Electrical auxiliary splice

Abstract

An auxiliary electrical splice comprising an insulator assembly including first and second insulators configured to electrically insulate electrical splice connections. The first insulator comprises: a support wall configured to extend longitudinally adjacent the splice connections; a central insulator plate extending laterally from the support wall and configured to extend between the splice connections; a first outer insulator plate extending laterally from the support wall, spaced from the central insulator plate, and including a pair of laterally extending end plate stiffening flanges and a pair of pullout guide flanges, each extending from a corresponding one of the end plate stiffening flanges to define a cavity for receiving a portion of the second insulator;and a second outer insulator plate extending laterally from the support wall, spaced from the central insulator plate on a side opposite the first outer insulator plate, and configured to engage the second insulator;

Description

Field of InterestThe present disclosure relates generally to the field of cable cables. More particularly, the disclosure relates to an auxiliary splice for connecting line cables.BackgroundAuxiliary splices are used for selectively connecting and disconnecting electrical conductors in a circuit, for example in a high voltage circuit in an automobile. A housing and insulators can be used in the auxiliary splices to hold and insulate the electrical conductors to be spliced. It is desirable that the housing and the insulators be inexpensive and be easily assembled. In addition, it is desirable that, during assembly, it can be seen that the housing comprising the auxiliary splice is locked in the assembled position when it is in use.OverviewIn one aspect, an embodiment provides an auxiliary electrical splice for connecting cable cables to splices, the auxiliary electrical splice comprising: an insulator assembly comprising a first insulator and a second insulator configured to act to secure and between the splices to electrically isolate the splices, the first insulator comprising: a support wall configured to extend longitudinally adjacent the splices; a central insulator plate extending laterally from the support wall and configured to extend between the splices; a first outer insulator plate extending laterally from the support wall spaced apart from the central insulator plate and comprising a pair of end plate stiffening flanges extending laterally and a pair of extension guide flanges each extending from a corresponding one of the end plate stiffening flanges to define a cavity for receiving a portion of the second insulator; and a second outer insulator plate extending laterally from the support wall spaced apart from the central insulator plate on a side opposite the first outer insulator plate and configured to engage the second insulator.In one aspect, an embodiment provides an auxiliary electrical splice for connecting cable cables to splices, the auxiliary electrical splice comprising: an insulator assembly comprising a first insulator and a second insulator configured to act to secure and between the splices to electrically isolate the splices, the first insulator comprising: a support wall configured to extend longitudinally adjacent the splices; a central insulator panel extending laterally from the support wall and configured to extend between the splices; a first outer insulator panel extending laterally from the support wall spaced from the central insulator panel and comprising a receiving hole configured to engage the second insulator; and a second outer insulator plate extending laterally from the support wall spaced apart from the central insulator plate on a side opposite the first outer insulator plate and including a barb configured to engage the second insulator to maintain the first insulator and the second insulator in an assembled position.In one aspect, an embodiment provides an integrated housing and holder structure to reduce parts and assembly and disassembly time. In one aspect, an embodiment provides an external locking feature between the housing and a housing end cap to visually ensure that both are fully locked together and to facilitate disassembly. In one aspect, an embodiment provides cable claws to releasably lock the cable cables to the housing and the housing end cap, providing strain relief. In one aspect, an embodiment provides an insulator assembly that enables easy assembly, including insulator plates that do not tend to warp to prevent detents from loosening during assembly, lead-in flanges for guiding the electrical conductors adjacent the splices, and substantially identical first and second insulators that mate to facilitate part selection and assembly.Additional understanding of these examples will be obtained by studying the following detailed description and the accompanying drawings.Brief Description of the DrawingsFig. 