Abstract:
An enclosure for a wire connection includes a base and a cover. The base includes a bottom and a pair of longitudinal sidewalls disposed between the first and second ends. The cover includes a main body and a first wire securing member. According to one aspect, the cover further includes a second wire securing member. In another aspect, the first and second wire securing members are configured to engage first and second wires, respectively, to reduce strain on a connection between the first and second wires. In a further aspect, the first wire securing member is configured to engage the first wire to create a first bend in the first wire that extends into a first opening in the bottom of the base to reduce strain on the connection.

Description:
BACKGROUND AND SUMMARY 
       [0001]    The present invention relates to electrical wire connections, and more particularly, to enclosures for an electrical wire connection in an appliance. 
         [0002]    In appliances such as washers, driers, refrigerators, freezers, ranges, and stoves, two or more wires are often joined together via an electrical splice. Traditionally, the splice is typically over-molded with polyvinyl chloride (PVC) cylinder or covered with heat shrink tape to electrically isolate the splice. However, either method of covering the splice is labor intensive and requires additional operations in the appliance assembly process which, in turn, increases the manufacturing cost of the appliance. 
         [0003]    In accordance with the present invention, an enclosure for a wire connection in an appliance includes a base and a cover. The base includes a bottom and a pair of longitudinal sidewalls disposed between the first and second ends. The cover includes a main body and a first wire securing member. According to one aspect, the cover further includes a second wire securing member. In another aspect, the first and second wire securing members are configured to engage first and second wires, respectively, to reduce strain on a connection between the first and second wires. In a further aspect, the first wire securing member is configured to engage the first wire to create a first bend in the first wire that extends into a first opening in the bottom of the base to reduce strain on the connection. 
         [0004]    The wire connection enclosure of the present invention is advantageous over traditional constructions. For example, the wire connection enclosure of the present invention reduces strain on wire connections by a greater magnitude relative to a PVC cylinder or heat shrink tape. In addition, the wire connection enclosure of the present invention is less expensive and requires less time to assemble relative to over-molding PVC or applying heat shrink tape. Further, the wire connection enclosure of the present invention enables appliance manufactures to save manufacturing costs associate with equipment such as molding machines, and to save floor space required for such equipment. 
         [0005]    Additional advantages and features of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a perspective view showing an appliance of the present invention; 
           [0007]      FIG. 2  is a perspective view showing wires in the appliance extending into an enclosure for a connection between the wires; 
           [0008]      FIG. 3  is a perspective view showing the enclosure and the wires; 
           [0009]      FIG. 4  is an exploded, top perspective view showing the enclosure and the wires; 
           [0010]      FIG. 5  is a cross-sectional view, taken along line  5 - 5  of  FIG. 3 , showing the enclosure, the wires, and the connection between the wires; 
           [0011]      FIG. 6  is a bottom perspective view showing a cover of the enclosure; 
           [0012]      FIG. 7  is a bottom perspective view showing a base of the enclosure; 
           [0013]      FIG. 8  is a cross-sectional view similar to  FIG. 5  showing the enclosure with a push-in fastener extending from the base; 
           [0014]      FIG. 9  is a cross-sectional view similar to  FIG. 5  showing the enclosure with an edge-biter fastener extending from the base; 
           [0015]      FIG. 10  is a cross-sectional view similar to  FIG. 5  showing the enclosure with a zip tie loop extending from the base; 
           [0016]      FIG. 11  is a top perspective view showing an alternative enclosure of the present invention in a closed position with wires extending into the alternative enclosure; 
           [0017]      FIG. 12  is a first top perspective view showing the alternative enclosure in an open position, the wires, and the connection between the wires; 
           [0018]      FIG. 13  is a second top perspective view showing the alternative enclosure in the open position; 
           [0019]      FIG. 14  is a bottom perspective view showing the alternative enclosure in the open position; 
           [0020]      FIG. 15  is a cross-sectional view, taken along line  15 - 15  of  FIG. 11 , showing the alternative enclosure, two of the wires, and the connection; and 
           [0021]      FIG. 16  is a cross-sectional view, taken along line  16 - 16  of  FIG. 11 , showing the alternative enclosure and one of the wires. 
       
    
    
       [0022]    Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
       DETAILED DESCRIPTION 
       [0023]    Referring to  FIGS. 1 and 2 , an appliance  10 , such as a washer or a dryer, includes a control panel  12  having a front side  14  and a back side  16 . The back side  16  of the control panel  12  includes a lid or door  18  that opens, as shown in  FIG. 2 , to provide access to various electrical components within the appliance  10 . The electrical components include a first wire  20 , a second wire  22 , a third wire  24 , a fourth wire  26 , and an enclosure  28  for a connection  30  between the wires  20 ,  22 ,  24 ,  26 , such as an electrical splice. The enclosure  28  covers and protects the connection  30  and exposed portions of the wires  20 ,  22 ,  24 ,  26  to electrically isolate the same and thereby prevent a short circuit. In addition, the enclosure  28  secures the wires to reduce the amount of strain on the connection  30 . 
