Patent Publication Number: US-2022224023-A1

Title: Wire Nut Electrical Connector

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application claims priority to, and the benefit of, U.S. Provisional Application No. 63/137,273, which was filed on Jan. 14, 2021 and is incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to the field of electrical connectors. More specifically, the present invention relates to an improved wire nut or electrical connector that enables a user to easily test wire leads for electricity, connection, low voltage or other issues. The improved wire nut or electrical connector is comprised of a funnel-shaped housing with an interior metal spiral thread, and a relatively small opening at the top end of the housing to allow a testing probe to be easily inserted into the housing to test the wire leads contained therein. The device offers a convenient solution for testing wires, and eliminates the need to disassemble the connection to test the wires contained therein. Accordingly, the present disclosure makes specific reference thereto. Nonetheless, it is to be appreciated that aspects of the present invention are also equally applicable to other like applications, devices and methods of manufacture. 
     BACKGROUND OF THE INVENTION 
     By way of background, electrical connectors are electro-mechanical devices that are widely used in electronic products such as computers, personal digital assistants and many more devices, to join electrical conductors such as wires, and provide electrical connections and signal transmission between electronic devices. Various types of electrical connectors such as twist-on wire connectors (also known as wire nuts, wire connectors, cone connectors or thimble connectors), and more are available in the market, that simply allow fastening of two or more electrical connectors or wire leads to create an electrical circuit. In order to ensure performance and quality of the electrical circuit, the electrical connector performance and the performance of the wire leads are required to be tested. 
     Traditionally, a test system for evaluating an electrical connector includes a circuit board and a test instrument, to which the electrical connector to be tested for electricity, low voltage or other parameters is attached. The electrical connector to be tested generally includes an insulative housing and a plurality of conductive wire lead terminals. The insulative housing has a cavity, and the conductive terminals are received in the cavity. Test instruments typically include two different types of test heads, a clip-type and a probe-type. Electrical connections include multiple wires and cables, so when the clip-type test head is used, the pitch of the conductive terminals is small, and it is not easy to accurately clamp a clip-type test head to the lead wire ends. Additionally, when the probe type test head is used, the probe-type test head tends to slip on the conductive terminals, thereby causing misdetection of the electrical connector to be tested. 
     The existing electrical connectors have other drawbacks as well. To test the performance of the electrical connector connection, the user is required to push the tester leads up inside the connector to test for power, and if there are too many wires connected, the user has to take off the electrical connector, such as wire nuts or wire caps, to test the wires. This process takes time and energy and can result in a loss of productivity. The resultant test can be unreliable, as the test is conducted when the connector is removed. The connection of the wire leads can change when the connector is placed back onto the wire leads. 
     Therefore, there exists a long felt need in the art for an improved electrical connector that may be used by professionals or homeowners to easily test the wires and electrical connectors for electricity, low voltage and other parameters. There is a long felt need in the art for an improved wire nut that does not require the user to insert the testing leads inside the wire nuts to test the wires. Further, there is a long felt need in the art for an improved wire nut that eliminates the need to remove the wire caps or wire nuts to test the wires. Furthermore, there is a long felt need in the art for an improved wire nut that allows quick and easy testing of wires, and therefore saves the time of the user. There is a long felt need in the art for an improved electrical connector that does not require the users to expend a great deal of effort in testing the wire leads connected by the electrical connector. Finally, there is a long felt need in the art for an improved wire nut that eliminates the need to take the connection apart, while still enabling accurate testing of wire leads. 
     The subject matter disclosed and claimed herein, in one potential embodiment, comprises an electric testing assistance tool in the form a wire nut or electrical connector. The connector comprises: a funnel-shaped flame resistant insulating device, having a top end and a bottom end; the top end having a smaller diameter than the diameter of the bottom end; a central hole on the top end to receive a testing probe of a tester device; an internal metal spiral thread connected to a metal ball connection at one end and connected to a plurality of wire leads on the opposite end; the wire leads extend from the bottom end opening and are connected to a target wiring whose electrical parameters and continuity are to be measured using the electric testing assistance tool; and, the testing probe touches the metal ball to measure the electric parameters and continuity of the target wiring. 