1 is a schematic perspective view of an auxiliary electrical splice. Fig. 2 is a schematic, partially exploded perspective view of an auxiliary splice, but only a portion of the lead cables are shown. FIG. 3 is a schematic perspective view of line cables and an isolator assembly before the isolator assembly is attached to the line cables. FIG. 4 is a schematic perspective view of a portion of an insulator assembly. FIG. 5 is a schematic perspective view of a portion of an insulator assembly. FIG. 6 is a schematic, partially cut-away view of an insulator assembly. FIG. 7 is a schematic, partially cut-away view of an insulator assembly prior to assembly. FIG. 8 is a schematic perspective view of line cables and an insulator assembly attached to the line cables. FIG. 9 is a schematic perspective view of a portion of a housing and a housing end cap prior to attachment to the housing. FIG. 10 is a schematic perspective view of a housing end cap. FIG. 11 is a schematic perspective view of wire cables, cable claws, and cable holding brackets.Detailed DescriptionThe following detailed description and the accompanying drawings describe and illustrate various embodiments of an auxiliary electrical splice. The description and illustration of these examples is intended to enable those skilled in the art to make and use an auxiliary electrical splice in accordance with this invention. They are not intended to limit the scope of the claims in any way.In Figs. 1 and 2 an example of an auxiliary electrical splice 20 is shown, which is adapted for splicing line cables 22a, 22b, 22c. The auxiliary electrical splice 20 may be used, for example, in the high voltage range (e.g., 48 volts, 100 volts, 300 volts, or higher). The line cables 22a, 22b, 22c each include a pair of electrical conductors 24a, 24b, 24c joined together at a pair of splices 26. The pair of splices 26 are included in a splice assembly 28. For clarity of description, a longitudinal direction 18 is indicated by arrows labeled 18 and a lateral direction 19 is indicated by arrows labeled 19 in the drawings. The line cables 22 a, 22 b, 22 ctherefore run substantially in the longitudinal direction 18.The splice assembly 28 includes a housing 30, a housing end cap 32, inner housing members 34a, 34b, an insulator assembly 36, gaskets 38a, 38b, 38c, annularly spaced cable claws 40a, 40b, 40c, and cable retaining brackets 42a, 42b, 42c. The housing 30 includes an outer wall 44 defining a cavity 45 (best seen in FIG. 9 ) into which the line cables 22 a, 22 b, 22 cextend. Integrally formed with the outer wall 44 at a first longitudinal end 46 are retainers 48a, 48b, the first retainer 48a being shaped to receive and retain the first lead cable 22a and the second retainer 48b being shaped to receive and retain the second lead cable 22b. As used herein, the term integral means that the elements that are integral are a single monolithic part that can be molded (e.g., cast) as a single part or separately molded and permanently attached (e.g., bonded) to be a single monolithic part. Because the outer wall 44 and the brackets 48 a, 48 bare integral, the number of parts and the complexity of assembly are reduced when the auxiliary electrical splice 20 is joined. Each of the brackets 48a, 48b includes respective cable retaining receptacles 50a, 50b and alignment flanges 52a, 52b. In each of the holders 48 a, 48 bis located a corresponding seal 38 a, 38 bwhich surrounds one of the line cables 22 a, 22 bin each case. The outer wall 44 also includes tab engagement receptacles 54 (one on a first side and a substantially identical one on an opposite side of the outer wall 44). Adjacent each tab engagement receptacle 54 is a corresponding guide flange 56.Referring to the example illustrated in FIGS. 3 to 8, referring to FIGS. 1 and 2, the insulator assembly 36 includes a first insulator 58 aand a second insulator 58 bwhich may be formed of an electrically non-conductive material (e.g., plastic). The first and second insulators 58 a, 58 bmay have substantially the same size and shape, with one of the two being inverted with respect to the other and their open ends facing each other (as best seen in FIGS. 