Abstract:
An electrical splice connector comprising a frame, at least one set of cooperating wedge members movably mounted to the frame, and a first spring connected between a first one of the wedge members and the frame. The wedge members have opposing sides adapted to contact opposite sides of an electrical conductor. The spring extends at least partially along a length of the first wedge member.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates to electrical connectors and, more particularly, to a connector for splicing two conductors together.  
           [0003]    2. Prior Art  
           [0004]    U.S. Pat. No. 4,698,031 discloses a connector for ends of two conductors. The connector has two sets of jaws and springs biasing the jaws in opposite directions for automatically clamping onto an inserted conductor. There is a desire to provide a connector similar to that disclosed in U.S. Pat. No. 4,698,031, but which can have additional features such as a pre-latching feature for the jaws, an anti-reverse system for the jaws, or a spring system which can reduce the length of the connector.  
         SUMMARY OF THE INVENTION  
         [0005]    In accordance with one embodiment of the present invention, an electrical splice connector is provided comprising a frame, at least one set of cooperating wedge members movably mounted to the frame, and a first spring connected between a first one of the wedge members and the frame. The wedge members have opposing sides adapted to contact opposite sides of an electrical conductor. The spring extends at least partially along a length of the first wedge member.  
           [0006]    In accordance with another embodiment of the present invention, an electrical splice connector is provided comprising a frame having an open side for receiving ends of two oppositely extending electrical conductors through the open side; a first wedge movably connected to the frame along a first length of the frame; and a second wedge movably connected to the frame along a second length of the frame which is spaced from the first length. The end of a first one of the electrical conductors can be inserted through the open side of the frame and contact the first wedge. The end of a second one of the electrical conductors can be inserted through the same open side of the frame and contact the second wedge.  
           [0007]    In accordance with another embodiment of the present invention, an electrical splice connector is provided comprising a frame having two ends with a conductor passage aperture in each end and a side between the two ends which has a conductor entrance aperture contiguous with the passage apertures; and a first set of cooperating wedge members movably mounted to the frame. Each wedge member is located and retained in a separate retaining groove of the frame. The wedge members have opposing surfaces adapted to contact opposite sides of an electrical conductor. The conductor is inserted through the entrance aperture and extends out of a first one of the end passage apertures. The wedge members of the first set directly contact each other to move with each other along the frame. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]    The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein:  
         [0009]    [0009]FIG. 1 is an exploded perspective view of a connector incorporating features of the present invention;  
         [0010]    [0010]FIG. 2 is a top plan view of the frame of the connector shown in FIG. 1;  
         [0011]    [0011]FIG. 3 is a bottom, front, inside perspective view of one of the wedge members shown in FIG. 1;  
         [0012]    [0012]FIG. 4 is a bottom, front, outside perspective view of another one of the wedge members shown in FIG. 1;  
         [0013]    [0013]FIG. 5 is a side elevational view of one of the spring clips show in FIG. 1;  
         [0014]    [0014]FIG. 6 is a partial cross-sectional view of the pre-latching system of the connector shown in FIG. 1;  
         [0015]    [0015]FIG. 7 is a partial cross-sectional view of the anti-reversing feature of the connector shown in FIG. 1;  
         [0016]    [0016]FIG. 8 is an exploded perspective view of an alternate embodiment of a connector incorporating features of the present invention;  
         [0017]    [0017]FIG. 9 is a schematic cross-sectional view of another alternate embodiment of a connector incorporating features of the present invention;  
         [0018]    [0018]FIG. 10 is a cross-sectional view of the connector shown in FIG. 9 taken along line  10 - 10 ;  
         [0019]    [0019]FIG. 11A is a bottom plan view of one of the wedge members shown in FIG. 9;  
         [0020]    [0020]FIG. 11B is a front side elevational view of the wedge member shown in FIG. 11A;  
         [0021]    [0021]FIG. 11C is a bottom plan view of another one of the wedge members shown in FIG. 9;  
         [0022]    [0022]FIG. 12A is a top plan view of another embodiment of the present invention; and  
         [0023]    [0023]FIG. 12B is a side elevational view of the embodiment shown in FIG. 12A. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0024]    Referring to FIG. 1, there is shown an exploded perspective view of an electrical connector  10  incorporating features of the present invention intended to connect ends of two conductors A, B to each other. Although the present invention will be described with reference to the embodiments shown in the drawings, it should be understood that the present invention can be embodied in many alternate forms of embodiments. In addition, any suitable size, shape or type of elements or materials could be used.  
