Insert wire connector and termination assembly for use in an insert wire connector

Abstract

Plug-in wire connector, which includes: a housing (12, 164, 188) having a hollow interior and at least one first and one second wire opening (40, 70, 126, 170, 174, 190, 192), wherein the first and the second wire opening each have a longitudinal axis and allow the ends of wires inserted into the wire openings to extend into the interior, wherein the first and the second wire opening (40, 70, 126, 170, 174, 190, 192) are oriented in opposite directions and the axes of the first and the second wire opening (40, 70, 126, 170, 174, 190, 192) are spaced apart from each other, a busbar (334) which can be connected to the wires inserted into the first and second wire openings (40, 70, 126, 170, 174, 190, 192), wherein the busbar (334) is arranged in the interior of the housing (12, 164, 188) and is configured to passively receive a force exerted on the wires, and a spring element (336) with a foot (338) which is arranged in the interior of the housing (12,164,188) and is configured to pretension a first wire end inserted through the first wire opening (40,126,170,190) into a connection with the busbar (334) and to pretension a second wire end inserted through the second wire opening (70,126,174,192) into a connection with the busbar (334), wherein the foot (338) has a pair of spaced-apart bands with first and second surfaces, wherein the busbar (334) comprises a first part (334A) and a second part (334B) and wherein the busbar (334) and the spring member (336) are integrated into a connection arrangement (332) wherein the first part (334A) is attached to the first surfaces of the straps of the foot (338) and the second part (334B) is attached to the second surfaces of the straps of the foot (338) such that the straps of the foot (338) are arranged in a layered configuration between the first part (334A) and the second part (334B) of the busbar (334).

Description

[0001] The present invention relates to push-in wire connectors and a termination arrangement for use in a push-in wire connector. As the name suggests, push-in wire connectors function by simply inserting the stripped ends of two or more wires or conductors into the connector. Once the wires have been inserted, no further steps such as closing, crimping, twisting, or stripping, nor any further action on the connector, are required to establish the connection. Therefore, a push-in wire connector offers advantageously low labor costs. The push-in wire connector performs various functions, such as electrically insulating the conductors from the environment, holding the conductors within the connector, and establishing an electrical connection between the conductors.

[0002] The function of electrical insulation is usually fulfilled by a housing made of an electrically insulating material. The housing generally has a hollow interior. The stripped ends of two or more electrical conductors can be inserted into the interior through openings in the housing. In this way, the stripped ends of the conductors are completely enclosed by the insulating housing.

[0003] The function of establishing an electrical connection is fulfilled by an electrically conductive connecting element.

[0004] The connecting element, often referred to as a busbar, is positioned within the housing in such a way that it can be connected to all conductors inserted into the housing. The connecting element provides a current path between all inserted conductors. Because the primary function of the busbar is to establish an electrical connection, it is usually made of a highly conductive material such as copper or tinned copper. However, even a busbar with high conductivity will not provide a good electrical connection between the conductors if the conductors are not held firmly in contact with the busbar. Therefore, a spring element is typically incorporated, which interacts with the busbar to press the conductors firmly against it.The spring element can be arranged in various ways, for example, integrated into the housing, integrated into the busbar, or provided as a separate component inside the housing. In any case, the spring element presses all conductors into a firm mechanical and electrical connection with the connecting element.

[0005] The function of holding the conductors in the housing is fulfilled by a retaining element that engages the ends of the inserted conductors and prevents them from being pulled axially out of the housing. Like the spring element, the retaining element can also be integrated into the housing. Alternatively, the retaining element and the spring element can be configured as a combined unit within the housing. In either case, the retaining element engages the conductors and prevents their unintentional removal from the housing. In some embodiments, the retaining element can be released, allowing the conductors to be removed from the housing without damaging the components. In other embodiments, where the conductors must not be removed from the wire connector under any circumstances, the retaining element is designed so that it cannot be released.

[0006] As mentioned above, the retaining element is often combined with the spring element to provide a force that presses the inserted conductor into contact with the connecting element and prevents the conductor from being pulled out. In a typical configuration, an elastic metal retaining element with spring fingers is provided. When a conductor is inserted into the housing, it engages a spring finger, causing it to bend from its initial position. This bending of the spring finger generates a compressive force acting on the conductor, pressing it into firm contact with the busbar. The spring finger is angled to allow the conductor to be inserted beyond the finger in one direction, while its self-locking configuration prevents the conductor from being pulled out in the opposite direction.By engaging the spring finger in the conductor, the two functions of pressing the conductor against the busbar and preventing the conductor from being pulled out of the housing are fulfilled.

[0007] JP S56-9676 U shows a plug-in wire connector in which two conductor ends are inserted into a housing on opposite sides and are held inside the housing by spring links on the respective sides of the housing, pressing the inserted conductor ends into contact with a connecting link.