3 and 8 ). Because the two insulators 58 a, 58 bare substantially the same, the features of only one insulator will be discussed, the discussion referring to both insulators 58 a, 58 b.The insulator 58a includes a central insulator plate 60, a first outer insulator plate 62a and a second outer insulator plate 62b, the outer insulator plates 62a, 62b being located on and spaced from both sides of the central insulator plate 60. The insulator plates 60, 62a, 62b are joined by a support wall 63 that is generally perpendicular to the plates 60, 62a, 62b. The first outer insulator plate 62a includes a pair of receiving holes 64 and an alignment notch 65. extending along opposite edges of the first outer insulator plate 62a are faceplate stiffening flanges 66a, 66b which extend generally perpendicular to the first outer insulator plate 62a toward the central insulator plate 60. Extending from each of the end plate stiffening flanges 66a, 66b are respective extension guide flanges 70a, 70b. The pull-out guide flanges 70a, 70b extend generally perpendicularly from the respective faceplate stiffening flanges 66a, 66b and parallel to, but spaced from, the outer insulator panel 62a. The support wall 63 comprises insertion flanges 68 a, 68 bat the opposite ends in the longitudinal direction 18. The insertion flanges 68 a, 68 bare angled away from the support wall 63 from the central insulator plate 60. The second outer insulator plate 62b includes a pair of barbs 72 each arranged to align with and engage one of the receiving holes 64 on a mating insulator 58a, 58b, respectively, when the two insulators 58a, 58b are fully mounted in the insulator assembly 36. Two pairs of flex slots 74 are located in the second outer insulator plate 62b, each pair of flex slots 74 being located on opposite sides of the corresponding barb 72. This allows local bending of the second outer insulator plate 62 bduring assembly. The second outer insulator plate 62b includes a plate alignment flange 76 which is arranged to align with and engage the alignment notch 65 on a mating insulator 58a, 58b, respectively, when the pair of insulators 58a, 58b are fully inserted into the insulator assembly 36. The second outer insulator plate 62b also includes a pair of pull-out alignment flanges 75 configured to assist in retaining the second outer insulator plate 62b in the pull-out guide flanges 70a, 70b.The joining of the two insulators 58 a, 58 bis now explained. The first insulator 58a is oriented such that an open side (the side opposite the support wall 63) faces the electrical conductors 24a, 24b, 24c (as best shown in Figure 3). The second insulator 58b is oriented such that its open side faces the electrical conductors 24a, 24b, 24c, but from the opposite side of the electrical conductors 24a, 24b, 24c, and is inverted such that its first outer insulator plate 62a is aligned with the second outer insulator plate 62b of the first insulator 58a and its second outer insulator plate 62b is aligned with the first outer insulator plate 62a of the first insulator 58a (as best shown in Figure 3). The first and second insulators 58 a, 58 bare aligned with the electrical conductors 24 a, 24 b, 24 csuch that the central insulator plate 60 of each insulator can slide between the splices 26 (as best shown in FIGS. 3 and 7 ). The first and second insulators 58 a, 58 bare aligned such that the second outer insulator plate 62 bof the second insulator 58 bslides between the first outer insulator plate 62 aand the extraction guide flanges 70 a, 70 bof the first outer insulator plate 62 aand the first outer insulator plate 62 aand their extraction guide flanges 70 a, 70 bslides around the second outer insulator plate 62 bof the first insulator 58 a(as best seen in FIG. 7 ). The first and second insulators 58 a, 58 bare then slid laterally toward each other, with the flexing slots 74 allowing the barbs 72 to flex until the barbs 72 are aligned with their respective receiving holes 64 (as best seen in FIGS. 7 and 8 ). The insulation unit 36 is now secured around the splices 26.Referring to the example shown in FIGS. 9 and 10, a portion of the housing 30 and the associated housing end cap 32 are shown with reference to FIGS. 1 and 2. The tab engagement receptacles 54 (one of which in FIG. 9 ) and the guide flanges 56 extend outwardly from the outer wall 44 adjacent an opening at a second longitudinal end 80 of the cavity 45 defined by the outer wall 44. the housing end cap 32 includes an inner flange 82 extending around a perimeter sized and shaped to slide within the