         [0024]    Referring to  FIGS. 3 and 4 , the enclosure  28  includes a base  32  and a cover  34 . The base  32  and the cover  34  can be formed (e.g., molded) separately from a polymeric material (e.g., polyethylene, polypropylene). In various implementations, the enclosure  28  can include a tether  36  that couples the cover  34  to the base  32  to maintain the cover  34  with the base  32  for shipping and handling purposes. The base  32  has a first end  38  and a second end  40  and includes a bottom  42 , a pair of longitudinal sidewalls  44 , and an open top  46 . The cover  34  has a first end  48  and a second end  50  and includes a rectangular cuboid main body  52  and two pairs of flexible brackets  54  extending from opposite longitudinal sides of the main body  52 . 
         [0025]    The flexible brackets  54  can be slid over the longitudinal sidewalls  44  of the base  32  to couple the cover  34  to the base  32  using a snap or interference fit. When the cover  34  is coupled to the base  32 , the first end  38  of the base  32  and the first end  48  of the cover  34  cooperate to define a first open end  56  of the enclosure  28 , which is shown receiving the wires  20 ,  22 . In addition, the second end  40  of the base  32  and the second end  50  of the cover  34  cooperate to define a second open end  58  of the enclosure  28 , which is shown receiving the wires  24 ,  26 . 
         [0026]    The base  32  further includes ramped protrusions  60  and lateral walls  62  intersecting the longitudinal sidewalls  44  at the longitudinal midpoint of the base  32 , and the flexible brackets  54  of the cover  34  define openings  64  for receiving the ramped protrusions  60 . As the flexible brackets  54  of the cover  34  are slid over the longitudinal sidewalls  44  of the base  32 , the brackets  54  deflect outward due to engagement with sloped surfaces  66  on the ramped protrusions  60 . Once inner surfaces  68  of the flexible brackets  54  are slid past underside surfaces  70  of the ramped protrusions  60 , the brackets  54  return to their original state and the ramped protrusions  60  extend through the openings  64 . In turn, the underside surfaces  70  of the ramped protrusions  60  engage the inner surfaces  68  of the flexible brackets  54  to retain the cover  34  onto the base  32 . 
         [0027]    The lateral walls  62  of the base  32  can be used to position the cover  34  relative to the base  32  before coupling the cover  34  to the base  32 . For example, slots  72  between the flexible brackets  54  of the cover  34  can be aligned with the lateral walls  62 . Then, as the flexible brackets  54  are slid over the longitudinal sidewalls  44  of the base  32 , the lateral walls  62  can engage the slots  72  to guide the cover  34  until the ramped protrusions  60  extend through the openings  64 . At that point, a top surface  74  on the bottom  42  of the base  32  can act as a stop by engaging an underside surface  76  of the flexible brackets  54  to ensure that height of the open ends  56 ,  58  is sufficient to receive the wires  20 ,  22 ,  24 ,  26 . The bottom  42  of the base  32  define slots  78 , which can provide access for a tool, such as a flathead screwdriver, to pry the flexible brackets  54  away from the longitudinal sidewalls  44  to remove the cover  34  from the base  32 . 
         [0028]    With additional reference to  FIG. 5 , before the cover  34  is coupled to the base  32 , a crimp connector  80  can be placed over the connection  30  between the wires  20 ,  22 ,  24 ,  26  and crimped, and then the wires  20 ,  22 ,  24 ,  26  can be placed in the base  32 . Although the connection  30  is a two-to-two connection (i.e., a connection between the two wires  22 ,  24  and the two wires  26 ,  28 ), the enclosure  28  can be used with other connections. For example, the enclosure  28  can be used with a two-to-one connection a three-to-one connection, a three-to-two connection, or a five-to-five connection. In addition, the enclosure can be used to connect wires having different gauges. 
         [0029]    With additional reference to  FIGS. 6 and 7 , the cover  34  further includes wire securing members  82 , such as rectangular tabs or standoffs, extending from an underside surface  84  of the main body  52 , and the bottom  42  of the base  32  defines openings  86 . One of the securing members  82  is located between the first end  50  of the cover  34  and the longitudinal midpoint of the cover  34 , and the other one of the securing members  82  is located between the longitudinal midpoint of the cover  34  and the second end  50  of the cover  34 . The securing members  82  cooperate with the openings  86  to secure the wires  20 ,  22 ,  24 ,  26  within the enclosure  28  and thereby reduce the amount of strain on the connection  30 . 
