Abstract:
A junction box containing at least one electrical terminal is connected for displacement between unfastened and fastened positions relative to a carrier element, whereby during movement of the housing toward the fastened position, a U-shape contact spring is progressively displaced on a contact tab portion of the terminal within the junction box from a retracted position to a clamping position, thereby to bend a deformable relatively small thin conductor into contiguous lateral engagement with the contact tab portion.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     A junction box containing an electrical terminal is mounted for displacement on a carrier element from an unfastened position to a fastened position, thereby to operate a clamping spring to deform and clamp a deformable conductor into lateral contiguous engagement with a tab portion of the terminal.  
         [0003]     2. Description of the Related Art  
         [0004]     There is a need in the electrical connector art to provide a connecting terminal that is simple in terms of design and that can be mounted in a particularly easy manner upon a carrier element and which is operable to connect a first thin conductor with an additional conductor having a diameter that is considerably larger than that of the first conductor, especially a conductor having a diameter that is a multiple of the smaller first diameter. In particular, it should be possible in a simple manner to connect a data line having a diameter of less than 1 mm, in particular, less than 0.5 mm, with a conductor having a multiple diameter of, for example, more than 1 or 2 mm.  
       BRIEF SUMMARY OF THE INVENTION  
       [0005]     Accordingly, a primary object of the present invention is to provide a junction box that is mounted for displacement from an unfastened position to a fastened position relative to a carrier element, thereby to simultaneously displace a clamping spring from a retracted position to a clamping position, whereby a thin conductor is deformed and clamped to the contact tab portion of a terminal contained within the junction box housing.  
         [0006]     According to a more specific object of the invention, the contact tab portion contains an opening through which the thin bare conductor is inserted, whereby movement of the clamping spring toward the clamping position causes the wire to be deformed into contiguous engagement and electrical contact with both sides of the contact tab. The contact tab is formed on a bus bar having a leg portion provided with a screw-operated fastening clamp by means of which a second conductor of larger diameter may be electrically connected in a positive rigid manner with the thin deformable conductor. The bus bar preferably has a U-shaped configuration, thereby defining a transverse portion provided with a female contact that permits the connection of a third large conductor with the small thin conductor. The additional conductors, for instance, can involve a very thin data line upon the carrier element, which is inserted into the passage hole only during assembly. Thereupon, the housing is mounted upon the carrier element and is engaged there, whereby the tension spring firmly clamps the thin data line upon the carrier element. Into the additional connection device, one can then introduce a conductor with a considerably larger diameter—for example, from a residential or commercial wiring installation. It is thus not only possible in a simple manner to contact the very thin conductor as such without any problems, but it is possible in the simplest way also to connect the very thin conductor with a definitely thicker conductor.  
         [0007]     According to an advantageous feature of the invention, the U-shaped clamping spring is made in the shape of a tulip, which clamping spring is displaced on the contact tab toward the clamping position by means of a stationary abutment shoulder provided on the carrier element. During the displacement of the junction block toward the fastened position relative to the carrier element, the abutment shoulder extends within a guide groove contained within the housing of the junction box.  
         [0008]     The structure of the connecting terminal features a simple design and assembly is possible without special tools in the manner of mounting the housing on the carrier element in an automated fashion in a simple manner.  
         [0009]     In a particularly preferred manner, the junction box housing, in a rather inexpensive manner, has a sectional construction with an upper housing part and a lower housing part that can be engaged in interlocking relation. In a practical manner, the upper part of the housing on its side facing toward the lower part of the housing is made open and displays at least one or several partitions which subdivide the space in the lower part of the housing into a corresponding number of chambers depending on the number of connecting devices—for example, 2, 3 or more—of a particular design. One of the connecting devices is inserted here in each of the chambers as a transit connection. Both the number of the chambers and the number of the connecting devices can thus be varied to make widely differing connections in a simple fashion.  