cavity 45 such that a seal 84 disposed about the inner flange 82 seals against an inner surface of the outer wall 44 of the housing 30. The housing end cap 32 also includes a pair of outer flange locks 86 each configured to mate with a corresponding one of the lock-engaging receptacles 54 to secure the housing end cap 32 to the outer wall 44 of the housing 30. A third cable holder 48c extends around a passage 88 through which the line cable 22c extends. The third cable holder 48c includes cable retaining receptacles 90 and alignment flanges 92 configured to mate with the third cable retaining bracket 42c.In the example shown in FIG. 11, referring to FIGS. 1 and 2, the cable claws 40 a, 40 band the cable holding brackets 42 a, 42 bare attached around the respective line cables 22 a, 22 b, with the corresponding pairs of electric conductors 24 a, 24 bextending up to the splices 26. The cable claws 40 a, 40 beach comprise an annular holder 94 a, 94 b, from which a set of longitudinally extending claw arms 96 a, 96 bextends. Each of the claw arms 96 a, 96 bhas a radially inwardly extending protrusion 97 a, 97 bconfigured to engage the outer surface of the respective cable 22 a, 22 b. Each of the cable-retaining brackets 42 a, 42 bincludes a pair of retaining arms 98 a, 98 bconfigured to engage the corresponding cable-retaining brackets 50 a, 50 bto retain the cable-retaining brackets 42 a, 42 bto the housing 30. Each of the cable support brackets 42a, 42b also includes an annular body 99a, 99b that surrounds a respective one of the cable cables 22a, 22b. The cable claw 40 cand the cable holding bracket 42 cmay be substantially the same as the cable claws 40 a, 40 band the holding brackets 42 a, 42 b, and thus will not be separately explained here.Referring now to the example shown in Figs. 1 to 11, the joining of the auxiliary electric splice 20 will be explained. The lead wire 22a is passed through the wire holding bracket 42a, the wire claw 40a, the packing 38a, the holder 48a, and the cavity 45. The same steps of assembly are performed with the cable 22b. The lead cable 22c is passed through the cable holding bracket 42c, the cable claw 40c, the packing 38c, the holder 48c, and the housing end cap 32. The pairs of electrical conductors 24a, 24b and 24c are interconnected (as best seen in Figures 2 and 3). The insulator assembly 36 is then assembled as described above to ensure that the splices 26 remain electrically disconnected. Then, the inner housing members 34a, 34b are assembled around the splices 26, the splice assembly 28 and the ends of the cable cables 22a, 22b, 22c. The housing 30 and the housing end cap 32 are then slid toward each other in the longitudinal direction 18, with the respective guide flanges 56 guiding the outer flange locks 86 into engagement with the corresponding tab engagement receptacles 54. Because the tab engagement receptacles 54 are external to the housing 30 and are visible to the assembler, it can ascertain that the housing end cap 32 is locked to the housing 30. The gaskets 38a, 38b, 38c are slid along the respective line cables 22a, 22b, 22c and into the respective holders 48a, 48b, 48c. The cable claws 40 a, 40 b, 40 care pushed along the respective lead cables 22 a, 22 b, 22 ctoward the respective holders 48 a, 48 b, 48 c. The cable support brackets 42a, 42b, 42c are slid along the respective cable conduits 22a, 22b, 22c until the support arms 98a, 98b, 98c engage the respective cable support receptacles 50a, 50b, 50c. When the cable retaining brackets 42 a, 42 b, 42 care slid into position, the protrusions 97 a, 97 b, 97 cof the claw arms 96 a, 96 b, 96 care pushed radially inward into engagement with the respective lead cable 22 a, 22 b, 22 cand thus secure the position of the lead cables 22 a, 22 b, 22 crelative to the housing 30 and the housing end cap 32.Those skilled in the art will understand that various modifications and alternatives to the described and depicted embodiments may be developed in light of the general teachings of the disclosure and that the various elements and features of one example described and depicted herein may be combined with various elements and features of another example without departing from the scope of the invention. Accordingly, the specific examples disclosed herein have been selected by the inventor(s) merely for the purpose of describing and illustrating examples of the invention and are not intended to limit the scope of the invention or its scope, which is given in the full breadth of the appended claims and all equivalents thereof.

