Electrical splice connector for connecting cable and conductor pair

Abstract

An electrical splice connector (100, 200) is disclosed that includes a first splice terminal (202) crimped to wire conductors (208, 212) of two wire cables (210, 214), and a second splice terminal (204) crimped to wire conductors (216, 218) of the cables (210, 214). The connector comprises a separating insulator (206, 502) made of a dielectric material, the separating insulator having a separate cavity (220, 222) for each splice terminal (202, 204), the cavities being separated by dielectric walls (224, 506). According to the design, proper insulation and separation between the two splicing terminals are ensured, and the safety and reliability of electric connection are improved.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Patent Application No. 18 / 506,431, filed on November 10, 2023, entitled “Electrical Splice Connector For Connecting Electrical Cables With Conductor Pairs,” the entire disclosure of which is incorporated herein by reference. Technical Field

[0002] The present invention generally relates to an electrical splicing connector for connecting cables and conductor pairs, such as unshielded twisted pair cables for Ethernet communications. Background Art

[0003] Various devices and methods have been used to splice cables and conductor pairs together, such as Figure 1 The unshielded twisted pair cable 100 is shown. The first method involves simply twisting each end of the conductor pair in one cable to its corresponding counterpart in the other cable. The second method uses two insulation displacement contact (IDC) splicing devices that cut through the cable insulation to establish physical and electrical contact between the conductor pairs in one cable and their corresponding counterparts in the other cable. The third method uses a press-fit connector in which the two conductor ends of each cable are pressed between two pieces of metal. The insulation of the cable is stripped away, exposing the conductors within the cable to form a physical and electrical connection. In each splicing method, the capacitive coupling between the contact pairs is not well controlled, which may affect the impedance of the spliced ​​connection and the frequency response characteristics of the spliced ​​cable. These splicing methods are not suitable for use in harsh environments, such as those of automobiles or other ground, marine or aerospace vehicles, because they cannot meet the mechanical, electrical and environmental requirements required in these applications. Summary of the invention

[0004] In some aspects, the technology described herein relates to an electrical splice connector, comprising: a first splice terminal crimped to a first wire conductor of a first wire cable and crimped to a first wire conductor of a second wire cable, a second splice terminal crimped to a second wire conductor of the first wire cable and crimped to a second wire conductor of the second wire cable, and a separator insulator formed of a dielectric material, the separator insulator having a first cavity and a second cavity, the first splice terminal being disposed in the first cavity and the second splice terminal being disposed in the second cavity. The second cavity is separated from the first cavity by a wall formed of the dielectric material.

[0005] In some aspects, the technology described herein relates to a method of splicing a first wire cable to a second wire cable, comprising the steps of: joining the first wire conductors of the first wire cable and the first wire conductor of the second wire cable by crimping a first splice terminal to the first wire conductor of the first wire cable and the first wire conductor of the second wire cable; joining the second wire conductors of the first wire cable and the second wire conductor of the second wire cable by crimping a second splice terminal to the second wire conductor of the first wire cable and the second wire conductor of the second wire cable; placing the first splice terminal in a first cavity of a separator insulator; and placing the second splice terminal in a second cavity of the separator insulator separated from the first cavity by a wall.

[0006] In some aspects, the technology described herein relates to an electrical splicing connector for connecting a first wire cable having a first wire conductor and a second wire conductor and a second wire cable having the first wire conductor and the first wire conductor, the electrical splicing connector comprising: a first splicing terminal, the first splicing terminal configured to be crimped to the first wire conductor of the first wire cable and to the first wire conductor of the second wire cable; a second splicing terminal, the second splicing terminal configured to be crimped to the second wire conductor of the first wire cable and to the second wire conductor of the second wire cable; and a separating insulator formed of a dielectric material, the separating insulator having a first cavity and a second cavity, the first splicing terminal being disposed in the first cavity and the second splicing terminal being disposed in the second cavity. The second cavity is separated from the first cavity by a wall formed of the dielectric material. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0008] Figure 1 is an isometric view of an electrical cable having paired electrical conductors according to the prior art.

