Wire connector

Abstract

A wire connector has a body with an open end through which one or more wires are insertable and a closed end. The body includes a first body portion and a second body portion pivotably connected to the first body portion by a hinge so that when the hinge is open, an inner space of the body is accessible and when hinge is closed, the inner space of the body is only accessible through the open end. The wire connector also includes a locking mechanism to keep the hinge in the closed position. The inner space is formed by a first cutout in the first body portion and a second cutout in the second body portion. Each of the first and second cutouts is provided with one or more retainers to releasably retain ends of wires inserted in inner space.

Description

[0001] WIRE CONNECTOR

[0002] Field of the Invention

[0003] The invention relates to wire connectors, also known as wire nuts or wire caps, that protect the end of a wire or electrically couple two or more wires.

[0004] Background

[0005] Wire connectors are known in the industry for electrically coupling wires. Wire connectors are generally formed of a plastic housing and, in one commonly used form, include a tapered, conductive inner connector, often a spring or inwardly threaded receiver, that grips the bare ends of one or more wires onto which it is rotatably connected. An oftentimes cumbersome twisting motion is required to couple and uncouple the wire end(s) from the wire connector. In another commonly used form that does not require any twisting motion, the wire connectors are crimped to couple the wire end(s). To remove the wire end(s), the wire connector must be deformed again, typically rendering the wire connector not reusable.

[0006] There therefore exists a need for an improved electrical wire connector.

[0007] Summary of the Invention

[0008] A wire connector is disclosed that includes a body having an open end for inserting one or more wires and a closed end. The body is formed from two portions — a first body portion and a second body portion — that are pivotably connected by a hinge. This hinge allows the body to be opened, providing access to an internal space, or closed, in which case the internal space is only accessible through the open end. A locking mechanism is provided to keep the hinge securely in the closed position.

[0009] The inner space of the connector is defined by a first cutout in the first body portion and a second cutout in the second body portion. Each of these cutouts includes one or more retainers configured to releasably retain the ends of wires inserted into the connector. In certain embodiments, the hinge is a living hinge, and the locking mechanism includes a hook and catch arrangement between the body portions.

[0010] Some versions of the connector include alignment features such as a ridge and a corresponding recess to help ensure precise closure. The inner space of the body may have a substantially conical shape, tapering from the open end toward the closed end to better guide and retain wires.

[0011] Each retainer may comprise a base attached to or integral with a cutout wall and a prong extending at an acute angle, with specific geometric proportions that enhance grip. In an exemplary embodiment, a length of the base is at least twice a width of the base.

[0012] The connector body may itself be conical and made of, or coated with, electrically non-conductive material for insulation purposes. In contrast, the inner walls of the cutouts may be formed from, or coated with, electrically conductive material to facilitate electrical contact with inserted wires.

[0013] In another embodiment, the wire connector comprises a body with an open end through which one or more wires are insertable and a closed end. The body includes a first body portion and a second body portion pivotably connected to the first body portion by a hinge so that when the hinge is open, an inner space of the body is accessible and when hinge is closed, the inner space of the body is only accessible through the open end. A locking mechanism keeps the hinge in the closed position. The inner space is formed by a first cutout in the first body portion and a second cutout in the second body portion. A first insert is insertable into the first cutout and a second insert is insertable into the second cutout. Each of the first and second inserts is provided with at least one retainer to releasably retain ends of wires inserted in inner space.

[0014] Each of the first and second inserts can be made of or coated with an electrically conductive material. The at least one retainer of the first and second inserts each comprises a base that is attached to or integral with a wall of the respective first and second inserts and a prong that extends from the base at an acute angle. In an exemplary embodiment, a length of the base is at least twice a width of the base.

[0015] In certain embodiments, the hinge is a living hinge, and the locking mechanism includes a hook and catch arrangement between the body portions.

[0016] Some versions of the connector include alignment features such as a ridge and a corresponding recess to help ensure precise closure. The inner space of the body may have a substantially conical shape, tapering from the open end toward the closed end to better guide and retain wires.