[0008] Pressing the conductor against the busbar naturally requires a stable structure that can withstand the compressive force of the spring finger. A stable hold for the busbar can be provided by the spring element and / or the housing; however, problems can arise when the wire connector is used with twisted wire. Twisted wires tend to flatten or splay out when subjected to the compressive force of the spring finger. Because the compressive force and the resistance of the spring finger are only generated when the spring finger is bent, flattening or splaying of a twisted wire reduces this bending, potentially preventing the spring finger from fulfilling its function. The present invention aims to eliminate this problem.

[0009] Another problem with some conventional push-in wire connectors is that they are designed to accept varying numbers of wires, with all incoming wires entering the housing from one direction. In other words, the openings in the housing are all on one side. Therefore, if wires are fed to the connector from different directions, the ends of at least some of them must be bent back 180° to allow the wires to be inserted. This adds extra work to the installation of the connector. US Patent 6,132,238 A provides an example of this type of connector. US Patents 6,093,052 A and 4,133,595 A provide examples of wire connectors with wire openings facing different directions.

[0010] Other problems with existing push-in wire connectors arise from their relatively bulky nature. This makes them difficult to install in confined spaces. Furthermore, their manufacture requires a significant amount of material, increasing costs. Another issue is the large quantity of comparatively expensive materials used in state-of-the-art push-in wire connectors. Some wire connectors incorporate complex contacts or terminals made of copper or similar materials. These contacts are often formed from blanks by repeatedly folding or bending them to create overlapping layers of material. The blanks themselves are complexly shaped, requiring them to be stamped from sheets, resulting in an excessive amount of waste.Many existing structures waste material, unnecessarily increasing the overall cost of the wire connector.

[0011] DE 10 2008 032 267 A1 shows further embodiments of a plug-in wire connector which has a connection arrangement located in a housing with at least one busbar and at least one spring element.

[0012] The object of the invention is to further improve the insert wire connectors and termination arrangement for use in an insert wire connector. This object is achieved by the insert wire connectors with the features of claims 1 and 16, and by a termination arrangement with the features of claim 9.

[0013] The present invention relates to a plug-in wire connector with an improved housing, consisting of a first (e.g., left) and a second (e.g., right) housing part which are connected to each other. Each housing part comprises an opening facing one direction and a wire receiving box facing another direction. Each wire receiving box is aligned with the wire opening of the other housing part and thus faces a different direction than the wire entry opening of its own housing part.

[0014] A connection assembly is mounted inside the housing. This assembly includes a busbar with an integrated spring element. The spring element has spring fingers on opposite sides of the busbar. These spring fingers are aligned with corresponding wire openings and engage conductors inserted into the housing, pressing the conductors into contact with the busbar. The busbar comprises a first section with a first surface and a second section with a second surface.

[0015] The spring element has a foot which has a pair of spaced-apart bands with first and second surfaces.

[0016] The busbar is integrated with the base in such a way that the base's straps are arranged in a layered configuration between the first and second parts of the busbar. The first part of the busbar is directly connected to the first surfaces of the base's straps, and the second part is directly connected to the second surfaces of the base's straps.

[0017] The wires entering the wire connector through opposing openings overlap to create the shortest possible housing. This connection design allows for efficient use of metal materials, thus minimizing the cost of the wire connector. Fig. Figure 1 is a perspective view of the plug-in wire connector of the present invention. Fig. 2 is a sectional view through the longitudinal center of Fig. 1. Fig. Figure 3 is a side view of the second housing part. Fig. Figure 4 is a top view of the second housing part. Fig. Figure 5 is a view from below of the second part of the housing. Fig. Figure 6 is an end view from the right of the second housing part. Fig. Figure 7 is an end view from the left of the second housing part. Fig. Figure 8 is a sectional view along line 8-8 of Fig. 6. Fig. Figure 9 is a sectional view along line 9-9 of Fig. 6. Fig. 10 is a sectional view along line 10-10 of Fig. 6. Fig. Figure 11 is a side view of the first housing part. Fig. Figure 12 is a top view of the first housing part. Fig. Figure 13 is a view from below of the first part of the housing. Fig. Figure 14 is an end view from the right of the first housing part. Fig. Figure 15 is an end view from the left of the first housing part. Fig. Figure 16 is a sectional view along line 16-16 of Fig. 14. Fig. 17 is a sectional view along line 17-17 of Fig. 14. Fig. Figure 18 is a sectional view along line 18-18 of Fig. 14. Fig. Figure 19 is a sectional view along line 19-19 of Fig. 14. Fig. Figure 20 is a perspective view of a connection arrangement. Fig. 21 is an end view of the connection arrangement of Fig. 20. Fig. Figure 22 is a side view of the connection arrangement. Fig. 23 is a view along line 23-23 of Fig. 22. Fig. 24 is a sectional view along line 24-24 of Fig. 21. Fig. Figure 25 is a perspective view of an alternative embodiment, which is different from that of Fig. 1 is similar, but has six wire openings. Fig. Figure 26 is a perspective view of another alternative embodiment of a linear plug-in wire connector with three poles and two openings each. Fig. Figure 27 is a sectional view through one of the poles of the wire connector of Fig. 26. Fig. Figure 28 is a perspective view of an alternative embodiment of the connection arrangement that is not covered by the literal wording of the claim. Fig. 29 is a sectional view through the connection arrangement of Fig. 28 along line 29-29 from Fig. 30. Fig. 30 is a side view of the busbar of the connection arrangement of Fig. 28. Fig. 31 is a top view of the busbar of the connection arrangement of Fig. 28. Fig. Figure 32 is a perspective view of an alternative embodiment of a housing. Fig. Figure 33 is a perspective exploded view of the casing of Fig. 32. Fig. Figure 34 is a perspective view of another alternative embodiment of a housing. Fig. Figure 35 is a perspective exploded view of the casing of Fig. 34. Fig. Figure 36 is a side view of the case of Fig. 34. Fig. Figure 37 is a perspective view from above of another alternative embodiment of a connection arrangement that does not fall under the literal wording of the claim. Fig. Figure 38 is a perspective view from below of the connection arrangement of Fig. 37. Fig. Figure 39 is a perspective view from above of the embodiment of a connection arrangement falling within the literal wording of the claim. Fig. Figure 40 is a perspective view from below of the connection arrangement of Fig. 39.