[0009] Figure 2 is an exploded view of an electrical splice connector according to some embodiments of the present invention.

[0010] Figure 3 According to some embodiments of the present invention Figure 2 Isometric view of an electrical splicing connector.

[0011] Figure 4 is covered by a heat shrink tube according to some embodiments of the present invention Figure 2 Isometric view of an electrical splicing connector.

[0012] Figure 5 is an isometric view of a separator insulator of an electrical splice connector according to some embodiments of the present invention.

[0013] Figure 6is a flow chart of a method for splicing a first wire cable to a second wire cable according to some embodiments of the present invention. DETAILED DESCRIPTION

[0014] Figure 2 The electrical splice connector 200 shown is composed of four main components: two metal splice terminals 202, 204 and a separating insulator 206. Figure 3 As shown, the first splice terminal is crimped to the first wire conductor 208 of the first wire cable 210 and to the first wire conductor 212 of the second wire cable 214. The second splice terminal 204 is crimped to the second wire conductor 216 of the first wire cable 210 and to the second wire conductor 218 of the second wire cable 214. The splice terminals 202, 204 provide mechanical strength to the electrical splice connector 200 and prevent the electrical splice connector 200 from being pulled apart. Figure 4 As shown, the electrical splice connector 200 is covered by heat shrink tubing 402 .

[0015] The first splice terminal 202 and the second splice terminal 204 are disposed within a first cavity 220 and a second cavity 222 defined by a separator insulator 206. The separator insulator 206 is formed of a dielectric material, such as an engineering polymer. The first cavity 220 and the second cavity 222, and thus the first splice connector 202 and the second splice connector 204, are separated by a wall 224 between the first cavity 220 and the second cavity 222. In order to control the capacitive coupling between the first splice terminal 202 and the second splice terminal 204, and thus the electrical impedance of the electrical splice connector 200, the wall 224 may have one or more openings 226 between the first cavity 220 and the second cavity 222. Alternatively or additionally, the separator insulator 502 may be formed of a dielectric material such as an engineering polymer. Figure 5 One or more sections 504 of reduced thickness are shown in the wall 506 to control the capacitive coupling between the first and second splice terminals. In other embodiments, the wall of the separating insulator may be solid and have a constant thickness, depending on the capacitive coupling requirements between the first and second splice terminals needed to obtain the desired inductance of the electrical splice connector.

[0016] The separation insulator 206 maintains equal spacing between the first conductors 208, 212 and the second conductors 216, 218 of the first wire cable 210 and the second wire cable 214 within the electrical splicing connector 100, and is configured to closely match the average dielectric constant value between the first conductors 208, 213 and the second conductors 216, 218 in the first wire cable 210 and the second wire cable 214. This provides an electrical splicing connector 200 that has reduced signal attenuation and impedance values ​​that closely match unspliced ​​cables. The maximum outer dimension of the separation insulator 206 is less than or equal to the diameter of the first wire cable 210 and the second wire cable 214, thereby making it easier to package the spliced ​​cables in vehicle applications. Typically, the splicing method described in the background technology provides a splicing connection with a diameter that is much larger than the cable diameter.

[0017] The first splice terminal 202 is identical to the second splice terminal 204. The first splice terminal 202 defines a first wire stop 228 that contacts an end of the first wire conductor 208 of the first wire cable 210 and contacts an end of the first wire conductor 212 of the second wire cable 214. The second splice terminal 204 defines a second wire stop 230 that contacts an end of the second wire conductor 216 of the first wire cable 210 and contacts an end of the second wire conductor 218 of the second wire cable 214. The wire stops 228, 230 may be formed by wings that are crimped prior to the insertion of the cables 210, 214 into the wire crimp wings 232 of the splice terminal to provide the wire stops 228, 230.