Claims

An auxiliary electrical splice for connecting cable cables to splices, the auxiliary electrical splice comprising: an insulator assembly comprising a first insulator and a second insulator configured to act to secure and between the splices to electrically isolate the splices, the first insulator comprising: a support wall configured to extend longitudinally adjacent the splices; a central insulator plate extending laterally from the support wall and configured to extend between the splices; a first outer insulator plate extending laterally from the support wall spaced apart from the central insulator plate and comprising a pair of end plate stiffening flanges extending laterally and a pair of extension guide flanges each extending from a respective one of the end plate stiffening flanges to define a cavity for receiving a portion of the second insulator; and a second outer insulator plate extending laterally from the support wall spaced apart from the central insulator plate on a side opposite the first outer insulator plate and configured to engage the second insulator.The auxiliary electrical splice of claim 1, wherein the second insulator comprises: a second support wall configured to extend longitudinally adjacent the splices; a second central insulator plate extending laterally from the second support wall and configured to extend between the splices; a third outer insulator plate extending laterally from the second support wall spaced from the second central insulator plate and comprising a second pair of faceplate stiffening flanges extending laterally and a second pair of pull-out guide flanges each extending from a respective one of the second pair of faceplate stiffening flanges to define a second cavity receiving the second outer insulator plate; a fourth outer insulator plate extending laterally from the second support wall and spaced from the second central insulator plate on a side opposite the third outer insulator plate, the fourth outer insulator plate being received in the cavity of the first outer insulator plate.The auxiliary electrical splice of claim 2, wherein the second outer insulator plate slides laterally between the third outer insulator plate and the second pair of faceplate stiffening flanges to retain the second outer insulator plate to the third outer insulator plate, and the fourth outer insulator plate slides laterally between the first outer insulator plate and the pull-out guide flanges to retain the fourth outer insulator plate to the first outer insulator plate.The auxiliary electrical splice of claim 2, wherein one of the first outer insulator plate and the second outer insulator plate comprises a receiving hole and the other of the first outer insulator plate and the second outer insulator plate comprises a barb, and the third outer insulator plate or the fourth outer insulator plate comprises a second receiving hole and the other of the third outer insulator plate and the fourth outer insulator plate comprises a second barb, wherein when the first insulator is mated with the second insulator, the receiving hole engages and retains the second barb and the second receiving hole engages and retains the barb to secure the first insulator to the second insulator.The auxiliary electrical splice of claim 4, wherein the other of the first outer insulator plate and the second outer insulator plate comprises a pair of laterally extending flex slots adjacent and on opposite sides of the barb and the other of the third outer insulator plate and the fourth outer insulator plate comprises a second pair of laterally extending flex slots adjacent and on opposite sides of the second barb, wherein when the first insulator is mated with the second insulator, the pair of flex slots and the second pair of flex slots allow the barb and the second barb to flex toward the central insulator plate until the barb is aligned with the second receiving hole and the second barb is aligned with the receiving hole.The auxiliary electrical splice of claim 2, wherein the first outer insulator plate comprises a laterally extending alignment notch and the fourth outer insulator plate comprises a laterally extending plate alignment flange configured to engage the alignment notch when the first insulator and the second insulator are moved laterally toward each other to be fully assembled.An auxiliary electrical splice as claimed in claim 1, wherein the support wall includes two insertion flanges extending from respective opposite longitudinal ends of the support wall, each of the insertion flanges being oriented to form an angle away from the central insulator plate when the insertion flange extends away from the support wall.The auxiliary electrical splice of claim 1, wherein one of the first outer insulator plate and the second outer insulator plate comprises a receiving hole configured to engage the second insulator, and the other of the first outer insulator plate and the second outer insulator plate comprises a hook configured to engage the second insulator.The auxiliary electrical splice of claim 1, wherein one of the first outer insulator plate and the second outer insulator plate comprises an alignment slot extending