 18.

Claims: What is claimed is : 1. An electrical connector for an electrical lead comprising a first conductor and a second conductor, which connector comprises (1) a conductor-receiving member which comprises (a) a first channel in which the first conductor can be placed, and (b) a second channel in which the second conductor can be placed; and (2) a conductor-connecting member which comprises (a) a first conductor-contact section, (b) a first connection-making section, (c) a second conductor-contact section, and (d) a second connection-making section; the conductor-receiving member and the conductor-connecting member being (i) movable relative to each other between a unique mated configuration and a plurality of demated configurations; (ii) such that in at least some of the demated configurations, the first conductor can be placed in the first channel and the second conductor can be placed in the second channel; (iii) such that if the first conductor has been placed in the first channel and the second conductor has been placed in the second channel, the conductor-receiving member with the conductors placed therein and the conductor-connecting member can then be brought into the mated configuration, in which mated configuration the first conductor makes physical and electrical contact with the first conductor-contact section and the second conductor makes physical and electrical contact with the second conductor- contact section; and (iv) such that they cannot be brought into the mated configuration if the first conductor or the second conductor has been placed in direct physical contact with the respective conductor- contact section instead of being placed in the respective channel; and (3) closure means for maintaining the conductor-receiving member and the conductor-connecting member in the mated configuration. 2. A connector according to claim 1 which is an electrical plug for connecting an electrical lead comprising a first conductor and a second conductor to an electrical power outlet, wherein the conductor-connecting member comprises (1) a first contact member which comprises (a) a first prong suitable for insertion into one socket of the power outlet and (b) a first fuse-contact section, 13 (2) a second contact member which comprises (a) the first conductor-contact section and (b) a second fuse- contact section, (3) a third contact member which comprises (a) the second conductor-contact section and (b) a second prong suitable for insertion into the other socket of the power outlet, and (4) a signal member which is connected between the second and third contact members and which provides a signal when current is passing therethrough; the first and second prongs being arranged so that when they are inserted into the power outlet, the signal member provides a signal if a fuse connects the first and second fuse-contact sections and does not provide a signal if there is not electrical connection between the first and second fuse-contact sections. 3. A connector according to claim 1 or 2 wherein the conductor-receiving member is composed of insulating material, preferably a transparent insulating material. 4. A connector according to claim 2 wherein the signal member comprises a light . 5. A plug according to any one of the preceding claims wherein each of the first and second channels is in the form of a tunnel having a radial opening therein, and when the conductor- receiving member and the conductor-connecting member are in the mated configuration, the respective conductor-receiving sections pass through the radial openings. 14 6. A connector according to any one of the preceding claims wherein the conductor-receiving member further comprises a third channel in which a ground lead can be placed when the conductor- receiving member and the conductor-connector member are in at least some of the demated configurations, and the conductor- connecting member further comprises a ground-contact section which contacts the ground lead in the mated configuration and a ground connection-making section. 7. A connector according to claim 1 wherein at least one of (1) the first conductor-contact section and the first connection-making section, and (2) the second conductor-contact section and the second connection-making section, is made from a single piece of metal. 8. A connector according to any one of the preceding claims wherein (1) the first and second channels are sized to receive first and second conductors which are insulated with an electrically insulating material and (2) the first and second conductor-contact sections comprise insulation-piercing means which pierce the electrically insulating material when the first and second conductors are inserted into the conductor- receiving member and the conductor-receiving member and the conductor-connecting member are then brought into the mated configuration. 9. A connector according to claim 1 which is suitable for connecting a first electrical lead comprising first and second conductors and a second electrical lead comprising third and fourth conductors, and which comprises (4) a second conductor-receiving member which comprises (a) a third channel in which the third conductor can be placed, and (b) a fourth channel in which the fourth conductor * can be placed, the second conductor-receiving member being (i) movable relative to the conductor-connecting member between a second unique mated configuration and a plurality of demated configurations; (ii) such that in at least some of the demated configurations, the third conductor can be placed in the third channel and the fourth conductor can be placed in the fourth channel; (iii) such that if the third conductor has been placed in the third channel and the fourth conductor has been placed in the fourth channel, the second conductor-receiving member with the third and fourth conductors placed therein and the conductor-connecting member can then be brought into the second mated configuration, in which mated configuration the third conductor makes physical and electrical contact with the first connection-making section and the fourth conductor makes physical and electrical contact with the second connection-making section; and (iv) such that they cannot be brought into the second mated configuration if the third or the fourth conductor has been placed in direct physical contact with the first connection-making section or the second connection-making section instead of being placed in the third channel or the fourth channel; and (5) a second closure means for maintaining the second conductor-receiving member and the conductor- connecting member in the second mated configuration. 10. An electrical plug assembly which comprises (A) an electrical lead comprising a first conductor and a second conductor; (B) a connector according to any one of the preceding claims; and (C) closure means for maintaining the conductor-receiving member and the conductor-connecting member in the mated configuration, wherein the conductor-receiving member and the conductor- connecting member are in the mated configuration.

Inventors: TUCKER DONALD L, TUCKER, DONALD, L.
Applicants: RAYCHEM CORP, RAYCHEM CORPORATION
Application year: 1990
Main classification: H01R4
IPC codes: H01R4