[0018] like Figure 2 As shown, the first cable stop 228 is aligned with the second cable stop 230 within the separator insulator 206 by the terminal stop 234 defined at the ends of the first cavity 220 and the second cavity 222. These features further help reduce signal attenuation and closely match the impedance value to the original unspliced ​​cable.

[0019] The length of the splice terminals and the separating insulators are preferably minimized to limit electromagnetic interference (EMI) that may be caused by the electrical splice connector 100 .

[0020] The separation insulator is disposed in the heat shrink tubing 402. The heat shrink tubing 402 provides a barrier for environmental contaminants to prevent them from contacting the first and second conductors 208, 212, 216, 218 of the first and second wire cables 210, 214 and the first and second splice terminals 202, 204 to prevent degradation of the mechanical and electrical performance of the electrical splice connector 200.

[0021] like Figure 2As shown, the separator insulator 206 of the illustrated embodiment includes a first opening 226 and a separate second opening 226, which are positioned equidistant from the longitudinal center Y of the separator insulator 206. In other embodiments, the separator insulator can have a single opening or more than two openings, depending on the dielectric properties required to maintain an average dielectric constant value between the first conductor and the second conductor in the first wire cable and the second wire cable. The first splice terminal 202 and the second splice terminal 204 are equidistant relative to the lateral center X of the separator insulator 206.

[0022] Figure 6 The illustrated method 600 of splicing a first cable to a second cable includes: Step 602 , joining a first wire conductor of a first wire cable to a first wire conductor of a second wire cable by crimping a first splicing terminal to the first wire conductor; Step 604 , joining a second wire conductor of the first wire cable to a second wire conductor of the second wire cable by crimping a second splice terminal to the second wire conductor; Step 606, placing the first splicing terminal in the first cavity of the separation insulator; Step 608, placing a second splicing terminal in a second cavity of the partition insulator, the second cavity being separated from the first cavity by a wall; Step 610, forming at least one opening in the wall to control capacitive coupling between the first splicing terminal and the second splicing terminal; Step 612, placing heat shrink tubing on the separator insulator; and Step 614, heating the heat shrink tube so that the inner surface of the heat shrink tube contacts the partition insulator.

[0023] In some aspects, the technology described herein relates to an electrical splice connector, comprising: a first splice terminal crimped to a first wire conductor of a first wire cable and crimped to a first wire conductor of a second wire cable, a second splice terminal crimped to a second wire conductor of the first wire cable and crimped to a second wire conductor of the second wire cable, and a separator insulator formed of a dielectric material, the separator insulator having a first cavity and a second cavity, the first splice terminal being disposed in the first cavity and the second splice terminal being disposed in the second cavity, wherein the second cavity is separated from the first cavity by a wall formed of the dielectric material.

[0024] In some aspects, the technology described herein relates to an electrical splice connector in which at least one opening between a first cavity and a second cavity is formed in a wall to control capacitive coupling between a first splice terminal and a second splice terminal to control an electrical impedance of the electrical splice connector.

[0025] In some aspects, the technology described herein relates to an electrical splice connector in which at least a portion of a wall has a reduced thickness to control capacitive coupling between a first splice terminal and a second splice terminal to control an electrical impedance of the electrical splice connector.

[0026] In some aspects, the technology described herein is directed to an electrical splice connector, further comprising a heat shrink tubing in which a separator insulator is disposed.

[0027] In some aspects, the technology described herein relates to an electrical splice connector in which a first splice terminal is identical to a second splice terminal.

[0028] In some aspects, the technology described herein relates to an electrical splice connector wherein a first splice terminal defines a first cable stop that contacts an end of a first wire conductor of a first wire cable and contacts an end of a first wire conductor of a second wire cable, and wherein a second splice terminal defines a second cable stop that contacts an end of a second wire conductor of the first wire cable and contacts an end of a second wire conductor of the second wire cable.

[0029] In certain aspects, the technology described herein relates to an electrical splice connector in which a first wire stop is aligned with a second wire stop by a terminal stop defined in first and second cavities within a split insulator.

