Abstract
A gel filled electrical connector is disclosed and claimed. The connector has a base configured to house a gel fill insulating material and a plurality of 10-gauge or larger diameter wires; the base comprising a plurality of wire receptacles to receive a plurality of wires in a cavity in the base; a top cover sized to be securely and removably attached to the base, wherein the top cover comprises a plurality of wire connectors to strip insulation from the plurality of wire and to electrically connect the plurality of wires; and a gel deposited into the cavity to provide moisture resistance to the plurality of wires and plurality of wire connectors.
Claims
1. A gel filled electrical connector, comprising: a. a base configured to house a gel fill insulating material and a plurality of 10-gauge or larger diameter wires; b. the base comprising a plurality of wire receptacles to receive a plurality of wires in a cavity in the base; c. a top cover sized to be securely and removably attached to the base, wherein the top cover comprises a plurality of wire connectors to strip insulation from the plurality of wire and to electrically connect the plurality of wires; d. a gel deposited into the cavity to provide moisture resistance to the plurality of wires and plurality of wire connectors, wherein the gel comprises a hydrophobic dielectric.
2. The gel filled electrical connector of claim 1 wherein the base and the cover are formed from a Nylon, a polycarbonate, a plastic, or a resin.
3. The gel filled electrical connector of claim 1 wherein the wire connectors comprise a metal.
4. The gel filled electrical connector of claim 1 wherein the top further comprises a plurality of legs to frictionally engage a plurality of inner walls of the base to allow the top to be secured to the base.
5. (canceled)
6. The gel filled electrical connector of claim 1 wherein the gel comprises silicone.
7. (canceled)
8. A method for providing a moisture-resistant electrical connection between a plurality of wires comprising the steps of: a. Providing a base and a top cover wherein the top cover may be removably attached to the base; b. Providing a plurality of wire connectors secured to the top cover; c. Inserting a plurality of wires through a plurality of wire receptacles into a cavity of the base; d. attaching the top cover to the base so that the plurality of wire connectors engages and electrically connect the plurality of wires; e. filling the cavity with a moisture resistant gel, wherein the gel is a hydrophobic dielectric.
9. The method of claim 8 where in the base and the top cover are formed from a Nylon, a polycarbonate, a plastic, or a resin.
10. The method of claim 8 wherein the wire connectors comprise a metal.
11. The method of claim 8 wherein the top cover further comprises a plurality of legs to frictionally engage a plurality of inner walls of the base to allow the top to be secured to the base.
12. (canceled)
13. The method of claim 8 wherein the gel comprises silicone.
14. (canceled)
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a top-view of the gel filled connector.
[0008] FIG. 2 is a side-view of the gel filled connector.
[0009] FIG. 3 is a bottom-view of the gel filled connector.
[0010] FIG. 4 is a top-view of the gel filled connector with two wires secured therein.
[0011] FIG. 5 is a bottom-view of the gel filled connector with two wires secured therein.
[0012] FIG. 6 is a perspective view of the gel filled connector.
[0013] FIG. 7 is a bottom-view of the gel filled connector.
[0014] FIG. 8 is a perspective view of the gel filled connector without the top cover.
[0015] FIG. 9 is a side-view of the gel filled connector.
[0016] FIG. 10 is an end-view schematic of the gel filled connector without the top cover.
[0017] FIG. 11 is a bottom-view the cover for the gel filled connector.
[0018] FIG. 12 is a side-view of the top cover.
[0019] FIG. 13 is a top-view of the top cover.
[0020] FIG. 14 is a perspective-view of the top cover.
DETAILED DESCRIPTION
[0021] The devices and methods disclosed include one or more of the features, structures, methods, or combination thereof described. For example, a device or method may be implemented to include one or more of the features and/or processes described herein. Such device or method need not include all the features and/or processes described but may be implemented to include selected features and/or processes that provide useful structures and/or functionality. Various modifications and additions can be made to the disclosed embodiments. The scope of the present disclosure is not limited by the embodiments described but is defined by the claims set forth below and equivalents thereof.