[0018] Fig. Figure 1 shows a plug-in wire connector 10 according to the present invention. The plug-in wire connector 10 has a housing, generally designated by reference numeral 12. In this embodiment, the housing consists of two parts, namely a second (right in the figures) housing part 14 and a first (left in the figures) housing part 16. Each housing part comprises a wire entry opening facing one direction and a wire receiving box facing another direction. In this example, an optional test probe opening is provided next to the wire entry opening.

[0019] Details of the second housing part 14 are in Fig. 2-10 shown. As in Fig. As shown in Figure 3, the housing part comprises a lower section on the left side, which transitions into a middle section, which in turn transitions into an upper section on the second side. The second section is formed by a generally U-shaped wall 18. The wall 18 is bounded at the middle section by locking openings 20A, 20B. The middle section comprises a wire receiving box 22, which has an end wall 24 and a U-shaped guide wall 26. These walls define a hollow chamber that receives the end of a wire inserted into the wire connector. The guide wall 26 extends as shown in Figure 3. Fig. Figure 8 shows the guide wall 26 angled downwards to the left and supports the insertion of a wire into the receiving box 22. The first (here left) end of the guide wall 26 terminates in an angled spring retaining surface 28. The upper surfaces of the guide wall form a pair of laterally spaced shoulders. Fig. Figure 8 clearly shows that the wire storage box 22 opens to the left.

[0020] As in Fig. As shown in Figure 8, an S-shaped outer flange 32 is formed above the guide wall 26 and adjoining the two upper steps of the U-shaped wall 18. This flange fits into a corresponding flange of the first housing part, as will be explained below. The flange 32 transitions into the upper section, which generally comprises an oval shell 34. As is best described in Figure 8, the following applies: Fig. As can be seen in Figure 7, a second spring retaining surface 36 is provided at the first (here left) end of the shell. The second (here right) end of the shell is covered by an end wall 38. A wire entry opening 40 is defined by a wire tube 42. The inner end of the tube 42 tapers as shown in Figure 7. Fig. 8 is shown and connects to a wire holding block 44. The wire holding block 44 is located directly above the steps 30. A test sensor opening 46 is defined by a test tube 48 ( Fig. 6).

[0021] Fig. Figures 11-19 show details of the first housing part 16. A main body part 50 has a wire receiving box 52, which projects from the body part in a first direction (upwards in the figures). The wire receiving box 52 has an end wall 54 ( Fig. 6) An arc-shaped end section 56 extends from the wire receiving box. An inner flange 58 is attached to the body part 50 and the end section 56. The inner flange is as shown in Fig. Figure 14 shows that the inner flange is set back slightly from the outer edges of the body and the impact section. Furthermore, the inner flange is as shown in... Fig. Figure 11 shows a slightly S-shaped form to match the shape of the outer flange 32. A curved skirt 60 extends below the body part. Two arms 62 extend from the skirt 60 (forward in the figures). The arms terminate in outward-facing hooks 64.

[0022] When the housing parts are joined, the inner flange 58 fits into the outer flange 32 of the second housing part, with the outer flange abutting against the end faces of the buttress section and the body part. The skirt 60 and the arms 62 fit into the U-shaped wall 18 of the second housing part. The hooks 64 slide into the locking openings 20A, 20B to join the ends of the wall 18 together and hold the two housing parts together.

[0023] A U-shaped cutout 66 ( Fig. 15) is defined in an end wall 68 of the main body part. Directly above the cutout 66, a wire entry opening 70 is provided, extending through the main body part. Inside the body, a tapered ring 72 is provided, defining the inner end of the wire opening. The second (here right) end face of the ring defines a spring retaining surface 74. A wire retaining block 76 is attached to the upper edge of the tapered ring 72. The wire retaining block 76, the first part (upper in the figure) of the ring 72, the wire receiving box 52, and the end wall 54 define a hollow chamber that receives the end of a wire inserted into the wire connector. Below the inner flange, a central rib 78 and two angled spring retaining ribs 80 are provided. The ribs 80 are connected to the shoulders 82. The steps and the wire retaining block 76 support the positioning of the busbar, which is described below.