         [0030]    When the wires  20 ,  22 ,  24 ,  26  extend through the open ends  56 ,  58  of the enclosure  28  and the cover  34  is coupled to the base  32 , the securing members  82  engage the wires  20 ,  22 ,  24 ,  26  the create bends  88  therein. The bends  88  in the wires  20 ,  22 ,  24 ,  26  are disposed on opposite sides of the connection  30  and extend into the openings  86  such that the wires  20 ,  22 ,  24 ,  26  are routed in a serpentine pattern as shown in  FIG. 5 . The engagement between the securing members  82  and the wires  20 ,  22 ,  24 ,  26  at the bends  88  prevents the wires  20 ,  22 ,  24 ,  26  from moving longitudinally and thereby reduces the amount of strain on the connection  30 . In addition, the bottom  42  of the base  32  and the longitudinal walls  44  cooperate with the main body  52  of the cover  34  and the securing members  82  to enclose and thereby electrically isolate the connection  30  and exposed portions of the wires  20 ,  22 ,  24 ,  26  adjacent to the connection  30 . 
         [0031]    To quantify the amount by which the enclosure  28  reduces strain on a wire connection relative to an over-molded PVC cylinder, a pull-test was performed on a connection between two 18 gauge wires. When testing the over-molded PVC cylinder, the wires began to slide within the PVC cylinder when about 30 pounds (lbs) to 35 lbs (133 Newtons (N) to 156 N) of longitudinal force was applied to one of the wires. In contrast, when testing the enclosure  28 , the wires did not begin to slide within the enclosure  28  until about 50 lbs (222 N) of longitudinal force was applied to one of the wires. Thus, the enclosure  28  yields an approximate 40% improvement in the longitudinal load capacity of the connection relative to the PVC cylinder. In addition, as indicated above, these test results are for a connection between two wires. The enclosure  48  may provide a higher degree of strain relief for a connection between more wires, which may further increase the longitudinal load capacity of the connection. 
         [0032]    Referring to  FIGS. 8 through 10 , the enclosure  28  can include various mounting members for attaching the enclosure  28  to other components in the appliance  10 . The mounting members can be formed integral with the base  32  or the cover  34  or formed separate from the base  32  and the cover  34  and attached to the base  32  or the cover  34 . The mounting members can be formed (e.g., molded) from a polymeric material (e.g., polyethylene, polypropylene). 
         [0033]    In one example, the enclosure  28  can include a push-in clip  90  extending from the bottom  42  of the base  32 , as shown in  FIG. 8 , which may be referred to as a Christmas tree fastener. The push-in clip  90  includes a shank  92  having a conical distal end  94  and annular ribs  96  extending proximally from the shank  92 . The push-in clip  90  can be inserted into a hole in a component in the appliance  10 , such as a bracket, and the ribs  96  can engage a surface of the component surrounding the hole to fix the enclosure  28  to the component. 
         [0034]    In a second example, the enclosure  28  can include an edge-biter fastener  98  extending from the bottom  42  of the base  32 , as shown in  FIG. 9 . The edge-biter fastener  98  includes a shank  100  and a u-shaped channel  102  extending from the shank  100  and having barbed distal ends  104 . The u-shaped channel  102  can be sized to receive an edge of a component in the appliance  10 , such as a panel, and the distal ends  104  can pierce or bite into the component to fix the enclosure  28  to the component. In a third example, the enclosure  28  can include a zip tie loop  106  extending from the bottom  42  of the base  32 , as shown in  FIG. 10 . A zip tie or cable tie can be inserted through the loop  106  to secure the enclosure  28  to a component in the appliance  10 . 
         [0035]    Referring to  FIGS. 11 and 12 , an enclosure  110  electrically isolates and provides a strain relief for a connection  112 , such as a splice, between a first wire  114 , a second wire  116 , and a third wire  118 . The enclosure  110  includes a base  120 , a cover  122 , and a hinge  124  attaching the cover  122  to the base  120 . The base  120 , the cover  122 , and the hinge  124  can be integrally formed (e.g., molded) from plastic (e.g., polyethylene, polypropylene). In this regard, the hinge  124  can be a living hinge. 
         [0036]    The base  120  has a first end  126  and a second end  128  and includes a flat rectangular bottom  130  and wire retaining members  132 . The cover  122  has a first end  134  and a second end  136  and includes a rectangular main body  138 , longitudinal sidewalls  140 , platforms  144 , and flexible brackets  146 . The flexible brackets  146  extend through openings  148  in the bottom  130  of the base  120  when the cover  122  is rotated about the hinge  124  to close the enclosure  110 , as shown in  FIG. 11 . The retaining members  132  of the base  120  retain or secure the wires  114 ,  116 ,  118  to the base  120  when the cover  122  is rotated about the hinge  124  to open the enclosure  110 , as shown in  FIG. 12 . 