[0030] In some aspects, the technology described herein relates to an electrical splice connector in which a first cable stop and a second cable stop are located at a longitudinal center of a separator insulator.

[0031] In some aspects, the technology described herein relates to an electrical splice connector in which a first wire stopper and a second wire stopper are integrally formed with a first splice terminal and a second splice terminal, respectively.

[0032] In some aspects, the technology described herein relates to an electrical splice connector wherein at least one opening includes a first opening and a separate second opening positioned equidistant from a longitudinal center of a separator insulator.

[0033] In some aspects, the technology described herein relates to an electrical splice connector in which a first splice terminal and a second splice terminal are equidistant from a lateral center of a separator insulator.

[0034] In some aspects, the technology described herein relates to a method of splicing a first wire cable to a second wire cable, comprising: joining a first wire conductor of the first wire cable to a first wire conductor of a second wire cable by crimping a first splice terminal to the first wire conductor; joining a second wire conductor of the first wire cable to a second wire conductor of the second wire cable by crimping a second splice terminal to the second wire conductor; placing the first splice terminal in a first cavity of a separator insulator; and placing the second splice terminal in a second cavity of the separator insulator separated from the first cavity by a wall.

[0035] In some aspects, the technology described herein relates to a method that also includes forming at least one opening in a wall to control capacitive coupling between a first splice terminal and a second splice terminal.

[0036] In some aspects, the technology described herein is directed to a method that also includes the steps of placing a heat shrink tubing on a separator insulator and heating the heat shrink tubing so that an inner surface of the heat shrink tubing contacts the separator insulator.

[0037] In some aspects, the technology described herein relates to a method, which also includes: folding a first pair of stop tabs of a first spliced ​​terminal inward to form a first cable stop; before crimping the first spliced ​​terminal to the first wire conductor, placing an end of the first wire conductor of the first wire cable in contact with the first cable stop, and placing an end of the first wire conductor of the second wire cable in contact with the first cable stop; folding a second pair of stop tabs of the second spliced ​​terminal inward to form a second cable stop; and, before crimping the second spliced ​​terminal to the second wire conductor, placing an end of the second wire conductor of the first wire cable in contact with the second cable stop, and placing an end of the second cable conductor of the second wire cable in contact with the second cable stop.

[0038] In some aspects, the technology described herein relates to a method that also includes aligning the first cable stop and the second cable stop so that they are located at a longitudinal center of the separator insulator.

[0039] In some aspects, the technology described herein relates to a method that also includes separating a first cable stop from a second cable stop within a separator insulator.

[0040] In some aspects, the technology described herein relates to a method in which a first splice terminal is identical to a second splice terminal.

[0041] In some aspects, the technology described herein relates to a method wherein at least one opening includes a first opening and a separate second opening positioned equidistant from a longitudinal center of a separator insulator.

[0042] In some aspects, the technology described herein relates to a method that also includes placing a first splice terminal and a second splice terminal within a divider insulator such that they are equidistant from a lateral center of the divider insulator.

[0043] Although the present invention has been described according to the preferred embodiments of the present invention, the present invention is not intended to be limited thereto, but is only limited by the scope set forth in the following claims. For example, the embodiments described above (and / or their various aspects) can be used in combination with each other. In addition, various modifications can be made to adapt specific situations or materials to the teachings of the present invention without departing from its main scope. The dimensions, types, orientations of the various components described herein, and the number and position of the various components are intended to define the parameters of a specific embodiment, are not meant to be limiting, and are only prototype embodiments.

[0044] After reading the above description, many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of ordinary skill in the art. Therefore, the scope of the present invention is limited only by the appended claims and the full scope of equivalents encompassed by these claims.

[0045] As used herein, “one or more” includes a function performed by one element, a function performed by more than one element, such as in a distributed fashion, several functions performed by one element, several functions performed by several elements, or any combination of the above.