[0017] The connector body may itself be conical and made of, or coated with, electrically non-conductive material for insulation purposes. In contrast, the inner walls of the cutouts may be formed from, or coated with, electrically conductive material to facilitate electrical contact with inserted wires. The disclosed wire connector provides a combination of structural and material features to offer a secure, reusable, and electrically functional wire connection solution.

[0018] Brief Description of the Drawings

[0019] A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following description when considered in conjunction with the accompanying drawings wherein:

[0020] FIG. 1 shows an embodiment of a wire connector according to the invention in a closed configuration.

[0021] FIG. 2 shows the wire connector of FIG. 1 in an open configuration.

[0022] FIG. 3 shows an alternative embodiment of an arched hinge that can be used to open and close the wire connector of FIG. 1.

[0023] FIG. 4 shows another alterative embodiment of a living hinge that can be used to open and close the wire connector of FIG. 1.

[0024] FIG. 5 shows a prototype of the wire connector of FIG. 1.

[0025] Detailed Description

[0026] As required, embodiments are disclosed herein; however, it is to be understood that the disclosed embodiments are merely examples and that the devices and methods described below can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present subject matter in virtually any appropriately detailed structure and function. Further, the terms and phrases used herein are not intended to be limiting, but rather, to provide an understandable description of the concepts.

[0027] It can be advantageous to set forth definitions of certain words and phrases used throughout this disclosure. The terms “a” or “an”, as used herein, are employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the disclosure. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The term “coupled.” as used herein, is defined as “connected,” although not necessarily directly, and not necessarily mechanically. The term "communicate," as well as derivatives thereof, encompasses both direct and indirect communication. The terms "include" and "comprise," as well as derivatives thereof, mean inclusion without limitation. The term "or" is inclusive, meaning and / or. The phrase "associated with," as well as derivatives thereof, can mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to. be bound to or with. have, have a property of. have a relationship to or with, or the like. The phrase "at least one of," when used with a list of items, means that different combinations of one or more of the listed items can be used, and only one item in the list can be needed. For example, "at least one of: A. B, and C" includes any of the following combinations: A; B; C; A and B; A and C; B and C; and A, B, and C.

[0028] As used herein, the term "about" or "approximately" applies to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure. As used herein, the terms "substantial" and "substantially" means, when comparing various parts to one another, that the parts being compared are equal to or are so close enough in dimension that one skill in the art would consider the same. Substantial and substantially, as used herein, are not limited to a single dimension and specifically include a range of values for those parts being compared. The range of values, both above and below (e g., or greater / lesser or larger / smaller), includes a variance that one skilled in the art would know to be a reasonable tolerance for the parts mentioned.

[0029] Note that not all of the activities described in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities can be performed in addition to those described. Still further, the order in which activities are listed are not necessarily the order in which they are performed.

[0030] The invention generally relates to a reusable wire connector that does not require any- twisting coupling / uncoupling motion for connection of the wires with the connector and can be used with wire end(s) irrespective of whether the wire ends are twisted together. The wire connector according to the invention has a two-piece body that hinges open and closed. The hinge can be a traditional hinge or a living hinge. One body piece has a tab that mates with a corresponding tab on the other body piece to keep closed. Each body piece has a conical cutout for receiving the wires, which as noted above do not need to be twisted together. Each body piece has retainers (inclined ridges to help keep the wires in contact and to keep the wires inside the body pieces.

[0031] With reference to FIGS. 1-5, a wire connector 10 according to the present invention includes a body 12. Body 12 has an open end 14 through which one or more wires can be inserted and a closed end 16. Although body 12 is shown as having a substantially cylindrical shape, body 12 can have any other suitable shape, such as conical. In preferred embodiments, body 12 is made of an electrically non-conductive material, such as a polymer. However, the exterior surface of body 12 can be coated with an electrically non-conductive material.

[0032] Body 12 comprises a first body portion 18 and a second body portion 20. First and second body portions 18, 20 are connected by a hinge 22 so that when hinge 22 is open (FIG. 2), an inner space 24 of body 12 is accessible to easily remove any wires that have been inserted through open end 14 of body 12. When hinge 22 is closed (FIG. 1), inner space 24 is only accessible through open end 14 to allow insertion of any wires.