         [0010]     Advantageously, the bus bar is formed in a U-shaped manner in its upper area where one of the two longitudinal legs of the U engages the screw-operated clamping clip and where, adjoining the other of the two longitudinal legs, is provided an orthogonally arranged contact tab containing a connecting opening for receiving the thin conductor.  
         [0011]     It is also possible in an inexpensive manner to connect one additional contact each, especially a tulip contact, with the basic leg of the U-shaped bus bar in an integral manner—especially by way of the punch/bending technique.  
         [0012]     Preferably, the housing contains a first insertion opening opposite the bus bar contact tab portion, thereby to permit the insertion of the thin deformable conductor into the opening contained in the contact tab portion. A second opening is provided in the housing opposite the screw-operated clamping device, thereby to permit the insertion of the larger diameter second conductor. A third opening is provided in the housing opposite a female terminal provide on the transverse portion of the U-shaped bus bar.  
         [0013]     For the firm attachment and fixation of the housing upon the carrier element, there are furthermore provided pivot projection means that project into undercut recesses contained in the carrier element, whereby there is a rear grasping action on the opposite side of the housing by means of a catch hook on the carrier element that is caught on the housing when the housing after the nose has been pushed in swings up into the undercuts upon the carrier element.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     Other objects and advantages of the invention will become apparent from a study of the following specification when viewed in the light of the accompanying drawings, in which:  
         [0015]      FIGS. 1   a ,  1   b , and  1   c  are front perspective, rear perspective, and exploded views, respectively, of the junction box assembly of the present invention;  
         [0016]      FIG. 2   a  is a detailed perspective view of the terminal means of the junction box assembly of  FIG. 1   a ,  FIG. 2   b  is a detailed view indicating the procedure for mounting the junction box upon a carrier element, and  FIG. 2   c  is a detailed rear perspective view of the apparatus of  FIG. 2   b;    
         [0017]      FIG. 3   a  is a front perspective view of one of the bus bars of the terminal means of  FIG. 2   a ,  FIG. 3   b  is a side view of the junction box housing mounted on the carrier element, and  FIG. 3   c  is a detailed view of the terminal connection illustrated in  FIG. 3   b.;    
         [0018]      FIGS. 4   a ,  4   b , and  4   c  are front perspective views, rear perspective views, and exploded views, respectively, of a second embodiment of the invention;  
         [0019]      FIG. 5   a  is a front perspective view of the terminal means of  FIG. 4   a ,  FIG. 5   b  is a detailed side view illustrating the manner of mounting the junction box upon a carrier element, and  FIG. 5   c  is a detailed rear perspective view of the mounting means of  FIG. 5   b;    
         [0020]      FIGS. 6   a  and  6   b  are front perspective views illustrating the manner of bending of the deformable small conductor by the resilient spring;  FIG. 6   c  illustrates the manner of assembly of the terminal means of  FIG. 6   b ; and  FIG. 6   d  is a detailed view of the connection of the terminal to the conductor illustrated in  FIGS. 6   c.   
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]     Referring more particularly to  FIGS. 1   a - 1   c , the junction box assembly  1  of the present invention includes an upper section  2  and a lower section  3  that are interlocked together. The upper section  2  contains a bottom chamber that is divided by transverse wall  4  into a pair of chambers  5  and  6  that are adapted to receive a pair of bus bars  10 , respectively. Each bus bar has a generally U-shaped configuration and includes a pair of parallel leg portions  11  and  12  that are connected by a transverse portion  26 . The extremity of the leg portion  12  is provided with an orthogonally arranged contact tab portion  13  that contains an opening  14 . In accordance with a characterizing feature of the invention, there is provided on the tab portion  13  of each bus bar  10  a resilient U-shaped spring member  15  that is slidably displaceable between released and clamping positions respectively. Arranged on the transverse portions  26  of the bus bars are female contacts  17  having leg portions  16 .  