         [0025]    The connector  10  generally comprises a frame  12 , a first wedge  14 , a second wedge  16 , and springs  18 . In alternate embodiments less features or additional features could be provided. Referring also to FIG. 2, the frame  12  is preferably a one-piece metal member, such as a cast metal member. However, the frame could be comprised of more than one member, could be comprised of any suitable material(s), and/or could be made by any suitable manufacturing process. The frame  12  generally comprises a middle section  20  and two sections  22 ,  24  connected to each other by the middle section  20 . The two sections  22 ,  24  are substantially mirror images of each other. However, in alternate embodiments they could be different. Each section  22 ,  24  has opposite side walls  26 ,  28  which are angled relative to each other to form wedge shaped receiving areas  30 ,  32 . The frame  12  can have stiffening ribs to strengthen the wedge sections  22 ,  24 . The frame  12  has a substantially open top side which extends into the receiving areas  30 ,  32 . The opposite ends of the frame  12  have conductor passage apertures  34 ,  36  into the receiving areas  30 ,  32 . In this embodiment the middle section  20  is open on three sides. The tops of the side walls  26 ,  28  include inwardly extending retaining lips  38 . In this embodiment, one side  40  of the frame forms a common side for all three sections  20 ,  22 ,  24 . At the middle section  20 , the side  40  includes two latching bosses or projections  42  and two series of serrations or grooves  44 . The side  40  also includes spring grooves  46  and guide rails or projections  48 . In alternate embodiments the frame could have more or less features, the features could be arranged in any suitable manner on the frame, and/or the features could have any suitable size or shape.  
         [0026]    The two wedges  14 , 16  are substantially the same, but merely orientated in reverse orientations relative to each other. However, in alternate embodiments more or less than two wedges could be provided, and the wedges could have different shapes. Referring also to FIGS. 3 and 4, in this embodiment each wedge has two wedge members  50  and  52 . However, in alternate embodiments each wedge could have more or less than two wedge members. The first wedge member  50  is preferably a one-piece cast metal member. However, in alternate embodiments the first wedge member  50  could be comprised of multiple members, could be comprised of any suitable material(s), and/or could be manufactured by any suitable process.  
         [0027]    The first wedge member  50  generally comprises four sides  54 ,  56 ,  58 ,  60  located between a front end  62  and a rear end  64 . The inner side  54  has a curved conductor contact surface  66 . The inner side  54 , proximate the bottom side  58 , also comprises a wedge member interlock projection  70 . The top side  56  has a finger contact section  68  adapted to allow a finger of a user to move the first wedge member. However, in an alternate embodiment the finger contact section might not be provided, or any suitable type of section for direct interaction with the user could be provided. The thickness of the first wedge member  50  between the two lateral sides  54  and  60  increases from the front end  62  to the rear end  64  to form a general wedge shape. The bottom side  58  generally comprises a latching recess  72 , a spring contacting section  74 , and a groove  76 .  
         [0028]    The sides  60  of the first wedge members  50  are located against the inner surfaces of the sides  28  of the frame  12 . The bottom sides  58  are located against the side  40  of the frame  12  with the spring contacting section  74  extending into respective ones of the spring grooves  46 . One of the guide projections  48  extends into each of the grooves  76 . The retaining lips  38  of the sides  28  extend over a portion of the top sides  56  of the first wedge members.  
         [0029]    The second wedge member  52  is preferably a one-piece cast metal member. However, in alternate embodiments the second wedge member  52  could be comprised of multiple members, could be comprised of any suitable materials(s), and/or could be manufactured by any suitable process. The second wedge member  52  generally comprises four sides  78 ,  80 ,  82 ,  84  located between a front end  86  and a rear end  88 . The inner side  78  has a curved conductor contact surface  90 . The inner side  78 , along the bottom side  82 , also comprises a wedge member interlock recess  92 . The thickness of the second wedge member  52  between the two sides  78  and  84  increases from the front end  86  to the rear end  88  to form a general wedge shape. The bottom side  82  generally comprises a recess  94 , a spring contacting section  96 , and a groove  98 .  