[0024] In Fig. Figures 20-24 show a connection arrangement 84 that is not covered by the literal wording of the claim. The connection arrangement comprises a busbar 86 held on a spring member 88. The spring member comprises a foot 90, which is connected at a first fold line to a first leg 92 extending in a first direction (upwards in the figure) and at a second fold line to a second leg 94 extending in a second direction (downwards in the figures). The foot has a pair of spaced-apart bands 96. The bands have openings (not shown) to receive rivets of the busbar, as explained below. Each leg 92, 94 comprises a U-shaped slot defining a spring finger 98. The spring finger is integrally connected to the leg at one end and has a free end 100 at the other end. As in Fig. 22 and Fig. As shown in Figure 24, the spring fingers 98 are bent out of the plane of the legs 92, 94. The free end 100 may also be slightly angled relative to the rest of the finger to provide an optimal angle for gripping a wire inserted under the wire finger. The spring element 88 is preferably made of an elastic metal such as stainless steel.

[0025] When the spring finger 98 of leg 92 is installed in the housing, it is positioned opposite the wire entry opening 40, so that a wire (conductor) inserted into the second housing part encounters the spring finger and moves it in the first direction (upwards in the figures) as it penetrates further into the housing. The free end of the spring finger 98 presses against the conductor, thus preventing the conductor from being pulled out of the housing part. Furthermore, the conductor is pressed into firm contact with the upper surface of the busbar 86. The spring finger 98 of leg 94 is positioned accordingly opposite the wire entry opening 70. A wire inserted into the first (here left) housing opening 70 encounters the spring finger 98 and moves it in the second direction (downwards in the figures). The free end of the spring finger 98 holds the conductor in the housing and pre-tensions it into contact with the lower surface of the busbar.

[0026] The following describes details of the busbar 86. The busbar is generally a rectangular section made of thin copper sheet. The busbar defines a thickness between a first surface 102 (pointing upwards in the figures) and a second surface 104 (pointing downwards in the figures). It should be noted that the terms "top" and "bottom" are used here for reference purposes only, and the busbar may be oriented in any direction in actual use. The first surface of the busbar 86 defines an inlet edge 106A, an outlet edge 108A, and a wire crossing axis 110A extending between the inlet edge and the outlet edge. The inlet edge is understood here to be the edge of the busbar that is first crossed by a conductor inserted into the housing. The outlet edge is the edge of the busbar that may subsequently be crossed by the inserted conductor.The wire crossing axis is the position where a conductor lies due to the housing design and the position of the busbar within the housing. The second surface (lower in the figures) of the busbar 86 accordingly defines an inlet edge 106B, an outlet edge 106B, and a wire crossing axis 110B extending from the inlet edge to the outlet edge. It should be noted that the inlet edges 106A and 106B are located on opposite sides of the busbar.

[0027] The busbar 86 is attached to the base 90 of the spring member 88 by means of rivets 112, which extend into the openings of the base described above. The rivets 112 on the upper surface 102 can be formed by bending open a portion of the busbar. It should be noted that other methods can also be used to attach the busbar to the spring member, such as crimping, gluing, etc. Alternatively, the busbar can not be fixed to the spring at all, but instead be held by the housing.

[0028] As in Fig. 22 and Fig. As shown in Figure 24, the busbar has a wire receiving pocket 114 extending between the surfaces and generally aligned with the corresponding wire crossing axes. Furthermore, a wire engagement projection 116 is provided, extending between the surfaces and transverse to the corresponding wire crossing axes. The pockets 114 and the projections 116 can be formed by embossing the busbar, with a pocket on one surface and a corresponding projection on the other surface of the busbar. It should be clear that the pockets 114 and the projections 116 can provide a serpentine path for the conductor guided across the surface. This assists the spring finger 98 in holding the conductors in the housing. Depending on the diameter of the conductor, the pockets 114 can at least partially surround the conductor on three sides to prevent a twisted wire from spreading.

[0029] Fig. Figure 2 shows the assembled connector and the interaction of the individual parts. As mentioned above, the outer flange 32 of the second housing part fits over the inner flange 58 of the first housing part and connects to the end section 56 and the body part 50 of the first housing part. The hooks 64 hold the two housing parts together. The spring element 88 is fixed between the housing parts. The busbar 86 is held laterally by the retaining block 76 on the left side and the retaining block 44 on the second (here, right) side. Recesses 82 and 30 engage with the busbar to prevent movement in either direction (upwards or downwards in the figures). The leg 92 of the spring element extending in the first direction (upwards in the figures) is enclosed between the spring retaining surface 36 of the second housing part and the spring retaining ribs 80 of the first housing part.The leg 94 extending in the second direction (downwards in the figures) is enclosed between the spring retaining surface 28 of the second housing part and the spring retaining surface 74 of the first housing part.

