Apparatus and method for protection of electrical contacts

• US 4,600,261 A
• Filed: 10/12/1982
• Issued: 07/15/1986
• Est. Priority Date: 10/12/1982
• Status: Expired due to Term

• Current Assignee: Tyco Electronics Corporation (TE Connectivity Ltd. (United Kingdom))
• Original Assignee: Raychem Limited (TE Connectivity Limited)
• Inventors: Debbaut, Christian A. M.
• Primary Examiner(s): BILINSKY, ZENON
• Application Number:
  US06/434,011
• Time in Patent Office: 1,372 Days
• Field of Search: 339/116 R, 339/116 C, 339/115 R, 339/49 B, 339/115 C, 339/143 R, 29/877, 29/862, 29/863, 174/76
• US Class Current: 439/521
• CPC Class Codes: H01B 17/60 Composite insulating bodies
• CPC Class Codes: H01R 4/22 End caps, i.e. of insulating or conductive material for covering or maintaining connections between wires entering the cap from the same end
• CPC Class Codes: H01R 4/70 Insulation of connections end caps H01R4/22
• CPC Class Codes: H01R 4/72 using a heat shrinking insulating sleeve
• CPC Class Codes: H02G 15/003 Filling materials, e.g. solid or fluid insulation
• CPC Class Codes: H02G 15/043 with end caps, e.g. sleeve closed at one end
• CPC Class Codes: H02G 15/10 protected by boxes, e.g. by distribution, connection or junction boxes
• CPC Class Codes: H02G 15/18 protected by sleeves, e.g. for communication cable two-part covers H02G15/10 ; preforms having internal stresses B29C61/00
• CPC Class Codes: H05K 3/284 for encapsulating mounted components H05K1/185 takes precedence
• CPC Class Codes: Y10T 29/4921 with bonding

Abstract

An apparatus and method for protection of electrical contacts. The protection apparatus ensures that the electrical contacts are protected when they are otherwise located in an adverse environment. To this end, the protection apparatus includes an insulating gel that is characterized by a cone penetration value from approximately 150 to 350 (10^-1 mm); an ultimate elongation of at least approximately 200%; a maximum tensile strength of approximately 20 psi; and a cohesive strength greater than its adhesive strength. The protection apparatus further includes a first means to contain the gel, a second means to retain the gel within the first means and a force means which acts on the first means so that the gel is maintained in compressive contact with the electrical contacts and substantially encapsulates a conductive portion of the electrical contacts.

Claims

1. A protection apparatus for an electrical contact, comprising:

(a) an insulating gel characterized by;

(1) a cone penetration value from approximately 150 to 350 (10^-1 mm);

(2) an ultimate elongation of at least approximately 200%;

(3) a maximum tensile strength of approximately 20 psi;

(4) a cohesive strength greater than its adhesive strength;

(b) first means to contain said gel; and

(c) second means to retain said gel within said first means; and

(d) force means which acts on said first means so that said gel is maintained in compressive contact with said electrical contact and substantially encapsulates a conductive portion of said electrical contact, whereby upon release of said force means and a disengagement of said first means from said electrical contact, said gel remains substantially with said first means.

5. A protection apparatus as recited in claims 1 or 3, wherein said first means to contain said gel comprises a housing that includes side walls, end walls and a bottom wall.

6. A protection apparatus as recited in claim 5, wherein said first means to contain said gel further comprises a plurality of partitions, wherein each partition included in said plurality encapsulates a terminal binding post.

7. A protection apparatus as recited in claim 5, wherein said housing is plastic.

8. A protection apparatus as recited in claims 1 or 3, wherein said second means to retain said gel includes means to provide a surface area of said first means greater than a surface area of said electrical contact.

9. A protection apparatus as recited in claim 8, wherein said second means includes a mechanical protrusion located within said first means.

12. A protection apparatus as recited in claims 1 or 3, wherein said gel is substantially inert towards said substrate.

13. A protection apparatus as recited in claims 1 or 3 wherein said gel is hydrolytically stable and moisture-insensitive.

14. A protection apparatus as recited in claims 1 or 3, wherein said gel is tacky.

15. A protection apparatus as recited in claims 1 or 3, wherein said gel is non-tacky.

16. A protection apparatus as recited in claims 1 or 3, wherein said gel has a volume resistivity of at least approximately 10⁹ ohm centimeters.

2. A method for protecting an electrical contact, comprising the steps:

(a) providing an insulating gel characterized by;

(1) a cone penetration value from approximately 150 to 350 (10^-1 mm);

(2) an ultimate elongation of at least approximately 200%;

(3) a maximum tensile strength of approximately 20 psi;

(4) a cohesive strength greater than its adhesive strength; and

(b) providing first means of containing said gel;

(c) providing second means for retaining said gel within said first means; and

(d) applying a force means for acting on said first means so that said gel is maintained in compressive contact with said electrical contact and substantially encapsulates a conductive portion of said electrical contact.

17. A telephone circuit wire connector environmentally protected per the process of claim 2.

18. A telephone termination block environmentally protected per the process of claim 2.

19. A telephone splice connector environmentally protected per the process of claim 2.

3. A protection apparatus for a termination block of the type that includes a substrate that supports a plurality of environmentally unprotected terminal binding posts, comprising:

(a) an isolating gel characterized by;

(1) a cone penetration value from approximately 150 to 350 (10^-1 mm);

(2) an ultimate elongation of approximately 200%;

(3) a maximum tensile strength of approximately 20 psi;

(4) a cohesive strength greater than its adhesive strength;

(b) first means to contain said gel;

(c) second means to retain said gel within said first means; and

(d) force means which acts on said first means so that said gel is maintained in compressive contact with said binding posts and substantially encapsulates an electrically conductive portion of said binding posts.

10. A protection apparatus as recited in claim 3, wherein said force means is a directional force that acts along an axis defined by a terminal binding post.

11. A protection apparatus as recited in claim 3, wherein said force means is realized by a nut and bolt assembly which compresses said first means against said terminal binding post.

4. A protection apparatus for an electrical contact, comprising:

(a) an aliphatic polyurethane composition extended with an admixture of mineral oil and vegetable oil from approximately 70 to 80%, the ratio of mineral oil to vegetable oil being approximately 0.7 to 2.4;

(b) first means to contain a composition;

(c) second means to retain said composition within said first means;

(d) force means which acts on said first means so that said composition is maintained in compresive contact with said electrical contact and substantially encapsulates a conductive portion of said electrical contact.