     The improved wire nut or electrical connector of the present invention overcomes the drawbacks of the existing electrical connectors. The improved wire nut or electrical connector of the present invention features a small plastic or thermoplastic housing, including a small hole in a top end of the housing where the test leads are inserted for testing voltage or continuity. The opening at the top end of the housing eliminates the need to remove the wires for testing, saves time and improves the accuracy of the electrical test. 
     In this manner, the improved wire nut or electrical connector of the present invention accomplishes all of the forgoing objectives, and provides a relatively safe, convenient and quick solution to test the performance of the electrical connector connections and the wire leads. The improved wire nut of the present invention is also user-friendly, as it does not require the users to take off the wire caps to test the performance of the wire leads, and saves the time and effort of the testers. 
     SUMMARY 
     The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed innovation. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some general concepts in a simplified form as a prelude to the more detailed description that is presented later. 
     The subject matter disclosed and claimed herein, in one embodiment thereof, comprises an electric testing assistance tool in the form a wire nut or electrical connector comprising of a funnel-shaped flame-resistant insulating device having a top end and a bottom end, the top end having a smaller diameter than the diameter of the bottom end, a central hole on the top end to receive a testing probe of a tester device, an internal metal spiral thread connected to a metal ball connection at one end, and connected to a plurality of wire leads on the opposite end, wherein the wire leads extend from the bottom end opening, the wire leads are connected to a target wiring whose electrical parameters and continuity are to be measured using the electric testing assistance tool, and the testing probe touches the metal ball to measure the electric parameters and continuity of the target wiring. The tester device is connected to an electric parameter measuring device to record and display the measured parameters. 
     In a further embodiment of the present invention, a method of testing for voltage or continuity of a wiring or a connector is disclosed and comprises: connecting one or more wire leads extending from a bottom end of a wire nut device to the wiring or the connector; inserting a probing lead into a hole on a top end of the wire nut device wherein the probing lead is connected to a measuring device such as an ammeter, a voltmeter or any other similar device through a wire; and, the probing lead maintains an electrical connection with the wiring or the connector through a metal ball and an internal metal spiral thread present within the wire nut device. 
     In yet a further embodiment of the present invention, a method for testing an electrical connection of wire leads is disclosed. The method comprises: providing a wire lead connector for retaining and testing at least two wire leads connected therewith; the wire lead connector including a connector housing having an open bottom end and a partially open top; the partially open top end comprises a central hole; providing a metal spiral thread having an open bottom end and a closed top end; threading the metal spiral thread inside the connector housing, wherein the spiral thread closed top end spaced below the central hole; turning the wire lead connector onto at least two wire leads; inserting a testing probe of a tester device into the central hole; contacting the spiral thread closed top end with the testing probe; and, determining an electrical connection of the at least two wire leads. 
     The subject matter disclosed and claimed herein, in another embodiment thereof, comprises: an improved wire nut or electrical connector comprising a small plastic funnel or tapered structure with an interior metal spiral thread having a solid end; a small hole at the top end; a small metal ball proximal to the hole; and, a plurality of wire leads attached to the interior of the funnel structure. The improved wire nut or electrical connector can be used by professionals or homeowners for testing electricity or low voltage. The small hole on the top end of the wire nut structure allows a user to insert a test lead or probe within the connector for testing voltage, power, continuity or other parameters. 
     The advantage of the present invention is that it provides a small plastic funnel or tapered electric testing assistance device with an interior metal spiral thread with a solid end, and a small hole in the plastic housing at the top end for inserting an electric testing probe therethrough. The device may come in different colors and different sizes. The device is useful to measure electrical characteristics of any type of wiring, circuit, connector or electrical connection. The device is lightweight, portable and cost-effective. 