[0046] It should also be understood that, although in some cases, the terms first, second, etc. are used to describe various elements in this article, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, without departing from the scope of the various described embodiments, the first contact can be referred to as the second contact, and similarly, the second contact can be referred to as the first contact. Both the first contact and the second contact are contacts, but they are not identical contacts.

[0047] The terms used in the description of the various embodiments herein are for the purpose of describing specific embodiments only and are not intended to be limiting. As used in the description of the various described embodiments and in the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and encompasses all possible combinations of one or more associated listed items. It should also be understood that the terms "comprises", "containing", "includes" and / or "comprising" used in this specification specifically refer to the presence of stated features, wholes, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, parts and / or groups thereof.

[0048] As used herein, the term "if" may be alternatively interpreted as "when" or "in" or "in response to determining" or "in response to detecting", depending on the context. Similarly, the phrase "if it is determined" or "if [the state or event] is detected" may be alternatively interpreted as meaning "upon determining" or "in response to determining" or "upon detecting [the condition or event]" or "in response to detecting [the condition or event]", depending on the context.

[0049] In addition, although the terms of regulations or directions may be used herein, these elements should not be limited by these terms. Unless otherwise specified, all regulations or directions are used to distinguish one element from another element, and unless otherwise specified, do not represent any particular order, order of operation, direction or orientation.

Claims

1. An electrical splicing connector (100, 200), comprising: a first spliced ​​terminal (202) crimped to a first wire conductor (208) of a first wire cable (210) and crimped to a first wire conductor (212) of a second wire cable (214); a second splicing terminal (204), the second splicing terminal being crimped to a second wire conductor (216) of the first wire cable (210) and being crimped to a second wire conductor (218) of the second wire cable (214); as well as A separation insulator (206, 502) is formed of a dielectric material and has a first cavity and a second cavity, wherein the first splicing terminal (202) is arranged in the first cavity and the second splicing terminal (204) is arranged in the second cavity, wherein the second cavity is separated from the first cavity by a wall (224, 506) formed of a dielectric material.

2. The electrical splicing connector (100, 200) according to claim 1, characterized in that: At least one opening between the first cavity and the second cavity is formed in the wall (224, 506) to control capacitive coupling between the first splice terminal (202) and the second splice terminal (204), thereby controlling the electrical impedance of the electrical splice connector (100, 200).

3. The electrical splicing connector (100, 200) according to claim 2, characterized in that: The at least one opening includes a first opening and a separate second opening located equidistant from a longitudinal center of the separator insulator (206, 502).

4. The electrical splicing connector (100, 200) according to claim 1, characterized in that: At least one section of the wall (224, 506) has a reduced thickness to control capacitive coupling between the first splice terminal (202) and the second splice terminal (204), thereby controlling the electrical impedance of the electrical splice connector (100, 200).

5. The electrical splicing connector (100, 200) according to claim 1, characterized in that: Also included is a heat shrink tube, in which the separation insulator (206, 502) is disposed.

6. The electrical splicing connector (100, 200) according to claim 1, characterized in that: The first splicing terminal (202) defines a first cable stopper (228), the first cable stopper contacts an end of the first wire conductor (208) of the first wire cable (210) and contacts an end of the first wire conductor (212) of the second wire cable (214), wherein the second splicing terminal (204) defines a second cable stopper (230), the second cable stopper contacts an end of the second wire conductor (216) of the first wire cable (210) and contacts an end of the second wire conductor (218) of the second wire cable (214).

7. The electrical splicing connector (100, 200) according to claim 6, characterized in that: The first cable stop (228) is aligned with the second cable stop (230) by a terminal stop (234) defined in the first cavity (220) and the second cavity (222) within the divider insulator (206, 502).

8. The electrical splicing connector (100, 200) according to claim 7, characterized in that: The first cable stopper and the second cable stopper are located at a longitudinal center of the separator insulator (206, 502).

9. The electrical splicing connector (100, 200) according to claim 6, characterized in that: The first cable stopper and the second cable stopper are formed integrally with the first splicing terminal (202) and the second splicing terminal (204), respectively.