         [0030]    The second wedge members  52  are located against the inner surfaces of the sides  26  of the frame  12 . The bottom sides  82  are located against the side  40  of the frame  12  with the spring contacting section  96  extending into respective ones of the spring grooves  46 . Respective ones of the guide projections  48  extend into the grooves  98 . The retaining lips  38  of the sides  26  extend over a portion of the top sides  80 . In the embodiment shown, the second wedge members  52  also each comprise a clip  100  (see FIG. 5). The clip  100  has a mounting section  102  and a latch section  104 . The clip  100  could be comprised of sheet metal or any other suitable material. The mounting section  102  is fixedly attached to the second wedge member  52  in the recess  94  by any suitable means. The tips  106  of the latch section  104  extend in a downward direction from the bottom side  82  of each second wedge member. However, in alternate embodiments the clip  100  might not be provided, or could be attached to the first wedge members, or could have any suitable shape, or could be formed integrally with the second wedge member.  
         [0031]    The springs  18 , in the embodiment shown, are coil springs, but any suitable springs could be provided. In this embodiment a spring  18  is provided for each wedge member  50 ,  52 . However, in alternate embodiments more or less springs could be provided, such as one spring for each pair of wedge members  50 ,  52 . The springs  18  in this embodiment are intended to be compression springs. The springs  18  are located in respective ones of the spring grooves  46 . One end of each spring  18  is located against the inward closed end  47  of its respective groove  46 . The opposite end of each spring is located against one of the spring contact sections  74 ,  96 . In the embodiment shown the spring contact sections  74 ,  96  merely comprise projecting bosses. However, in alternate embodiments any suitable type of spring contact sections could be provided. The compression springs  18  exert forces on the wedge members  50 ,  52  to bias the wedges  14 ,  16  towards the ends of the frame  12 . The wedge spring mechanism is a feature that causes the wedges to put an initial force on the conductor during the insertion. The force is such that it maintains enough friction between the wedges and the conductor such that, as the conductor is pulled during installation, it allows the wedges to “set” without the conductor slipping through the wedges. In one embodiment the connector utilizes a compression spring for each wedge to develop the force. In another embodiment the connector utilizes an extension spring for each wedge to develop the force. The wedges have interlocking fingers that prevent one wedge advancing at a different rate than the other. In both embodiments the grooves for the springs are in the base of the body of the connector opposed to the sides of the body of the connector. This allows the wedges to be designed such that the maximum surface of the wedge is in contact with the sides of the body of the connector. This permits the greatest surface contact for electrical conduction between the wedges and the body of the connector. The orientation of the grooves and springs also makes the need for additional sheet metal components unnecessary.  
         [0032]    As noted above, the wedge members  50 ,  52  comprise an interlock projection  70  and an interlock recess  92 , respectively. The projection  70  of the wedge member  50  extends into the recess  92  of the opposite wedge member  52  for each wedge  14 ,  16 . This interlocks the pairs of wedge members  50 ,  52  to each other to move together in directions C relative to the longitudinal axis of the receiving areas  30 ,  32  and frame  12 . However, the pairs of wedge members  50 ,  52  for each wedge  14 ,  16  are able to move or slide relative to each other in directions D, transverse to directions C, while still being interlocked with each other. In alternate embodiments any suitable type of movable interlocking engagement between pairs of wedge members could be provided, or no interlocking engagement could be provided.  
         [0033]    The embodiment shown in FIG. 1 includes a latch system comprising the latching bosses  42  and the latching recesses  72 . However, in alternate embodiments the connector might not have a latching system, or any suitable type of system for latching or retaining the wedges in rearward positions could be provided. Referring also to FIG. 6, the bosses  42  and recesses  72  are suitably sized and shaped relative to each other, and the bosses  42  are suitably orientated at the rear of the path of the first wedge members  50 , such that the bosses  42  can extend into the recesses  72  when the first wedge members  50  are in rearward retracted positions on the frame  12 ; i.e.: located at middle section  20 . Each boss  42  has a rear latching surface  108  and a ramp surface  110 . Each first wedge member  50  has a latch surface  112  in the rear of the recess  72  and a ramp surface  114  behind the recess  72  on the bottom side  58 . When the latching surfaces  108 ,  112  contact each other, the first wedge member  50  is latched to the frame  12  at its rearward position and, even though its spring  18  exerts a biasing force against the first wedge members  50 , is prevented from moving forward towards one of the ends of the frame. Because of the interlock between pairs of the wedge members  50 ,  52 , the associated opposite second wedge member  52  is also prevented from moving forward even though its spring exerts a biasing force against it. The ramp surfaces  110  and  114  allow the first wedge member  50  to be more easily moved onto the boss  42 . The finger contact sections  68  of the first wedge members  50  allow the wedges to be more easily moved by the user to the rearward positions, such as by clamping the two finger contact sections  68  in a single hand, between thumb and forefinger, and squeezing. The finger contact sections  68  also provide a convenient location for a user to grasp the first wedge member  50  and lift its rear end up, as indicated by arrow E in FIG. 6, to disengage the two latching surfaces  108 ,  112  from each other and allow the springs  18  to move the wedge members  50 ,  52  on the frame  12  towards the ends of the frame and towards the conductor clamping positions for the wedges  14 ,  16 . The pre-latching feature keeps the jaws open for ease of conductor insertion during installation. In one embodiment a small recess in the underside of one of the wedges (wedge which has finger tab) and a small boss in the surface of the connector body accomplish this. When the wedges are retracted to insert the conductor the boss engages with the recess in the bottom of the wedge keeping the wedges open temporarily. To close the wedges, the finger tab on the wedge is lifted up causing the recess to disengage from the boss.  