     To the accomplishment of the foregoing and related ends, certain illustrative aspects of the disclosed innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles disclosed herein can be employed and are intended to include all such aspects and their equivalents. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The description refers to provided drawings in which similar reference characters refer to similar parts throughout the different views, and in which: 
         FIG. 1  illustrates a perspective view of one potential embodiment of the wire nut electric connector of the present invention in accordance with the disclosed structure, wherein the connector is removably attached to a plurality of electric wires; 
         FIG. 2  illustrates a top view of one potential embodiment of the wire nut electric connector of the present invention in accordance with the disclosed structure, wherein the connector has a continuous opening in its top portion for receipt of a probe; 
         FIG. 3  illustrates a perspective view of the internal components of one potential embodiment of the wire nut electric connector of the present invention in accordance with the disclosed structure; 
         FIG. 4  illustrates a perspective view of one potential embodiment of the wire nut electric connector of the present invention in accordance with the disclosed structure, wherein a probe is being used to test the wires within the connector without having to dismantle the connection; and 
         FIG. 5  illustrates a perspective view of one potential embodiment of two separate wire nut electric connectors of the present invention in accordance with the disclosed structure, wherein a probe is being used to test the wires within the connectors without having to dismantle the connections. 
     
    
    
     DETAILED DESCRIPTION 
     The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate a description thereof. Various embodiments are discussed hereinafter. It should be noted that the figures are described only to facilitate the description of the embodiments. They are not intended as an exhaustive description of the invention and do not limit the scope of the invention. Additionally, an illustrated embodiment need not have all the aspects or advantages shown. Thus, in other embodiments, any of the features described herein from different embodiments may be combined. 
     As noted above, there exists a long felt need in the art for an improved electrical connector that may be used by professionals or homeowners to easily test the wires and electrical connectors for electricity, low voltage and other parameters. There is a long felt need in the art for an improved wire nut that does not require the user to insert the testing leads inside the wire nuts to test the wires. Further, there is a long felt need in the art for an improved wire nut that eliminates the need to remove the wire caps or wire nuts to test the wires. Furthermore, there is a long felt need in the art for an improved wire nut that allows quick and easy testing of wires, and therefore saves the time of the user. There is a long felt need in the art for an improved electrical connector that does not require the users to expend a great deal of effort in testing the wire leads connected by the electrical connector. Finally, there is a long felt need in the art for an improved wire nut that eliminates the need to take the connection apart and allows accurate testing of wire leads. 
     The present invention, in one exemplary embodiment, is a novel electric testing assistance tool in the form of a wire nut or electrical connector comprising: a tapered flame-resistant insulating device having a top end and a bottom end; the top end having a smaller diameter than the diameter of the bottom end; a central hole on the top end to receive a testing probe of a tester device; an internal metal spiral thread including a metal ball connection at one end; a plurality of wire leads at an opposing end wherein the wire leads extend from the bottom end opening; the wire leads are connected to a target wiring whose electrical parameters and continuity are to be measured using the electric testing assistance tool; and, the testing probe touches the metal ball to measure the electric parameters and continuity of the target wiring. 
     Referring initially to the drawings,  FIG. 1  illustrates a perspective view of one potential embodiment of the wire nut electric connector  100  of the present invention in accordance with the disclosed structure, wherein the connector  100  is removably attached to a plurality of electric wires. The improved wire nut or electric connector  100  of the present invention is in the form of a small plastic or thermoplastic tapered connector having a top end  102  and a bottom end  106 . The top end  102  has a small opening  1020  generally centered at the top end  102  to receive a tester lead or probe for testing voltage or current. The bottom end  106  has the opening  1060  from which a plurality of wire leads  108  can extend therefrom. The connector  100  can be tightened around a wiring such as a copper wiring for testing and also completing a circuit. 
