Electrical connector apparatus and method

• US 6,705,884 B1
• Filed: 08/16/2000
• Issued: 03/16/2004
• Est. Priority Date: 08/16/1999
• Status: Expired due to Term

• Current Assignee: Centerpin Technology, Inc.
• Original Assignee: Centerpin Technology, Inc.
• Inventors: McCarthy, Dale C.
• Primary Examiner(s): Bradley, P. Austin
• Assistant Examiner(s): LEON, EDWIN A
• Application Number:
  US09/640,355
• Time in Patent Office: 1,308 Days
• Field of Search: 439/394, 439/583, 439/584, 439/427
• US Class Current: 439/394
• CPC Class Codes: H01R 4/5033 using wedge or pin penetrating into the end of a wire in axial direction of the wire
• CPC Class Codes: H01R 43/01 for connecting unstripped conductors to contact members having insulation cutting edges
• CPC Class Codes: H01R 9/053 using contact members penetrating insulation

Abstract

The subject invention relates to an electrical connector for coupling to an insulated electrical conductor or a coaxial cable of the type having an inner conductor enclosed in an inner concentric insulation and having a generally concentric conductive sheath therearound and an outer insulation enclosing the conductive sheath. The subject connector can have a housing having an electrically conductive portion and a bore therein. The subject connector can also have an electrically conductive pin mounted in the housing with one end protruding axially into the housing bore. A second end of the conductive pin can extend in an opposite direction within a second housing bore. The electrically conductive center pin can have a hollow portion extending thereinto from the protruding end and can have an annular sharpened edge on the protruding end. One or more slits can extend along the side of the center pin from the protruding end to form a plurality of center pin segments. Inserting an insulating electrical conductor into the housing bore and into engagement with the hollow center pin drives the center pin into the insulation of the electrical conductor and around the electrical conductor'"'"'s inner conductor. A segmented center pin can allow the plurality of segments to expand where necessary in order to accommodate various sizes of electrical conductors. One or more conductive arms can be electrically connected to the conductive housing portion and have pointed ends sized for piercing the outer insulation of the insulated electrical conductor. A closure member can be used for forcing and/or securing engagement of the pointed ends of the conductive arms through the outer insulation. For embodiments for use with coaxial cable, the conductive arms are insulated from the electrical conductive pin and the conductive arms are insulated from the electrical conductive pin and the pointed ends of the conductive arms can be shaped relative to one another to pierce the conductive sheath without contacting the center conductor.

Claims

1. An electrical connector for coupling to an electrical conductor having an inner conductor enclosed with an inner insulation and a generally concentric conductive sheath and enclosed in an outer insulation, said electrical connector comprising:

a housing having an electrically conductive portion;

an electrically conductive prong, wherein at least a portion of said prong is hollow for receiving the inner conductor of the electrical conductor, wherein said hollow portion of said prong comprises a plurality of slits which extend a length of the hollow portion of said prong which receives the inner conductor, wherein said plurality of slits create a plurality of prong segments; and

at least one conductive clamping arm connected to said electrically conductive portion of said housing and insulated from said electrically conductive prong, said at least one conductive clamping arm having an end for driving through an outer insulation layer of the electrical conductor and making electrical contact with the conductive sheath of the electrical conductor without contacting the inner conductor.

2. The electrical connector according to claim 1, wherein at least one slit allows the first end of the prong to expand upon receiving an inner conductor of the electrical conductor.

3. The electrical connector according to claim 1, wherein said prong is hollow extending from a first end of said prong and hollow extending from a second end of said prong such that the first end of said prong can receive the inner conductor of the electrical conductor and the second end of said prong can receive an inner conductor of an additional electrical conductor to which the electrical conductor is to be coupled.

4. The electrical connector according to claim 1, wherein said prong is hollow extending from a first end of said prong and solid extending from a second end of said prong such that the first end of said prong can receive the inner conductor of the electrical conductor and the second end can electrically contact an external apparatus to which the electrical conductor is to be coupled.

5. The electrical connector according to claim 1, further comprising an insulating base which attaches said prong to the housing and insulates said prong from the housing.

6. The electrical connector according to claim 1, wherein an edge of the prong is sharpened.

7. The electrical connector according to claim 1, wherein an edge of the prong is beveled.

8. The electrical connector according to claim 1, further comprising:

means for maintaining said at least one conductive clamping arm in position, wherein once the end of each of said at least one conductive clamp is driven through the outer insulation layer of the electrical conductor making electrical contact with the conductive sheath, said means for maintaining said at least one conductive clamping arm in position is positioned to maintain said at least one conductive clamping arm in position such that said at least one conductive clamping arm maintains electrical contact with the conductive sheath.