[0033] The present invention contemplates other mechanisms for opening and closing first and second body portion 18, 20. For example, FIGS. 3 and 4 show alternatives to hinge 22 to open and close first and second body portions 18. 20. In FIG. 3. an arched hinge 26 is used and in FIG. 4, a living hinge 28 is used.

[0034] Regardless of the mechanism used, first and second body portions 18, 20 can be provided with a locking mechanism to keep first and second body portions 18, 20 in the closed position. In this regard and as best seen in FIGS. 2-4, first body portion 18 includes a hook 30 that engages with catch 32 to maintain first and second body portions 18, 20 in the closed position. In an alternative embodiment, hook 30 is provided on second body portion 20 and catch 32 is provided on first body portion.

[0035] In exemplary embodiments, an end 34 of hook 30 can be pushed and / or an end 36 of hook 30 opposite to end 34 can be pulled to release hook 30 from catch 32. To help prevent unintended release of hook 30 from catch 32 and to help ensure alignment of first and second body portions 18, 20, a ridge 38 on first body portion 18 aligns with and is received in a recess 40 on second body portion 20. Alternatively, ridge 38 can be provided on second body portion 20 and recess 40 can be provided on first body portion 18.

[0036] With reference primarily to FIG. 2, inner space 24 of body 12 is formed by a cutout 42 in first body portion 18 and a corresponding cutout 44 in second body portion 20. In exemplary embodiments, inner space 24 (formed by cutouts 42. 44 when hinge 22 is closed) has a substantially conical shape, being wider at open end 14 of body 12 and tapering at closed end 16 of body 12. The taper facilitates insertion of wire ends at open end 14 and brings the wire ends into contact. However, this contact is not required if cutouts 42, 44 are made of or coated with an electrically conductive material.

[0037] Each of cutouts 42, 44 is provided with one or more retainers 46. In a preferred embodiment, cutout 42 is provided with two retainers 46 and cutout 44 is provided with two retainers 46. Retainers 46 retain the ends of wires in inner space 24. To remove the ends of wires from inner space 24, hinge 22 is opened. Each of retainers 46 includes a base 48 that is attached to or integral with the wall that forms cutout 42 (or cutout 44) and a prong 50 that extends from base 48 at an acute angle. The acute angle helps to guide wire ends being inserted into open end 14 of body 12 toward the center of inner space 24 and once inserted, also assists in retaining the ends of wires in inner space 24. Retainers 46 or a portion thereof such as prong 50 can be made of or coated with an electrically conductive material.

[0038] Base 48 has a width W and a length L. In exemplary’ embodiments, length L is at least twice width W. Having length L, which is integral to or attached to the wall that forms cutout 42 (or cutout 44), twice width W improves the ability of retainers 46 to retain the ends of wires in inner space 24.

[0039] FIG. 5 shows an alternative embodiment that does not have retainers 46 integral to or attached to the wall that forms cutout 42 (or cutout 44). Instead, one or more retainers 46 are provided on an insert 52 which is inserted into cutout 42 of first body portion 18. Retainers 46 are also provided on an insert 54 which is inserted into cutout 44 of second body portion 20. Inserts 52, 54 can be made of or coated with an electrically conductive material.

[0040] As previously noted, retainers 46 help retain the ends of wires in inner space 24. To remove the ends of wires from inner space 24, hinge 22 is opened. Each of retainers 46 includes a base 48 that is attached to or integral with insert 52 or insert 54 and a prong 50 that extends from base 48 at an acute angle. The acute angle helps to guide wire ends being inserted into open end 14 of body 12 toward the center of inner space 24 and once inserted, also assists in retaining the ends of wires in inner space 24. Retainers 46 or a portion thereof such as prong 50 can be made of or coated with an electrically conductive material.

[0041] All references cited herein are expressly incorporated by reference in their entirety. It will be appreciated by persons skilled in the art that the invention is not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary’, it should be noted that all of the accompanying draw ings are not to scale. There are many different features to the invention and it is contemplated that these features may be used together or separately. Thus, the invention should not be limited to any particular combination of features or to a particular application of the invention. Further, it should be understood that variations and modifications within the spirit and scope of the invention might occur to those skilled in the art to which the invention pertains. Accordingly, all expedient modifications readily attainable by one versed in the art from the invention set forth herein that are within the scope and spirit of the present invention are to be included as further embodiments of the invention.

