In-Line Electrical Wire Connector

1. Field of the Invention

This invention relates to electrical connectors and, more specifically to in-line electrical connectors.

2. Background of the Invention

In the distant past the joining of electrical conductors invariably involved twisting the two or more conductors together and soldering them. Names like "Western Union connection" and others were adopted and well known amongst electricians and hobbyists. There followed the "wire nuts" which comprised a plastic outer shell and a single, un-directionally threaded insert. To use this connector the conductors were laid, or held, with their exposed ends in the same direction, twisting the ends together and applying the wire nut to the inter-twined conductors. Twisting the wire nut in a clockwise direction would draw the ends of the conductors into tight contact with each other and with the conductive thread in the nut, forming a satisfactory electrical connection. The problem with the wire nuts of the prior art was that the joint which they formed was, overall, bulky and in many instances very difficult to effect. Also, the radical change in direction required of the conductor made the use of the wire nut difficult if one of the conductors came from around a corner, or the like.

Therefore, it is an object of this invention to provide a wire connector that overcomes the problems and disadvantages of prior art devices.

It is a further object of this invention to provide a simple, low cost wire connector which is easy to apply and effects an electrically low resistance and mechanically strong inter-wire connection.

The present invention can best be understood by referring to the description which follows and taking it in conjunction with the accompanying drawings, in which:

FIG. 1 is a side, elevational view of an electrical connector according to the present invention;

FIG. 2 is an end view of the connector of FIG. 1;

FIG. 3 is a cross sectional view taken along the line 3--3 in FIG. 1, and;

FIG. 4 is a side elevational view of a modification of the connector of FIG. 1.

In FIGS. 1, 2 and 3 connector 10 includes an electrically insulative plastic shell 12, which is generally cylindrical and has a series of coaxial, tapered, or frustro-conical openings 14, 16, 18 and 20, therethrough. Embedded in the bounding surface of frustro-conical surfaces 16 and 18 but exposed for electrical contact on its inner surface is a continuous, conductive metal thread-wire 19 wound in a right-handed fashion in opening 16 and in a left-handed fashion in opening 18. The point of reversal in wire-winding direction is, generally, at the center of shell 12 where openings 16 and 18 join. The thread-wire has spring-like properties.

As can be seen in FIG. 2, openings 14 and 20 have threaded walls 22 and 24, respectively, without electrical conductivity. These regions can be considered feed-in or starter regions for the conductors to be joined.

A knurled grip-portion 26 is provided, centrally, in shell 12 to permit a firm grip of connector 10.

After any insulation has been removed from each of two wires one is inserted as far as possible in opening 20 and the other is inserted as far as possible in opening 14. Knurled region 26 is then gripped and shell 12 is turned in the direction in which the wires are drawn into shell 12. This process is continued until both wires are firmly engaged by continuous thread wire 19. The taper of openings 16 and 18 and, hence, the taper of frustro-conically wound thread-wire 19 must be gradual to assure extensive contact between thread-wire 19 and the wires being joined, thus ensuring good mechanical strength and good electrical conductivity therebetween.

If the wires are of significantly different gauges one set of openings, such as openings 14 and 16, may be of lesser diameter than the other set of openings, such as openings 18, 20. This combination is shown in FIG. 4. Of course, each opening combination can accommodate a broad range of gauges because of the tapered nature of each such opening combination. However, for maximum mechanical strength and electrical conductivity, different sized opening combinations may be required.

Thread wire 19 may not be circular in cross-section but may have a sharpened or triangular cross-section in its area exposed in openings 16 and 18. Such an edge would permit the threadwire to grip the inserted conductors better.

While particular embodiments have been shown and described, it will be apparent to those skilled in the art that variations and modifications may be made without departing from the true spirit and scope of this invention. It is the purpose of the appended claims to cover all such variations and modifications.