9. The electrical connector according to claim 8, wherein said means for maintaining said at least one conductive clamping arm in position slides over said conductive clamping arms and locks into place.

10. The electrical connector according to claim 8, wherein said means for maintaining said at least one conductive clamping arm in position comprises an o-ring such that said means for maintaining said at least one conductive clamping arm in position resists moisture.

11. The electrical connector according to claim 8, wherein said means for maintaining said at least one conductive clamping arm in position comprises a sleeve which fits over said at least one conductive clamping arm.

12. The electrical connector according to claim 8, wherein said means for maintaining said at least one conductive clamping arm in position comprises molded plastic.

13. The electrical connector according to claim 8, wherein said means for maintaining said at least one conductive clamping arm in position comprises a rubber molded covering.

14. The electrical connector according to claim 8, wherein said means for maintaining said at least one conductive clamping arm in position comprises a heat shrink material.

15. The electrical connector according to claim 8, wherein said means for maintaining said at least one conductive clamping arm in position is a snap-on cap.

16. The electrical connector according to claim 15, wherein said snap-on cap comprises a lip which settles into an indentation on said housing.

17. The electrical connector according to claim 8, wherein the means for maintaining the at least one conductive clamping arm in position is a threadable cap.

18. The electrical connector according to claim 17, wherein said threadable cap comprises internal threads which removably thread onto external threads on said housing.

19. The electrical connector according to claim 1, wherein said electrical connector comprises a plurality of conductive clamping arms, and wherein the ends of the plurality of conductive clamping arms are pointed.

20. The electrical connector according to claim 19, wherein upon driving the pointed ends of said plurality of conductive clamping arms through the outer insulation layer and making electrical contact with the conductive sheath of the electrical conductor, a first side of each conductive clamping arm contacts a second side of an adjacent conductive clamping arm such as to prevent further penetration of each conductive clamping arm'"'"'s pointed end.

21. The electrical connector according to claim 20, where the pointed end of each conductive clamping arm is curved such that when the first side of each conductive clamping arm contacts the second side of an adjacent conductive clamping arm, the curved pointed ends of the conductive clamping arms forms a circular pattern.

22. The electrical connector according to claim 19, wherein a first surface of each conductive clamping arm from which the pointed end extends contacts the outer insulation layer of the electrical conductor so as to assist in holding the electrical conductor in place with respect to said electrical connector.

23. The electrical connector according to claim 22, wherein said first surface is textured such as to increase the frictional forces between said first surface and the outer insulation layer of the electrical conductor.

24. The electrical connector according to claim 22, wherein said first surface is curved to match the curve of the outer insulation layer of the electrical conductor.

25. The electrical connector according to claim 22, wherein the pointed end of each conductive clamping arm extends from said first surface such that when said first surface contacts the outer insulation layer the pointed end contacts but does not penetrate the conductive sheath of the electrical conductor.

26. The electrical connector according to claim 22, wherein the pointed end of each conductive clamping arm extends from said first surface such that when said first surface contacts the outer insulation layer the pointed end just penetrates through the conductive sheath of the electrical conductor.

27. An electrical connector for coupling to an electrical conductor having an inner conductor enclosed with an inner insulation and a generally concentric conductive sheath and enclosed in an outer insulation, said electrical connector comprising:

a housing having an electrically conductive portion, wherein said housing comprises a first bore for receiving an end of the electrical conductor and a second bore for receiving an end of an additional electrical conductor;

an electrically conductive prong, wherein at least a portion of said prong is hollow for receiving the inner conductor of the electrical conductor; and

at least one conductive clamping arm connected to said electrically conductive portion of said housing and insulated from said electrically conductive prong, said at least one conductive clamping arm having an end for driving through an outer insulation layer of the electrical conductor and making electrical contact with the conductive sheath of the electrical conductor without contacting the inner conductor.

28. An electrical connector for coupling to an electrical conductor having an inner conductor enclosed with an inner insulation and a generally concentric conductive sheath and enclosed in an outer insulation, said electrical connector comprising:

a housing having an electrically conductive portion;

an electrically conductive prong, wherein at least a portion of said prong is hollow for receiving the inner conductor of the electrical conductor; and

at least one conductive clamping arm connected to said electrically conductive portion of said housing and insulated from said electrically conductive prong, said at least one conductive clamping arm each having an end for driving through an outer insulation layer of the electrical conductor and making electrical contact with the conductive sheath of the electrical conductor without contacting the inner conductor,

wherein the electrical conductor is designed to receive an end of the electrical conductor that is flush, wherein the hollow portion of the electrically conductive prong penetrates the flush end of the electrical conductor as the hollow portion of the electrically conductive prong receives the inner conductor of the electrical conductor.