[0030] The use and function of the wire connector are described below. The stripped end of a wire is inserted into the wire entry opening 40 of the second housing part. As the wire end is inserted, it contacts the spring finger 98 of the leg 92 and pushes it in the first direction (upwards in the figures). The end of the conductor enters the receiving box 52 of the first housing part, thus anchoring the conductor and preventing it from spreading apart if it is a twisted wire. The stripped end of a second wire is inserted into the wire entry opening 70 of the first housing part. As the wire end is inserted, it contacts the spring finger 98 of the leg 94 and pushes it in the second direction (downwards in the figures).The end of the conductor enters the wire receiving box 22 of the second housing part, thereby anchoring the conductor and preventing it from spreading apart if it is a twisted wire.

[0031] It should be noted that in this example, the wire entry openings and the busbar are arranged such that the busbar is aligned at an angle of approximately 17° to the axes of the wire openings. The busbar is thus positioned at an angle of approximately 17° and forms a humped / angular surface over which the wire must pass, with the spring element pressing the wire against this surface. This improves the spring's holding force and the electrical contact between the busbar and the conductor. The busbar is positioned adjacent to the lower surface of opening 40 and the upper surface of opening 70. Consequently, the conductors contact the busbar on opposite sides. This allows for efficient use of the busbar material and permits the conductors to overlap longitudinally, thus enabling a shorter housing length.Furthermore, the design of the wire opening in one housing section and the wire receptacle in the other contributes to a compact housing design. This design eliminates the need for caps at the rear ends, i.e., for the wire entry points of the housings. This is because the connection assembly is held between the housing sections, thus rendering a separate retaining cap unnecessary.

[0032] Fig. Figure 25 shows a version of a linear plug-in wire connector 118 with six openings. The construction of the housing and the connection are essentially identical to that of the embodiment described above, wherein the devices are each doubled and two further wire openings are provided in each housing part and two further spring fingers are provided at a first and second position (e.g. in the figures above and below) on the spring member.

[0033] Fig. 26 and Fig. Figure 27 shows a further alternative embodiment. This is a linear plug-in wire connector with 3 poles and two openings. The construction of each pole is essentially similar to that in the embodiment of Fig. 1. A first housing part 122 and a second housing part 124 are provided. Each housing part has a wire entry opening 126 and a wire receiving box 128 opposite the wire entry opening of the other housing part. The connection arrangement 130 is essentially identical to the connection arrangement 84. Three separate connection arrangements 130 are provided, each receiving two wires. Thus, this wire connector establishes separate connections between three pairs of wires. The poles are arranged at angular intervals of 120° along a circle in a plane transverse to the longitudinal axis. This arrangement allows for the placement of three separate poles in a compact design.

[0034] Fig. 28 and Fig. Figure 29 shows an alternative embodiment of a connection arrangement 132 that is not covered by the literal wording of the claim. This connection arrangement is essentially identical to the connection arrangement 84, except that the relationship between the busbar and the spring is different. The connection arrangement 132 has a busbar 134 which is held by a spring member 136. The spring member comprises a base 138 which is connected to a leg 140 extending in a first direction (upwards in the figures) and a leg 142 extending in a second direction (downwards in the figures). The base has a pair of spaced-apart bands 144. A U-shaped slot in each leg defines a spring finger 146. Each spring finger has a free end 148.

[0035] Busbar 134 has a first (top in the figures) surface 150 and a second (bottom in the figures) surface 152. As before, the terms "top" and "bottom" are used here for reference purposes only. As in Fig. 30 and Fig. As shown in Figure 31, the first surface 150 of the busbar 134 further defines an inlet edge 154A and an outlet edge 156A. Again, the inlet edge is the edge of the busbar that is first crossed by a conductor inserted into the housing, while the outlet edge is the edge of the busbar that is last crossed by the inserted conductor. The second surface 152 of the busbar 134 similarly defines an inlet edge 154B and an outlet edge 156B. It should be noted that the inlet edges 154A and 154B are located on opposite sides of the busbar.

[0036] The busbar 134 is attached to the foot 138 of the spring member 136 by means of rivets 158 which extend into openings in the foot.

[0037] As in Fig. As shown in Figures 28-31, the busbar has a wire receiving pocket 160 on each surface. Furthermore, a wire engagement projection 162 is provided on each surface. The pockets 160 and the projections 162 can be formed by embossing the busbar, with a pocket on one surface and a corresponding projection on the other surface of the busbar. The pocket on one surface is aligned with the projection on the other surface, so that the surfaces are generally symmetrical.

[0038] Fig. 32 and Fig. Figure 33 shows an alternative embodiment of the housing. This is a two-part housing 164 connected by a snap-fit ​​connection, which generally has the same structure as in Fig. 1-19, but has a different locking arrangement. A first housing part 166 and a second housing part 168 are provided. The first housing part 166 has a first wire entry opening 170 and a wire receiving box 172. The second housing part 168 has a second (lower in the figures) wire entry opening 174 and a wire receiving box 176 opposite the upper wire entry opening 170 of the other housing part. The wire entry openings are thus oriented in different directions. The electrical connector 132 fits inside the housing. The first end of the first housing part has a locking plate 178 with a hook 180 pointing in a first direction (upwards in the figures). The plate fits into a recess 182 on the second housing part, so that the hook 180 can engage in the recess to hold the two housing parts together.A similar plate 184 is provided near the lower end of the first housing part and can engage in a recess 186 at the lower end of the second housing part.