         [0022]     The front of the lower housing section  3  contains a pair of front openings  19  that receive relatively small deformable conductors  20  that extend within the openings  14  contained in the contact tab portions  13  of the bus bars  10 , as will be described in greater detail below. The lower housing section  3  also contains a pair of larger openings  18  that receive conductors  120  of larger diameter that extend within openings contained in clamping clip members  7  that are mounted on the upper leg portions  11  of the bus bars  10 , as best shown in  FIG. 2   a . Tensioning screw means  8  extend through a pair of openings  9  contained in the upper portion of the upper housing section  2  for engagement with the corresponding threaded openings contained in the clip members  7 , as is known in the art. Thus, when a tension screw is rotated to draw the clip member  7  in an upwardly extending direction, the associated conductor  120  is biased into electrical engagement with the lower surface of the upper leg  11  of the corresponding bus bar  10 . Finally, a pair of third conductors  220  may be inserted through openings  30  contained in the upper portion of the upper section  2  for engagement with the contact  17  on the transverse portions  26  of the bus bars  10 , respectively. The lower housing section  3  is provided with a catch member  27  that is adapted to extend within a corresponding opening  28  contained in the front wall of the upper housing section  2 , thereby to fasten lock the housing sections in interlocking relation.  
         [0023]     Referring now to  FIGS. 2   a  and  2   b , in order to connect a relatively small deformable conductor  20  with a bus bar  10  contained within the housing  1 , the conductor  20  is inserted through the front opening  19  contained in the lower housing section  3 , which conductor extends within an opening  14  contained within the tab portion  13  of the bus bar  10 . As best shown in  FIG. 2   b , pivot projections  20  extending rearwardly from the rear portion of the lower housing section  3  extend within corresponding recesses  22  contained in a carrier element  24 . In accordance with a characterizing feature of the present invention, as the housing  1  is pivoted downwardly about the pivot axis defined between the pivot projections  21  and the recesses  22 , the contact spring  15  engages a stationery upwardly extending shoulder portion  32  on the carrier element  24 , whereupon the spring  15  is displaced upwardly relative to the tab portion  13 , thereby to deform the conductor into the clamping condition of  FIG. 3   c , whereupon portions of the conductor  20  are clamped by spring  15  in contiguous engagement with opposed lateral surfaces of the tab portion  13 . Thus, the conductor  20  is maintained in rigid electrical connection with the tab portion  13  of the bus bar  10 . Similarly, the conductors  120  may be inserted through the openings  18  for connection with the upper legs  11  of the bus bars  10  by means of the clip members  7  as operated by the clamping screws  8 , and the conductors  220  may be inserted through the housing openings  30  for connection with the resilient terminal means  17  connected with the transverse wall  26  of the bus bars  10 . The bottom edge portion of the lower housing section  3  contains a plurality of guide slots  33  ( FIG. 1   c ) that receive the support shoulders  32  of  FIG. 2   c  when the housing member  1  is pivoted toward its fastened position on the carrier element  24 .  
         [0024]     Referring now to the embodiment of  FIGS. 4   a - 6   c , the major difference between this embodiment and the prior embodiment is the omission of the resilient contacts  17  on the rear surfaces of the transverse portions  26  of the bus bars  10 . As shown in  FIG. 4   b , the rear portion of the upper housing section  2  contains openings  36  that provide access for test probes for engaging the rear surfaces of the bus bars  10 .  
         [0025]     As before, during pivotal movement of the housing  1  about the pivot axis defined by the pivot projection  21  and the recess  22  of  FIG. 5   b , the conductor  20  is deformed by the displacement of spring  15  into engagement with the opposite lateral surfaces of the contact tab portion  13 . Thus, as shown in  FIG. 6   d , the conductor  20  is deformed by spring  15  into engagement with opposed lateral surfaces of the electrical tab portion  13 .  
         [0026]     The invention is particularly suitable for connecting very thin deformable relatively delicate conductors  20  with the tab portion  13  of the bus bar  10  in a very positive rigidly supported manner. The conductor  20  has a diameter on the order of 0.3 mm.  
         [0027]     While in accordance with the provisions of the Patent Statutes the preferred forms and embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that various changes may be made without deviating from the inventive concepts set forth above.