Method and device for making a protected electrical connector

• US 5,639,992 A
• Filed: 10/18/1994
• Issued: 06/17/1997
• Est. Priority Date: 10/12/1982
• Status: Expired due to Fees

• Current Assignee: Tyco Electronics Corporation (TE Connectivity Limited)
• Original Assignee: Raychem Corporation (TE Connectivity Limited)
• Inventors: Debbaut, Christian Arthur Marie-Louise
• Primary Examiner(s): Kincaid, Kristine L.
• Assistant Examiner(s): Nguyen, Chau N.
• Application Number:
  US08/324,420
• Time in Patent Office: 973 Days
• Field of Search: 174/84 R, 174/76, 174/84 C, 174/87, 174/92, 174/93, 29/855, 29/858, 29/868, 29/749, 29/871, 29/872, 29/862, 524/157, 524/267, 524/491, 524/848
• US Class Current: 174/84.00R
• 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

Abstract

An apparatus and method for protection of electrical contacts as well as a process for splicing electrical wires that are to be exposed to an adverse environment. The protection apparatus ensures that the electrical contacts are protected when they are otherwise located in an adverse environment. In a particular embodiment, the apparatus includes a connector, an insulating sleeve adapted to retain the connector, and an encapsulant. The encapsulant, which is disposed with protection apparatus, e.g. the insulating sleeve, has a cone penetration value of 100 to 350 (10^-1 mm) and an ultimate elongation of at least 200% and preferably an elastic modulus of less than 10⁷ dynes/cm².

Claims

1. A recoverable splice gel connector enclosure comprising:

a recoverable sleeve; and

a gel to seal cables emanating from the recoverable sleeve, the gel has an elongation of at least 50%, a cone penetration of from 100 to 350 (10^-1 mm) and an elastic modulus less than 10⁷ dynes/cm².

2. The enclosure according to claim 1 wherein the recoverable sleeve is heat recoverable.

3. The enclosure according to claim 2 wherein the gel is selected from the group consisting of an oil-extended polyurethane gel, a plasticizer extended polyurethane gel, a silicone gel.

4. The enclosure according to claim 3 wherein the gel is a silicone gel.

5. The enclosure according to claim 3 wherein the gel is a polyurethane gel.

6. The enclosure according to claim 2 wherein the gel has an elongation of at least 200% and an elastic modulus of less than 10⁶ dynes/cm².

7. The enclosure according to claim 1 further including an inline cable splice connector.

8. A kit of parts to seal a cable substrate comprising:

a) a heat recoverable sleeve; and

b) a cable sealing gel having an elongation of at least 50%, a cone penetration of from 100 to 350 (10^-1 mm) and an elastic modulus less than 10⁷ dynes/cm².

9. The kit of parts according to claim 8 wherein the gel is a silicone gel.

10. The kit of parts according to claim 9 wherein the gel is a polyurethane gel.

11. The kit of parts according to claim 8 further comprising an electrical wire cable splice connector capable of fitting under the heat recoverable sleeve.

12. An apparatus for protecting a substrate having a metal to metal electrical contact interface which comprises:

a support member;

an encapsulant which is adherent to the support member and has a cone penetration value of 100 to 350 (10^-1 mm) and an ultimate elongation of at least 200%; and

means to retain encapsulant, deformed by the metal to metal electrical contact interface, into close and conforming contact with the interface.

13. The apparatus according to claim 12, wherein the encapsulant is cured prior to coming into contact with any part of a substrate to be protected.

14. The apparatus according to claim 12 wherein the support member includes at least part of the substrate to be protected.

15. The apparatus according to claim 14 wherein the encapsulant is cured in contact with at least part of the substrate to be protected.

16. In combination, a substrate including at least one electrical contact element to establish an electrical contact connection combination with at least one additional metallic contact element, an electrically insulating gel associated with said substrate to protect the combination, said gel having an elastic modulus of less than 10⁶ dynes/cm² and an ultimate elongation of at least 200%, and a cone penetration of from about 150-350 (10^-1 mm), said gel preformed in the absence of the combination to be protected, wherein said gel undergoes elastic deformation at least at the interface between the combination and the deformed gel directly in contact therewith, and a member operably acting in conjunction with said substrate for maintaining the deformed gel into close and conforming contact with the combination.