29. The electrical connector according to claim 28, wherein said prong has at least one slit, the at least one slit allowing the first end of the prong to expand upon receiving an inner conductor of the electrical conductor.

30. The electrical connector according to claim 28, wherein said prong is hollow extending from a first end of said prong and hollow extending from a second end of said prong such that the first end of said prong can receive the inner conductor of the electrical conductor and the second end of said prong can receive an inner conductor of an additional electrical conductor to which the electrical conductor is to be coupled.

31. The electrical connector according to claim 28, wherein said prong is hollow extending from a first end of said prong and solid extending from a second end of said prong such that the first end of said prong can receive the inner conductor of the electrical conductor and the second end can electrically contact an external apparatus to which the electrical conductor is to be coupled.

32. The electrical connector according to claim 28, further comprising an insulating base which attaches said prong to the housing and insulates said prong from the housing.

33. The electrical connector according to claim 28, further comprising:

means for maintaining said at least one conductive clamping arm in position, wherein once the end of each of said at least one conductive clamp is driven through the outer insulation layer of the electrical conductor making electrical contact with the conductive sheath, said means for maintaining said at least one conductive clamping arm in position is positioned to maintain said at least one conductive clamping arm in position such that said at least one conductive clamping arm maintains electrical contact with the conductive sheath.

34. The electrical connector according to claim 33, wherein said means for maintaining said at least one conductive clamping arm in position comprises an o-ring such that said means for maintaining said at least one conductive clamping arm in position resists moisture.

35. The electrical connector according to claim 33, wherein said means for maintaining said at least one conductive clamping arm in position comprises a sleeve which fits over said at least one conductive clamping arm.

36. The electrical connector according to claim 33, wherein said means for maintaining said at least one conductive clamping arm in position comprises molded plastic.

37. The electrical connector according to claim 33, wherein said means for maintaining said at least one conductive clamping arm in position comprises a rubber molded covering.

38. The electrical connector according to claim 33, wherein said means for maintaining said at least one conductive clamping arm in position comprises a heat shrink material.

39. The electrical connector according to claim 33, wherein said means for maintaining said at least one conductive clamping arm in position slides over said at least one conductive clamping arm and locks into place.

40. The electrical connector according to claim 33, wherein said means for maintaining said at least one conductive clamping arm in position is a snap-on cap.

41. The electrical connector according to claim 40, wherein said housing includes an indentation and said snap-on cap comprises a lip which settles into said indentation on said housing.

42. The electrical connector according to claim 28, wherein said electrical connector comprises a plurality of conductive clamping arms, and wherein the ends of the plurality of clamping arms are pointed.

43. The electrical connector according to claim 42, wherein upon driving the pointed ends of said plurality of conductive clamping arms through the outer insulation layer and making electrical contact with the conductive sheath of the electrical conductor, a first side of each conductive clamping arm contacts a second side of an adjacent conductive clamping arm such as to prevent further penetration of each conductive clamping arm'"'"'s pointed end.

44. The electrical connector according to claim 43, where the pointed end of each conductive clamping arm is curved such that when the first side of each conductive clamping arm contacts the second side of an adjacent conductive clamping arm, the curved pointed ends of the conductive clamping arms forms a circular pattern.

45. The electrical connector according to claim 42, wherein a first surface of each conductive clamping arm from which the pointed end extends contacts the outer insulation layer of the electrical conductor so as to assist in holding the electrical conductor in place with respect to said electrical connector.

46. The electrical connector according to claim 45, wherein said first surface is textured such as to increase the frictional forces between said first surface and the outer insulation layer of the electrical conductor.

47. The electrical connector according to claim 45, wherein said first surface is curved to match the curve of the outer insulation layer of the electrical conductor.

48. The electrical connector according to claim 45, wherein the pointed end of each conductive clamping arm extends from said first surface such that when said first surface contacts the outer insulation layer the pointed end contacts but does not penetrate the conductive sheath of the electrical conductor.

49. The electrical connector according to claim 45, wherein the pointed end of each conductive clamping arm extends from said first surface such that when said first surface contacts the outer insulation layer the pointed end just penetrates through the conductive sheath of the electrical conductor.