[0039] An alternative embodiment of a housing is in Fig. 34-36 indicated by reference numeral 188. This housing is the same as that of Fig. Figures 1-19 are essentially similar with regard to the upper and lower openings 190, 192 and the receiving boxes 194, 196. However, instead of the snap connection, the housing 188 has a first housing half 198 and a second (lower in the figures) housing half 200, which can be joined together, for example, by ultrasonic welding along contact surfaces 202. This provides a particularly compact design. The electrical connection 132 fits inside the housing. As in Fig. As shown in Figure 35, the interior of the lower housing half has a seat 204 for holding the busbar or a foot part of the connector. Recesses 206 below the seat 204 hold the leg 142 of the spring 136 extending in the second direction (downwards in the figures), while a first wall 208 holds the leg 140 extending in the first direction (upwards in the figures). Similar surfaces on the upper housing half 198 serve to hold the connector in position.

[0040] In Fig. 37 and Fig. Figure 38 shows a further alternative embodiment of a connection arrangement 232, which is not covered by the literal wording of the claim. The connection arrangement 232 is similar to the connection arrangement 84, except that the relationship between the busbar and the spring element is different. In this case, the connection arrangement 232 has a busbar 234 that is formed integrally with a spring element 236. The spring element comprises a foot 238, which is connected to a leg 240 extending in a first direction (upwards in the figures) and a leg 242 extending in a second direction (downwards in the figures).

[0041] The busbar 234 is attached to the base 238 of the spring element 236 or formed integrally with it. In this example, the spring element 236 is preferably made of an elastic material such as a copper alloy or stainless steel. The material and mass used can be selected according to the wires used and the rated current. A U-shaped slot 240, 242 defines a spring finger 246, each spring finger 246 having a free end 248.

[0042] Busbar 234 has a first surface 250 and a second (lower in the figures) surface 252. As before, the terms "top" and "bottom" are used here only for reference purposes. As in Fig. 37 and Fig. As shown in Figure 38, the first surface 250 of the busbar 234 further defines an inlet edge 254A and an outlet edge 256A. Again, the inlet edge is the edge of the busbar that is first crossed by a conductor inserted into the housing, and the outlet edge is the edge of the busbar that is last crossed by an inserted conductor. The second surface 252 of the busbar 234 similarly defines an inlet edge 254B and an outlet edge 256B. It should be noted that the inlet edges 254A and 254B are located on opposite sides of the busbar.

[0043] Although not shown, the example of Fig. 37 and Fig. 38 also a wire receiving pocket and a wire engagement projection on each face of the busbar 234 as above with reference to the embodiments of Fig. 20-23 and Fig. 28-31 explain this further. As previously explained, such pockets and projections can be formed by embossing or pressing the busbar, forming a pocket on one face and a corresponding projection on the other face of the busbar. As in the other examples, if required, the pocket on one face can be formed in an orientation with the projection on the other face, so that the faces are generally symmetrical.

[0044] The embodiment of the connection arrangement 332, which falls under the literal wording of the claim, is in Fig. 39 and Fig. Figure 40 shows the further connection arrangement 332, which is similar to connection arrangement 84, except that the relationship between the busbar and the spring element is different. In this example, connection arrangement 332 has a busbar 334 that is formed integrally with a spring element 336. The spring element 336 comprises a base 338, which has a leg 340 extending in a first direction (upwards in the figures) and a leg 342 extending in a second direction (downwards in the figures).

[0045] Although not shown, foot 338 has a pair of spaced-apart ligaments 334, as does foot 90 in the example of Fig. 20-23 and foot 138 of the example of Fig. 28-31 is the case. However, it should be noted that foot 338 is also similar to foot 238 in the example of Fig. 37 and Fig. 38 can be formed. In both configurations, the busbar 334 has an upper part 334A and a lower part 334B made of a more conductive material, each located next to the upper and lower surfaces of the foot 338 of the spring element 336. A U-shaped slot in each leg 340, 342 defines a spring finger 346, each spring finger 346 having a free end 348.

[0046] In this layered sandwich-type configuration, the busbar 334 has a first surface 350, provided by the upper part 334A, and a second (lower in the figures) surface 352, provided by the lower part 334B. As before, the terms "top" and "bottom" are used here for reference purposes only. As in Fig. 39 and Fig. As shown in Figure 40, the first surface 350 of the busbar 334 further defines an inlet edge 354A and an outlet edge 356A. As in the other examples, the inlet edge is the edge of the busbar that is first crossed by a conductor inserted into the enclosure, and the outlet edge is the edge of the busbar that is last crossed by a conductor inserted into the enclosure. The second surface 352 of the busbar 334 similarly defines an inlet edge 354B and an outlet edge 356B. Note that the inlet edges 354A and 354B are located on opposite sides of the busbar.