10. The electrical splicing connector (100, 200) according to claim 1, characterized in that: The first splicing terminal (202) and the second splicing terminal (204) are equidistant from a lateral center of the separating insulator (206, 502).

11. A method (600) of splicing a first cable (210) to a second cable (214), comprising: connecting a first wire conductor (208) of a first wire cable (210) to a first wire conductor (212) of a second wire cable (214) by crimping a first splice terminal (202) to the first wire conductor; joining a second wire conductor (216) of the first wire cable (210) to a second wire conductor (218) of the second wire cable (214) by crimping a second splice terminal (204) to the second wire conductor; Placing the first splicing terminal (202) in a first cavity of a separating insulator (206, 502); as well as The second splice terminal (204) is placed in a second cavity of the separator insulator (206, 502), the second cavity being separated from the first cavity by a wall (224, 506).

12. The method (600) according to claim 11, characterized in that: Also includes: At least one opening is formed in the wall (224, 506) to control capacitive coupling between the first splicing terminal (202) and the second splicing terminal (204).

13. The method (600) according to claim 12, characterized in that: The at least one opening includes a first opening and a separate second opening located equidistant from a longitudinal center of the separator insulator (206, 502).

14. The method (600) according to claim 11, characterized in that: Also includes: placing a heat shrink tubing on the separator insulator (206, 502); as well as The heat shrink tube is heated so that the inner surface of the heat shrink tube contacts the partition insulator (206, 502).

15. The method (600) according to claim 11, characterized in that: Also includes: Folding the first pair of stop tabs of the first splicing terminal (202) inwardly to form a first cable stopper (228); Before crimping the first spliced ​​terminal (202) to the first wire conductor, placing an end of the first wire conductor (208) of the first wire cable (210) in contact with the first cable stopper (228), and placing an end of the first wire conductor (212) of the second wire cable (214) in contact with the first cable stopper (228); Folding the second pair of stop tabs of the second splicing terminal (204) inwardly to form a second cable stopper (230); as well as Prior to crimping the second splice terminal (204) to the second wire conductor, one end of the second wire conductor (216) of the first wire cable (210) is placed in contact with the second cable stopper (230), and one end of the second wire conductor (218) of the second wire cable (214) is placed in contact with the second cable stopper (230).

16. The method (600) according to claim 15, characterized in that: Also included is aligning the first cable stop and the second cable stop so that they are located at a longitudinal center of the divider insulator (206, 502).

17. The method (600) according to claim 15, characterized in that: Also included is aligning the first cable stop (228) and the second cable stop (230) within the divider insulator (206, 502).

18. The method (600) of claim 11, characterized in that: The first splicing terminal (202) is the same as the second splicing terminal (204).

19. The method (600) of claim 11, characterized in that: Also included is placing the first spliced ​​terminal (202) and the second spliced ​​terminal (204) within the divider insulator (206, 502) such that they are equidistant from a lateral center of the divider insulator (206, 502).

20. An electrical splicing connector (100, 200) for connecting a first wire cable (210) having a first wire conductor (208) and a second wire conductor (212) and a second wire cable (214) having a first wire conductor (216) and a second wire conductor (218), the electrical splicing connector (100, 200) comprising: a first spliced ​​terminal (202) configured to be crimped to the first wire conductor (208) of the first wire cable (210) and to be crimped to the first wire conductor (212) of the second wire cable (214); a second spliced ​​terminal (204) configured to be crimped to the second wire conductor (216) of the first wire cable (210) and to be crimped to the second wire conductor (218) of the second wire cable (214); as well as A separation insulator (206, 502) is formed of a dielectric material and has a first cavity and a second cavity, wherein the first splicing terminal (202) is arranged in the first cavity and the second splicing terminal (204) is arranged in the second cavity, wherein the second cavity is separated from the first cavity by a wall (224, 506) formed of a dielectric material.

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