     The electric connector  100  can be in the shape of a funnel or cone, including a tapered housing  104  and having an internal metal spiral  302  for completing the circuit between the wire leads  108  and the inserted test lead. The electric connector  100  is made up of flame-retardant thermoplastic material providing electrical insulation. The internal surface of the connector  100  can be threaded to assist in securing the internal metal spiral thereto, and to secure the connection of the wire leads  108  to the internal metal spiral. The exterior surface of the connector  100  provides a secure grip and can have opposing ribs  204 ,  206  across the exterior surface to improve grasping ability and comfort. The hole  1020  at the top end  102  is sized as per the standard sizes of the test leads used for probing. The wire leads  108  may be integrated to the electric connector  100  or may be removably attached to the internal metal spiral within the connector  100 . 
     It should be appreciated that the wire leads  108  can be connected to any type of wires or connectors for testing purpose and the tester lead or probe can be easily inserted into the hole  1020 , thus, allowing a user to perform testing without pushing the tester leads up inside the connector or touch the main wire in which the current or voltage needs to be tested. 
     Also, in cases where the connector  100  is used as a wire nut, the connector  100  is not required to be removed for testing, since the tester lead can be easily inserted into the hole  1020  for testing and probing the wire or circuit. The connection between the wires is not required to be taken apart for performing testing using the connector  100  of the present invention. The connector  100  provides a cost-effective and time-saving solution for users to check issues in the wiring and perform testing with minimal effort. The wire leads  108  are easily accessible to a user to connect to the target wire or connector system for testing the current, voltage or continuity of the target wire or connector system. The diameter of the bottom end  106  has a larger diameter than the diameter of the top end  102 , and the housing  104  can be tapered therebetween. 
       FIG. 2  illustrates a top view of one potential embodiment of the wire nut electric connector  100  of the present invention in accordance with the disclosed structure, wherein the connector has a continuous opening in its top portion for receipt of a probe. More specifically, a centralized hole or opening  1020  is present at top end  102  of the connector  100  that is used to insert a tester lead for performing probing and testing. The inner surface  202  is threaded, helping to secure the attachment of an internal metal spiral thread  302  for receiving wire leads. A pair of tabs  204 ,  206  extend outwardly from the bottom end  106  to provide assistance in securing, twisting, and operating the connector  100 . The tabs  204 ,  206  allow a user to make a comfortable grip for rotating or fastening the connector  100 . The central hole  1020  is relatively small in diameter relative to the bottom end  106 , and enables a user to guide an electrical tester or probe to wire leads within the connector  100  without having to remove a connector cap. 
       FIG. 3  illustrates a perspective view of the internal components of one potential embodiment of the wire nut electric connector  100  of the present invention in accordance with the disclosed structure. More specifically, the improved wire nut or electric connector  100  of the present invention has an internal metal spiral thread  302  along with a metal connector or closed end  300  in the form of a small metal ball. The metal ball  300  is proximal to, and recessed below, the top end  102  and is aligned with the central hole  1020  such that a probe tip of a tester lead inserted from the hole  1020  is directed toward the metal ball  300 . The metal ball  300  in contact with the metal spiral  302 , will indicate continuity of electrical connection if it exists with the wire leads contained therein. A plurality of wire leads may be permanently or removably connected to the metal spiral  302  and extend from the opening  1060  of the connector  100 . It is to be appreciated that the recessed metal ball  300  is protected from inadvertent contact with any surface in and around the housing  104 . Protecting inadvertent contact of the metal ball  300  with a metal surface (i.e. electrical box) protects the integrity of the electrical connection contained within the housing  104 . 
     The internal metal spiral  302  is fixed and can be threaded within the internal surface of the connector  100  for a secure and stable gripping for the wire leads and metal ball. The internal metal spiral  302  can be in the form of a square wire spring or cone-shaped spring for secure gripping. To replace or secure wire leads connected with the internal metal spiral  300 , soldering or electrical tape is not required. 