[0042] The description in the present application should not be read as implying that any particular element, step, or function is an essential or critical element that must be included in the claim scope. The scope of patented subject matter is defined only by the allowed claims. Moreover, none of the claims invokes 35 U.S.C. § 112(f) with respect to any of the appended claims or claim elements unless the exact words "means for" or "step for" are explicitly used in the particular claim, followed by a participle phrase identifying a function.

[0043] Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that can cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, sacrosanct or an essential feature of any or all the claims.

[0044] After reading the disclosure, skilled artisans will appreciate that certain features are, for clarity, described herein in the context of separate embodiments, can also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, can also be provided separately or in any sub-combination. Further, references to values stated in ranges include each and every value within that range.

[0045] The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated.

Claims

The Claims1 . A wire connector comprising: a body with an open end through which one or more wires are insertable and a closed end, the body including a first body portion and a second body portion pivotably connected to the first body portion by a hinge so that when the hinge is open, an inner space of the body is accessible and when hinge is closed, the inner space of the body is only accessible through the open end; a locking mechanism to keep the hinge in the closed position; wherein the inner space is formed by a first cutout in the first body portion and a second cutout in the second body portion; wherein each of the first and second cutouts is provided with one or more retainers to releasably retain ends of wires inserted in inner space.

2. The wire connector of claim 1. wherein the hinge is a living hinge.

3. The wire connector of any one of the previous claims, wherein the locking mechanism comprises a hook on one of the first and second body portions that engages a catch on the other of the first and second body portions.

4. The wire connector of any one of the previous claims, wherein one of the first and second body portions includes a ridge and the other of the first and second body portions includes a recess, the ridge aligning with and received in the recess when the hinge is in the closed position.

5. The wire connector of any one of the previous claims, wherein the inner space has a substantially conical shape, being wider at the open end of the body and tapering at the closed end of the body.

6. The wire connector of any one of the previous claims, wherein the one or more retainers of the first and second cutouts each comprises a base that is attached to or integral with a wall of the respective first and second cutouts and a prong that extends from the base at an acute angle.

7. The wire connector of claim 6, wherein a length of the base is at least twice a width of the base.

8. The wire connector of any one of the previous claims, wherein the body has a conical shape.

9. The wire connector of any one of the previous claims, wherein the body is made of an electrically non-conductive material or an exterior surface of the body is coated with an electrically non-conductive material.

10. The wire connector of any one of the previous claims, wherein each of the first and second cutouts has an inner wall, the inner wall provided with the one or more retainers, and wherein the inner wall is made of an electrically conductive material or is coated with an electrically conductive material.

11. A wire connector comprising: a body with an open end through which one or more wires are insertable and a closed end, the body including a first body portion and a second body portion pivotably connected to the first body portion by a hinge so that when the hinge is open, an inner space of the body is accessible and when hinge is closed, the inner space of the body is only accessible through the open end; a locking mechanism to keep the hinge in the closed position; wherein the inner space is formed by a first cutout in the first body portion and a second cutout in the second body portion; wherein a first insert is insertable into the first cutout and a second insert is insertable into the second cutout; wherein each of the first and second inserts is provided with at least one retainer to releasably retain ends of wires inserted in inner space.

12. The wire connector of claim 11, wherein each of the first and second inserts is made of or coated with an electrically conductive material.

13. The wire connector of claim 11 or 12, wherein the at least one retainer of the first and second inserts each comprises a base that is attached to or integral with a wall of the respective first and second inserts and a prong that extends from the base at an acute angle.

14. The wire connector of claim 13, wherein a length of the base is at least twice a width of the base.

15. The wire connector of any one of claims 11-14, wherein the locking mechanism comprises a hook on one of the first and second body portions that engages a catch on the other of the first and second body portions.

16. The wire connector of any one of claims 1 1-15, wherein one of the first and second body portions includes a ridge and the other of the first and second body portions includes a recess, the ridge aligning with and received in the recess when the hinge is in the closed position.

17. The wire connector of any one of claims 11-16, wherein the inner space has a substantially conical shape, being wider at the open end of the body and tapering at the closed end of the body.

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