         [0034]    The embodiment shown in FIG. 1 includes an anti-reverse feature comprising the serrations  44  on the frame  12  and the clips  100  on the second wedge members  52 . However, in alternate embodiments the connector might not have an anti-reverse feature, or any suitable type of anti-reverse feature for preventing the wedges  14 ,  16 , once moved towards their conductor clamping positions could be provided, from moving back towards their retracted positions. Referring also to FIG. 7, the serrations  44  preferably comprise a rear surface  116  having a steep slope and a front surface  118  having a more shallow slope. The tips  106  of the latch section  104  of the clips  100  can extend into the serrations. Because of the shallow slope of the front surfaces  118  of the serrations  44 , the latching sections  104  can relatively easily resiliently deflect out of the serrations (one at a time) as the second wedge members  52  are moved forward in direction C F  on the frame  12 ; towards their respective frame ends. However, if the second wedge member  52  is attempted to be moved in a reverse reward direction C R , the steep slope of the rear surface  116  and shape of the latch section  104  combine to block such rearward movement. This helps to insure that once the wedges  14 ,  16  clamp onto a conductor, they stay attached even if subjected to vibrations or temporary subsequent push-in of the conductor A or B. The anti-reverse feature prevents the wedges from disengaging from the conductor once the wedges are set on the conductor. One embodiment utilizes a strip spring attached to the underside of one of the wedges and a series or serrations on the connector body surface. As the wedge tightens onto the conductor, the strip spring progressively “clicks” into each successive serration. The serrations are designed such that they allow the spring to advance to the next serration as the wedges tighten around the conductor. This is accomplished by the geometry of the edges of the serrations. The edge of the serration that leads to the next serration as the wedge advances is angled. This allows the spring to freely disengage and then engage with the next serration. The edge of the serration adjacent to the previous serration is perpendicular to the body of the connector. This prevents the spring from disengaging and retracting to the previous serration. Thus, the spring  100  is free to advance forward to the next serration, but cannot go back to the previous serration.  
         [0035]    Once the connector  10  is assembled, its use is relatively simple. The wedges  14 ,  16  are maintained in their rearward pre-connection positions by the latch system  42 ,  72 . The conductor A is inserted in receiving area  32  between the opposite conductor contact surfaces  66 ,  90  of the wedge members  50 ,  52 . The conductor A can be inserted through the open top side of the frame  12  or through the end aperture  36 . In either event, the conductor A extends out of the end aperture  36 . The user then lifts the rear end of the first wedge member  50  by means of the finger contact section  68  to disengage the latch system  42 ,  72 . The springs  18  automatically push the wedge members towards the end of the frame; towards the end aperture  36 . The slide paths of the wedge members  50 ,  52  are angled relative to each other such that the wedge members  50 ,  52  move towards each other as they approach the end aperture  36 . The surfaces  66 ,  90  move into contact with opposite sides of the conductor A and clamp onto the conductor. Thus, the wedge  16  connects the conductor A to the frame  12 . The user can then pull on the conductor to more securely wedge the wedge members  50 ,  52  and conductor with each other in the wedge shaped receiving area  32 . The wedge  14  can operate in a similar fashion to connect the conductor B to the frame  12 . Thus, the connector  10  can electrically and mechanically connect the conductors A, B to each other. For each wedge, because of the interlocking nature of the pair of wedge members  50 ,  52 , they can simultaneously move together to clamp onto the conductors. The embodiment shown in FIG. 1 provides a relatively open frame which allows a user to actively see if the conductors A, B are fully inserted and if the wedge members  50 ,  52  move properly to clamp onto the conductors. The ends of the conductors A, B can be located along a common axis. However, the location of the springs  18  offset from the paths of the wedge members  50 ,  52  and axes of the conductors allows the frame  12  to have a shorter longitudinal length than conventional designs. However, in alternate embodiments the conductors might not have a common axis and the spring(s) might not be offset. The guide rails  48  and guide grooves  76 ,  98  help to insure proper spreading and closing of the wedge members relative to each other. The surfaces  66 ,  90  could have teeth to project or bit into the conductors.  