     In one embodiment, the connector  100  can have the dimensions of 20 mm in height (H) and 10 mm in diameter (D), wherein the diameter is of the bottom end  106  of the housing  104 . Alternatively, the connector  100  can have the dimensions of 26 mm in height (H) and 15 mm in diameter (D) wherein the diameter is of the bottom end  106  of the housing  104 . 
       FIG. 4  illustrates a perspective view of one potential embodiment of the wire nut electric connector  100  of the present invention in accordance with the disclosed structure, wherein a probe is being used to test the wires within the connector  100  without having to dismantle the connection. As shown, a tester lead  400  connected to a digital multimeter or other electric unit measuring device through a wire  404 , is used for probing and testing wires connected to the improved wire nut  100  of the present invention. More specifically, a probe tip  402  of the tester lead  400  is inserted into the hole  1020  on the top end  102  of the connector  100 . The hole  1020  is dimensioned so that the probe tip  402  easily inserts into the hole  1020  in a secure and stable manner. When inserted, the probe tip  402  is guided to, and makes contact with, the metal ball  300  present within the housing  104  of the connector  100  for checking the electrical status of wire leads  108 . 
     The wire leads  108  connected to the internal metal spiral thread  302  that is further connected to the metal ball  300  allows the probe tip  402  to test current and voltage value without removing the connector cap. Also, when the connector  100  is used as a wire nut, then the testing is performed without taking the connection apart from the target wiring or circuit. Thus, the testing is completed advantageously while the wire leads  108  are in their active use position. 
       FIG. 5  illustrates a perspective view of one potential embodiment of two separate wire nut electric connectors  100  of the present invention in accordance with the disclosed structure, wherein a probe is being used to test the wires within the connectors  100  without having to dismantle the connections. More specifically, the electrical connector  100  is designed to receive a tester probe without removing any connector cap to test a target wiring  502 . A plurality of wire leads  108 , extending from the connector  100  make connections with the target wiring  502 , to allows the tester lead to measure continuity and other electric parameters using the measuring device  500 . 
     It should be noted that using the connector  100 , the correct measurement of the target wiring is performed since the wire lead is connected to the desired wiring, even when a plurality of minute wires surrounds the target wiring. The tester device  400  is connected to the measuring device  500  using one or more wires  404  and the measuring device  500  displays the measured values. The connector  100  does not require the probing lead  402  of the tester device  400  to be in direct contact with the target wiring and thus allows a secure, safe and quick process of measuring electric parameters and continuity of the circuit. Even in the presence of multiple wires, the connector  100  offers an easy and correct method of measuring electric parameters. 
     The wire leads  108  of the connector  100  may become threaded, twisted or pressed together with the target wire for creating electrical continuity. The wire nut or connector  100  of the present invention is designed to test electrical connectivity and parameters simply and expeditiously by connecting a tester lead on the top end of the connector without altering or disturbing the electrical connection and removing the connector cap. 
     Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not structure or function. As used herein “improved wire nut or electrical connector”, “connector”, “electrical connector” and “improved wire nut” are interchangeable and refer to the improved wire nut or electrical connector  100  of the present invention. 
     Notwithstanding the forgoing, the improved wire nut or electrical connector  100  of the present invention can be of any suitable size and configuration as is known in the art without affecting the overall concept of the invention, provided that it accomplishes the above-stated objectives. One of ordinary skill in the art will appreciate that the size, configuration and material of the improved wire nut or electrical connector  100  as shown in the FIGS. are for illustrative purposes only, and that many other sizes and shapes of the improved wire nut or electrical connector  100  are well within the scope of the present disclosure. Although the dimensions of the improved wire nut or electrical connector  100  are important design parameters for user convenience, the improved wire nut or electrical connector  100  may be of any size that ensures optimal performance during use and/or that suits the user&#39;s needs and/or preferences. 
     Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. While the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that does not include all of the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof 
     What has been described above includes examples of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the claimed subject matter are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.