[0047] In this configuration, the attached busbar 334 becomes an integral part of the connection arrangement 332. The spring element 336 is preferably made of an elastic metal such as stainless steel, and the busbar sections 334A and 334B are made of tinned copper or another suitable metal. As in the preceding examples, the busbar sections can be attached to the spring element 336 by means of rivets extending into openings in the base 338. However, the busbar sections can also be attached in other ways. It is important that the two busbar sections 334A and 334B are conductively connected to the intermediate material of the base 338 by direct contact, by encapsulation, or by suitable fixing elements.

[0048] As explained above with reference to the other exemplary connection arrangements, the same applies to the example of Fig. 39 and Fig. 40 Each of the two faces of the busbar 334 is provided with a wire receiving pocket and a wire engagement projection. As explained, these pockets and projections can be formed by suitable processes such as casting, embossing, or pressing the busbar, with a pocket on one face and a corresponding projection on the other face of the busbar. As in the other examples, if required, a pocket in one face can be formed in alignment with a projection on the other face, so that the faces are generally symmetrical. In the example shown by Fig. 39 and Fig.40 Each busbar section 334A and 334B comprises a contoured central section that forms the entry for a conductor at the entry edge 354A and 354B and leads into a ramp that terminates in a projection 362 to facilitate the establishment of good contact with the conductor end of an inserted wire. Thus, when, as in the preceding examples, each corresponding conductor is pressed through an opening into a contact with a spring finger 346 and a busbar section 334A, 334B, the spring finger 346 of the spring member 336 is displaced to allow the entry of the conductor, the conductor being simultaneously pressed into a connection with the busbar 334 and anchored in the wire connector, and the free end 348 of the corresponding spring finger 346 counteracting any rearward movement or withdrawal of the wire. REFERENCE MARK LIST 10,118 Insert wire connectors 12,164,188 cases 14,124,168,198 first housing part 16,122,166,200 second housing part 18 Wall (U-shaped) 20A, 20B Locking openings 22, 52, 128, 172, 176, 194, 196 Wire storage box 24, 38, 54, 68 End wall 26 Guide wall (U-shaped) 28.74 spring holding surface 30,82,206 paragraphs 32 Outer flange (S-shaped) 34 oval bowls 36 second spring holding surface 40, 70, 126, 170, 174, 190, 192 Wire entry opening, wire opening 42 wire tube, pipe 44.76 Wire retaining block, retaining block 46 Test probe opening 48 test tube 50 Main body part, body part 56 Kick-off section (arc-shaped) 58 Inner flange 60 Apron (curved) 62 arms 64,180 hooks 66 Cutout (U-shaped) 72 Ring 78 rib 80 spring holder ribs 84,130,132,232,332 Connection arrangement 86,134,234,334 busbar 88,136,236,336 spring link 90, 138, 238, 338 feet 92, 140, 240, 340 first leg 94, 142, 242, 342 second leg 96, 144, 334 tapes 98, 146, 246, 346 spring finger 100, 148, 248, 348 free end 102, 150, 250, 350 first area 104, 152, 252, 352 second area 106A, 106B, 154A, 154B, 254A, 254B, 354A, 354B Entrance edge 108A, 108B, 156A, 156B, 256A, Exit edge 256B, 356A, 356B 110A wire crossing axis 112, 158 rivets 114, 160 wire collection bag, bags 116, 162 Wire engagement projection, projection 178, 184 Locking plate 182, 186 Further Study 202 Contact area 204 seats 208 Wall 240, 242 Slot (U-shaped) 334A first part of busbar 334 334B second part of busbar 334 362 lead