         [0037]    The flexible brackets  146  include blades  150  and tabs  152  extending from the blades  150 . The tabs  152  deflect toward the blades  150  as the flexible brackets  146  are inserted through the openings  148  in the cover  122 . When the tabs  152  are inserted completely through the openings  148 , the tabs  152  return to their original state and engage an underside surface  154  of the base  120  to keep the enclosure  110  closed. When the enclosure  110  is closed, the first end  126  of the base  120  and the first end  134  of the cover  122  cooperate to define a first open end  156  of the enclosure  110 , which is shown receiving the first wire  114 . In addition, the second end  128  of the base  120  and the second end  136  of the cover  122  cooperate to define a second open end  158  of the enclosure  110 , which is shown receiving the second and third wires  116 ,  118 . 
         [0038]    With additional reference to  FIGS. 13 and 14 , the retaining members  132  include longitudinal sidewalls  160 , flexible tabs  162   a ,  162   b , and annular ribs  164 . The longitudinal sidewalls  160  form u-shaped channels  166 , with one of the channels  166  receiving the first wire  114  and the other one of the channels  166  receiving the second and third wires  116 ,  118 . A crimp connector  168  ( FIG. 12 ) can be crimped onto the connection  112  before the wires  114 ,  116 ,  118  are placed in the u-shaped channels  166 . The base  120  can further include a semicylinder pocket  170  ( FIG. 14 ) extending from the underside surface  154  of the base  120  to provide clearance for the crimp connector  168 . 
         [0039]    After the connection  112  is formed, the wires  114 ,  116 ,  118  can be inserted through open tops  172  of the u-shaped channels  166 . As the wires  114 ,  116 ,  118  are inserted through the open tops  172 , the flexible tabs  162   a ,  162   b  deflect inward due to engagement with the wires  114 ,  116 ,  118 . When the wires  114 ,  116 ,  118  are inserted past the flexible tabs  162   a ,  162   b , the flexible tabs  162   a ,  162   b  return to their original state. The flexible tabs  162   a ,  162   b  can be sized based on the number and/or gauge of wires to be inserted into the u-shaped channels  166  to ensure that the wires can be inserted into the channels  166  and that the tabs  162   a ,  162   b  retain the wires. In this regard, the flexible tab  162   a  is slightly larger than the flexible tab  162   b  since the tab  162   a  retains only the first wire  114  while the tab  162   b  retains the second and third wires  116 ,  118 . 
         [0040]    With additional reference to  FIGS. 15 and 16 , the cover  122  further includes wire securing members  174 , such as rectangular tabs or standoffs, and c-shaped channels  176 . In addition, the bottom  130  of the base  120  defines openings  178  disposed in the u-shaped channels  166 . One of the securing members  174  is located between the first end  134  of the cover  122  and the longitudinal midpoint of the cover  122 , and the other one of the securing members  174  is located between the longitudinal midpoint of the cover  122  and the second end  126  of the cover  122 . The securing members  174  cooperate with the openings  178  to secure the wires  114 ,  116 ,  118  within the enclosure  110  and thereby reduce the amount of strain on the connection  112 . 
         [0041]    When the wires  114 ,  116 ,  118  are placed in the u-shaped channels  166  and the enclosure  110  is closed, the securing members  174  engage the wires  114 ,  116 ,  118  the create bends  180  therein. The bends  180  are disposed on opposite sides of the connection  112  and extend into the openings  178  in the base  120  such that the wires  114 ,  116 ,  118  are routed in a serpentine pattern as shown in  FIG. 15 . The engagement between the securing members  174  and the wires  114 ,  116 ,  118  at the bends  180  prevents the wires  114 ,  116 ,  118  from moving longitudinally and thereby reduces the amount of strain on the connection  112 . In addition, the bottom  130  of the base  120  and the longitudinal walls  160  cooperate with the main body  138  of the cover  122  and the securing members  174  to enclose and thereby electrically isolate the connection  112  and exposed portions of the wires  114 ,  116 ,  118  adjacent to the connection  112 . 
         [0042]    In addition, when the enclosure  110  is closed, the flexible tabs  162   a ,  162   b  deflect inward due to engagement with the securing members  174 . The flexibility of the tabs  162   a ,  162   b  allows the securing members  174  to be inserted into the u-shaped channels  166 . Further, when the enclosure  110  is closed, the c-shaped channels  176  of the cover  122  at least partially surround the connection  112  and exposed portions of the wires  114 ,  116 ,  118  to protect the same. Moreover, when the wires  114 ,  116 ,  118  are placed in the u-shaped channels  166 , the annular ribs  164  on the base  120  bite into the wires  114 ,  116 ,  118  to further secure the wires  114 ,  116 ,  118  to the base  120 . 
         [0043]    The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.