Electricity: conductors and insulators – Conduits – cables or conductors – Combined
Patent
1992-12-21
1995-01-03
Nimmo, Morris H.
Electricity: conductors and insulators
Conduits, cables or conductors
Combined
29872, 174 84R, 174DIG8, H01R 422, H01R 4300
Patent
active
053788559
DESCRIPTION:
BRIEF SUMMARY
This invention relates to electrical connectors, and especially to connectors for forming solder joints between conductors in such articles as automotive harnesses and the like.
Electrical harnesses, for example as manufactured in the automotive industry, are often quite complex. In some instances they are manufactured by forming two or more sub-assemblies of wires, terminals, connectors and any other components, and then forming electrical connection(s) between the sub-assemblies. In such a case the assembly of the harness my be controlled by computer permitting, with the aid of a monitor, the assembly operator to see schematically the lay up and to check correct build-up of the assembly at each stage of the harness manufacture. In order to enable this control process to operate the ends of the conductors of the sub-assemblies are connected, e.g. by means of spring contacts, and an electrical current or signal is passed through the assembly in order to obtain verification that the harness is correct. It is only after such verification is obtained that the clips are removed and a permanent electrical connection is formed.
According to the invention, there is provided a device for forming an electrical connection at the end of a bundle of elongate electrical conductors, which comprises an electrically insulating sleeve, a metallic connecting element located within the sleeve, and a quantity of solder for forming a permanent electrical connection between the conductors, the connecting element having a tapering internal surface which has a screw thread, so that a temporary electrical connection can be formed by screwing the bundle of conductors into the connecting element.
Preferably the device includes an element for holding the bundle before or while the permanent electrical connection is formed. For example the element may resist withdrawal of the bundle so that the connection will be able to withstand normal handling of the harness during assembly without the connection inadvertently becoming loose or breaking, but can be removed if desired, for example in order to replace one or more sub-assemblies. Such an element may, for example, comprise a ring located inside the sleeve which is provided with one or more teeth or gripping edges for engaging insulation of the conductors forming the bundle. The teeth or gripping members preferably have substantially the same axial inclination as has the screw thread of the connecting element, so that the bundle can be inserted into the sleeve by rotating the bundle within the sleeve and applying a forward pressure, but that removal of the sleeve from the insulated conductors by pulling and/or unscrewing is resisted. Alternatively, the element may be provided in order to hold the bundle during or immediately before recovery of the sleeve. For example, a fusible or infusible (cross-linked) polymeric ring, preferably a heat-shrinkable polymeric ring may be provided in the sleeve. Such a ring may be made to melt or recover before recovery of the sleeve if its melting or recovery point is lower than that of the recoverable sleeve recovery of the ring in this way can be used to reinforce the grip on the bundle and to eliminate or reduce the risk of piercing of the sleeve wall by the conductor strands. Such an element may, for example have a melting or softening point in the range of from 60.degree. to 100.degree. C. Examples of materials from which the polymeric ring may be formed include ionomers, e.g. Surlyn, or from polyamides, e.g. nylon 6, 66, 11 or 12. After the installed device has cooled, the element will assist in maintaining mechanical rigidity of the assembly.
The device according to the invention has the advantage that the conductors can be electrically joined to form a temporary joint which is disconnectable but is able to have a high degree of dependability, in order, for example to test the connected conductors, and can then be permanently joined with no further manipulation of the joint but simply by heating the sleeve in order to melt the solder. In addition
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Burkard Herbert G.
Nimmo Morris H.
Novack Sheri M.
Raychem SA
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