Claims

Insertion wire connector comprising: a housing (12, 164, 188) having a hollow interior and at least one first and one second wire opening (40, 70, 126, 170, 174, 190, 192), wherein the first and the second wire opening each have a longitudinal axis and allow the ends of wires inserted into the wire openings to extend into the interior, wherein the first and the second wire opening (40, 70, 126, 170, 174, 190, 192) are oriented in opposite directions and the axes of the first and the second wire opening (40, 70, 126, 170, 174, 190, 192) are spaced apart from each other; a busbar (334) connected to the wires inserted into the first and the second wire opening (40, 70, 126, 170, 174, 190, 192). wires can be connected, wherein the busbar (334) is arranged in the interior of the housing (12, 164, 188) and is designed to passively receive a force exerted on the wires, and a spring element (336) with a foot (338),which is arranged in the interior of the housing (12, 164, 188) and is configured to pretension a first wire end inserted through the first wire opening (40, 126, 170, 190) into a connection with the busbar (334) and to pretension a second wire end inserted through the second wire opening (70, 126, 174, 192) into a connection with the busbar (334), wherein the foot (338) has a pair of spaced-apart bands with first and second surfaces, wherein the busbar (334) comprises a first part (334A) and a second part (334B), and wherein the busbar (334) and the spring element (336) are integrated into a connection arrangement (332), wherein the first part (334A) is connected to the first surfaces of the bands of the foot (338) and the second part (334B) is connected to the second surfaces of the bands of the foot (338) is attached in such a way,that the bands of the foot (338) are arranged in a layered configuration between the first part (334A) and the second part (334B) of the busbar (334). Insert wire connector according to claim 1, characterized in that the integrated connection arrangement (332) is formed from a plurality of materials. Insert wire connector according to claim 1, characterized in that the integrated connection arrangement (332) is formed from a single material. Insert wire connector according to claim 1, further characterized by a first spring finger (346) for pre-tensioning the first wire end and a second spring finger (346) for pre-tensioning the second wire end. Plug-in wire connector according to claim 1, characterized in that the busbar (334) is arranged in the housing (12, 164, 188) for a connection along at least one side of each wire. Plug-in wire connector according to claim 1, characterized in that the busbar (334) allows the plugged-in wires to extend beyond the busbar (334) in opposite directions. Insert wire connector according to claim 1, characterized in that the housing (12,164,188) comprises at least two housing parts (14,124,168,198,16,122,166,200) and each housing part (14,124,168,198,16,122,166,200) has at least one wire receiving box (22,52,128,172,176,194,196) and at least one of the wire openings (40,70,126,170,174,190,192). Insert wire connector according to claim 1, characterized in that the busbar (334) has a first surface (350) and a second surface (352), each comprising a wire engagement projection. Connection arrangement for use in a plug-in wire connector, the connection arrangement comprising: a spring member (336) with a foot (338), the foot (338) having opposing first and second end parts, a pair of spaced-apart bands with first and second surfaces, a first leg (340) extending from the first end part of the foot (338) in a first direction, and a second leg (342) extending from the second end part of the foot (338) in a second direction, the first and second legs (340, 342) each having a spring finger (346), a busbar (334) integrated with the foot (338), the first spring finger (346) being configured to pre-tension a first wire end into a connection with the busbar (334), and the second spring finger (346) being configured to pre-tension a second wire end into a connection with the busbar (334) to be pretensioned;and wherein the busbar (334) comprises a first part (334A) attached to the first surfaces of the straps of the foot (338) and a second part (334B) attached to the second surfaces of the straps of the foot (338), such that the busbar (334) is integrated with the foot (338) in such a way that the straps of the foot (338) are arranged in a layered configuration between the first part (334A) and the second part (334B) of the busbar (334). Connection arrangement according to claim 9, characterized in that the spring member (336) and the busbar (334) of the connection arrangement (332) are made of a plurality of materials. Connection arrangement according to claim 10, characterized in that the busbar (334) is made of at least one material and the foot (338) of the spring member (336) is made of at least one material which differs from the at least one material of the busbar (334) in at least one aspect of conductivity and / or elasticity. Connection arrangement according to claim 11, characterized in that the busbar (334) comprises a first surface (350) and a second surface (352). Connection arrangement according to claim 9, characterized in that the spring member (336) and the busbar (334) of the integrated connection arrangement (332) are made of the same material. Connection arrangement according to claim 13, wherein the spring member (336) and the busbar (334) of the integrated connection arrangement (332) are formed in one piece. Connection arrangement according to claim 9, characterized in that the first surface (350) and / or the second surface (352) of the busbar (334) has a wire engagement projection. Insertion wire connector comprising: a housing (12, 164, 188) with at least two openings (40, 70, 126, 170, 174, 190, 192) facing in opposite directions, wherein the openings (40, 70, 126, 170, 174, 190, 192) each define an axis and allow wire ends inserted into the housing (12, 164, 188) to extend into an interior of the housing (12, 164, 188), wherein the axes of the openings (40, 70, 126, 170, 174, 190, 192) are spaced apart from each other, a busbar (334) arranged in the interior of the housing (12, 164, 188), and a first entry edge (354A) extending through a (40,70,126,170,174,190,192) is first crossed, and a second entry edge (354B) is defined, which is first crossed by a wire inserted into a second of the openings (40,70,126,170,174,190,192), wherein the first and second entry edges (354A,354B) are provided on opposite sides of the busbar (334),and a spring element (336) with a foot (338) arranged in the interior of the housing (12, 164, 188) and having a first upwardly extending leg (340) adjacent to the first entry edge (354A) and a second upwardly extending leg (343) adjacent to the second entry edge (354B), wherein each of the upwardly extending legs (340, 342) can engage a wire inserted into a corresponding opening (40, 70, 126, 170, 174, 190, 192) to press the wire into a connection with the busbar (334), and wherein the foot (338) has a pair of spaced-apart bands with first and second surfaces, wherein the busbar (334) comprises a first part (334A) and a second part (334B), and wherein the busbar (334) and the spring element (336) are integrated into a connection arrangement (332),in which the first part (334A) is attached to the first surfaces of the straps of the foot (338) and the second part (334B) is attached to the second surfaces of the straps of the foot (338) such that the straps of the foot (338) are arranged in a layered configuration between the first part (334A) and the second part (334B) of the busbar (334). Insert wire connector according to claim 16, characterized in that the integrated connection arrangement (332) is formed from a plurality of materials. Insert wire connector according to claim 16, characterized in that the integrated connection arrangement (332) is formed from a single material. Plug-in wire connector according to claim 18, characterized in that the busbar (334) and the spring element (336) of the integrated connection arrangement (332) are formed in one piece.

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