         [0036]    Referring now to FIG. 8 an exploded perspective view of an alternate embodiment is shown. In this embodiment the connector  120  is very similar to the connector  10 . However, the springs  122  are tension springs rather than compression springs. The frame  124  has extensions  126  at its opposite ends with pin holes  128 . Pins  130  are located in the pin holes  128  and first loops  132  at first ends of the springs  122  are mounted on the pins  130 . Second loops  134  at opposite second ends of the springs  122  are mounted on the posts  74 ,  96  (see FIGS. 3 and 4) of the wedge members  50 ,  52 . The springs  122  can exert a tension biasing force on the wedge members of the wedges  14 ,  16  to move the wedges towards clamping positions against the respective conductors A, B.  
         [0037]    Referring now to FIGS. 9 and 10 another alternate embodiment will be described. The connector  150  includes a frame  152 , two wedges  154 ,  156  and tension springs  158 . The frame  152  has an open center section  160  and two wedge sections  162 ,  164  similar to the sections  22 ,  24  shown in FIG. 1. However, the frame  152  does not have spring grooves  46  or guide rails  48 . Instead, the frame  152  has guide grooves  166  which cross each other at the center section  160 . However, in alternate embodiments the grooves  166  might not cross or intersect each other. Referring also to FIGS.  11 A- 11 C, the wedge members  168 ,  170  of the wedges  154 ,  156  are shown. The first wedge member  168  comprises an inner side with a conductor contact surface  172 , an outer side with a spring groove  174 , a bottom side with a guide rail or projection  176 , and two inward projections  178  with a guide slot  180  between the inward projections. The second wedge member  170  comprises an inner side with a conductor contact surface  182 , an outer side with a spring groove  184 , a bottom side with a guide rail or projection  186 , an inward projection  188 , and recesses  190  on opposite sides of the inward projection  188 . Guide rails  176 ,  186  are located in the guide grooves  166  to guide movement of the wedge members  154 ,  156  on the frame  152 . Inward projections  178  extend into recesses  190  and inward projection  188  extends into recess  180  such that the wedge members of each wedge can slide laterally inward and outward relative to each other, but are interlocked to move with each other in transverse directions. The springs  158  are located in the spring grooves  174 ,  184  of the wedge members. The springs  158  have ends  194 ,  196  clipped onto the wedge members and frame  152  such that the springs bias the wedges  154 ,  156  towards the opposite ends of the frame. The crossing nature of the grooves  166  allow increased range of movement for the wedge members. The paths of the wedges  154 ,  156  overlap at center section  160  for alternate positioning at center section  152 . The increase range of movement can provide wider gaps between the conductor contact surfaces  172 ,  182  for larger conductors or easier location of the conductors between the surfaces  172 ,  182 . The size of the frame can be smaller with this embodiment because of the increased range of movement for the wedges, the overlapping paths of the wedges  154 ,  156 , and the springs extending in grooves of the wedges rather than spring grooves of the frame.  
         [0038]    Referring now to FIGS. 12A and 12B, another alternate embodiment is shown. In this embodiment the connector  200  is substantially identical to the connector  150  shown in FIG. 9, but the frame  152 ′ includes a pre-latch  202 . The pre-latch  202  includes latch tabs  204 . The tabs  204  are adapted to latch onto the second wedge members  170  to keep the wedges  154  and  156  (not shown in FIGS. 12A and 12B) in retracted pre-connection positions. A user can unlatch the tabs  204  from the second wedge members by merely pulling or deflecting the ends  206  outward.  
         [0039]    It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.