17. A reusable apparatus for environmentally protecting at least one initially unprotected electrical contact element and a second contact element so that the electrical contact connection therebetween is environmentally protected, said apparatus comprising:

a reusable receptacle for housing the electrical contact connection;

a gel formed prior to making the electrical contact connection, said gel being disposed within said receptacle and having an ultimate elongation of at least 200%, and elastic modulus of less than 10⁶ dynes/cm² and a cone penetration of 100-350 (10^-1 mm); and

a repeatedly usable cooperative retention member interactive with said receptacle to maintain the gel deformed elastically at said electrical contact connection in contact therewith.

18. The apparatus according to claim 17 wherein the receptacle includes an insulation displacement electrical contact.

19. A device for protecting an electrical contact established between electrical contact elements which form an electrical contact combination comprising:

(i) a gel;

(a) has been preformed apart from the combination to be protected to have an elastic modules of less than 10⁶ dynes/cm² and an ultimate elongation of at least 200% with a cone penetration of from about 150-350% (10^-1 mm); and

(b) is capable of undergoing elastic deformation around the electrical contact combination;

(ii) a support member for said gel, said support member assisting in containing the gel and protecting the electrical contact element combination;

and

(iii) means, operatively associated with said support member for maintaining said gel deformed by the assembly of said combination into close conforming and direct contact with said electrical contact combination, at least part of said deformation of said gel being elastic deformation whereby said electrical contact combination is substantially encapsulated.

20. The device according to claim 19 wherein said support member includes an electrical contact element associated with said support member, and at least where part of said means for deforming includes a bolt member and said bolt member acts in combination with said support member and is associated with said electrical contact combination.

21. The device according to claim 19 wherein said support member includes an electrical contact element.

22. The device according to claim 21 wherein said electrical contact element is a wire.

23. The device according to claim 22 wherein the support member is adapted to receive said electrical wire having an end section free of insulation and which when the connector is crimped around said wire placed within the connector mechanically deforms wire into physical and electrical contact with the connector.

24. A protection apparatus for an electrical contact between at least two electrical contact elements comprising:

(a) an insulation gel characterized by;

(1) a cone penetration value from about 150-350% (10^-1 mm);

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

(3) a maximum tensile strength of about 20 PSI;

(4) a cohesive strength greater than its adhesive strength

(b) a first means to contain said gel; and

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

(d) a force retention member which cooperates with said first means so that said gel is maintained in compressive contact with the electrical contact elements, whereby said gel encapsulates the conductive portion of said electrical contact elements and upon release of said force retention member and a disengagement of said first means and disassociation of said electrical contact elements, said gel remains substantially with said first means.

25. A protection apparatus for an electrical contact combination, comprising;

(a) a gel composition characterized by;

(1) a cone penetration value approximately 150-350 (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 the gel;

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

(d) cooperative force means which acts on said first means so that said gel is maintained in compressive contact across said electrical contact combination and encapsulates the electrically conductive portion of said combination.

26. The apparatus according to claim 25 wherein the gel is a polysiloxane based gel.

27. An apparatus for protection of a substrate including an electrical contact element combination, comprising;

a gel, the gel being cured prior to coming into contact with the combination to be protected, the gel having a cone penetration value of 100-350 (10^-1 mm) and an ultimate elongation of at least 200%; and

means for deforming the gel into close and conforming and direct contact with the electrical contact combination.

28. The apparatus according to claim 27 having a support member wherein said support member comprises a plurality of individual open containers which are connected to each other and each of which contains a separate mass of the gel.

29. The apparatus according to claim 28 having a force member wherein the force member is selected from the group consisting of forces that are substantially nonvarying in time or dynamic.

30. The apparatus according to claim 27 wherein the gel is a polysiloxane based gel.