laterally and configured to engage the second insulator, and the other of the first outer insulator plate and the second outer insulator plate comprises a plate alignment flange extending laterally and configured to engage the second insulator.An auxiliary electrical splice according to claim 1, wherein the second insulator is identical to the first insulator.The auxiliary electrical splice of claim 1, further comprising: a housing having an outer wall configured to include the splices and including one of a tab engagement receptacle and an outer flange lock on an outer surface of the outer wall; and a housing end cap configured to cover one end of the housing and including the other of the tab engagement receptacle and the outer flange lock on an outer surface of the housing end cap, wherein the tab engagement receptacle and the outer flange lock are configured to releasably engage one another to secure the housing end cap to the housing.The auxiliary electrical splice of claim 11, further comprising a guide flange adjacent the tab engagement receptacle and configured to guide the outer flange latch into engagement with the tab engagement receptacle when the housing end cap is attached to the housing.The auxiliary electrical splice of claim 1, further comprising: a housing having an outer wall configured to include the splices; and a cable holder integral with the housing, the cable holder configured to receive and hold the cables.The auxiliary electrical splice of claim 1, further comprising: a housing end cap having a lead cable holder integrated with the housing end cap, the lead cable holder configured to receive and hold one of the lead cables.The auxiliary electrical splice of claim 1, further comprising: a housing having an outer wall configured to receive the splices; and cable claws configured to surround one of the lead cables and secure the one of the lead cables to the housing.An auxiliary electrical splice according to claim 15, wherein the cable claws comprise an annular bracket surrounding the one of the lead cables, claw arms extending longitudinally from the annular bracket, and protrusions, one at each end of the respective claw arms, the protrusions being adapted to press against an outer surface of the one of the lead cables to thereby secure the one of the lead cables to the housing.An auxiliary electrical splice for connecting cable cables to splices, the auxiliary electrical splice comprising: an insulator assembly comprising a first insulator and a second insulator configured to act to secure and between the splices to electrically isolate the splices, the first insulator comprising: a support wall configured to extend longitudinally adjacent the splices; a central insulator panel extending laterally from the support wall and configured to extend between the splices; a first outer insulator panel extending laterally from the support wall spaced from the central insulator panel and comprising a receiving hole configured to engage the second insulator; and a second outer insulator plate extending laterally from the support wall spaced apart from the central insulator plate on a side opposite the first outer insulator plate and including a barb configured to engage the second insulator to maintain the first insulator and the second insulator in an assembled position.An auxiliary electrical splice according to claim 17, wherein the second insulator is identical to the first insulator.The auxiliary electrical splice of claim 17, wherein one of the first outer insulator plate and the second outer insulator plate comprises an alignment slot extending laterally and configured to engage the second insulator, and the other of the first outer insulator plate and the second outer insulator plate comprises a plate alignment flange extending laterally and configured to engage the second insulator.An auxiliary electrical splice for connecting cable cables to splices, the auxiliary electrical splice comprising: an insulator assembly comprising a first insulator and a second insulator configured to act to secure and between the splices to electrically isolate the splices, the first insulator comprising: a support wall configured to extend longitudinally adjacent the splices; a central insulator plate extending laterally from the support wall and configured to extend between the splices; a first outer insulator plate extending laterally from the support wall, spaced apart from the central insulator plate and comprising a pair of end plate stiffening flanges and a receiving hole configured to engage the second insulator, the pair of end plate stiffening flanges extending from a respective one of the end plate stiffening flanges to define a cavity for receiving a portion of the second insulator; and a second outer insulator plate extending laterally from the support wall, spaced apart from the central insulator plate on a side opposite the first outer insulator plate and comprising a barb configured to engage the second insulator to maintain the first insulator and the second insulator in an assembled position; wherein the second insulator is identical to the first insulator.

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