[0022] Referring to FIG. 1, the gel field connector 10 is shown. The connector 10 comprises a base 40, the top cover 60, and a plurality of wire receptacles 70a, 70b, 70c positioned within the cavity of the base 40. The cover 60 connects to the base 40 using legs 140a, 140b, 140c, and 140d. Legs 140a-d are sized to create an interference-type fit of the top cover 60 to base 40. In a preferred embodiment, legs 140a-d have extrusions (not shown) positioned and sized to be received in notches (not shown) in base 40. Legs 140a-d may engage the interior walls of base 40. Alternatively, legs 140a-d may engage outer walls of base 40. Base 40 and the top cover 60 may be manufactured from a plastic, resin, or other suitable material sufficient to provide a protective covering to the cavity of the base 40. Top cover 60 is removably secured to base 40. Flange 120 provides protection against external forces dislodging wires 20, 30. Legs 140a-d provide releasably connecting structures to secure top 60 to base 40. Any structure known in the art will suffice to secure top 60 to base 40.
[0023] FIG. 2 shows a side view of connector 10. Top cover 60 is securely connected to base 40 to provide an enclosure for wire connectors 70a, 70b, and 70c. Connectors 70a-c may be horseshoe shaped or of any other design known to those skilled in the art. Connectors 70a-c may be manufactured from tin or any other metallic, electrically conductive material. Although the embodiment shown in FIG. 2 has three connectors 70a-c, any number of connectors may be provided without departing from the scope of the invention disclosed and claimed. The cavity of the base 40 is filled with a gel to provide moisture resistance and protection for the wires connected their end. In a preferred embodiment gel 50 is hydrophobic.
[0024] FIG. 3 shows a bottom view of the connector 10. Base 40 has a flange 120 that surrounds a plurality of wire receptacles 90, 100, 110. Wires 20, 30 are inserted into receptacles 90, 100, 110. FIG. 3 shows three receptacles, but any number of receptacles may be provided without departing from the scope of the invention disclosed and claimed.
[0025] FIG. 4 shows a top view of the connector 10 with wires 20, 30 connected therein. In this embodiment, cover 60 and legs 140a-d engage the inner walls of base 40. To connect the wires, the cover 60 is removed from the base 40, wires 20 and 30 are positioned within the cavity of the base 40. Wire connector 70a-c are attached to cover 60 so that when cover 60 is secured to base 40, connectors 70a-c strip away the insulation from wires 20, 30, and provide an electrical connection between the conductive material of wire 20 and the conductive material of wire 30. FIG. 5 shows a bottom view of the connector 10 with wires 20, 30 secured in the base 40.
[0026] FIG. 6 shows connector 10 in perspective. Connector 10 comprises a top cover 60 removably connected to a base 40. In this embodiment, cover 60 is inserted into cavity of base 40 so that wire receptacle 70a-c are positioned to engage and electrically connect wires 20, 30. Wires 20, 30 enter through wire receptacles 90, 100, 110. When the wires 20, 30 are inserted into the base 40, wire connectors 70a-c pierce the insulated covering of the wires 20, 30 to make an electrical connection between wires 20 and 30. Flange 120 provides some protection for dislodging the wires 20, 30 once they are connected. FIG. 7 shows a bottom view of connector 10 including base 40 and flange 120.
[0027] FIG. 8 shows a perspective view of base 40 without top cover. Base 40 provides a cavity 130 suitable to receive wires 20, 30 and wire connectors 70a-c when top 60 is positioned in cavity 130. Wires 20, 30 may be inserted through wire receptacles 90, 100, 110 into cavity 130. Once inserted, the wire connector 70a-c, preferably secured to top 60, are positioned in the cavity 130. When top 60 is positioned and secured to base 40, wire connectors 70a-c strip away the insulated coating of wires 20, 30 and allow an electrical connection to be formed between wires 20, 30.
[0028] FIG. 9 shows a side view of connector 10. Base 40 does not have top 60 connected to it. Flange 120 provides some protection from outside forces dislodging wires 20, 30. Wire receptacles 90, 100, 110 are openings into which wires 20, 30 may be inserted into base 40. The embodiment shown has three wire receptacles, however, any number of receptacles may be provided depending on the number of wires to be connected. FIG. 10 shows a side view of base 40 and flange 120.
[0029] FIG. 11 shows a bottom view of top cover 60. Top cover 60 has legs 140a-d to secure a top 60 to base 40. As shown in FIG. 12, legs 140a-d extend from top 60 and are designed with extrusions to fit complementary structure on base 40 sufficient to allow top 60 to be removably secured to base 40. One skilled in the art will recognize many ways to secure top 60 to base 40 without departing from the scope of this invention.
[0030] FIG. 13 shows a top view of top cover 60 comprising legs 140a-d. FIG. 14 shows a perspective view of top 60 with legs 140a-d. Top 60 is configured internally to receive one or more wire connectors 70a-c to allow the wire connectors to connect with wires 20, 30 when top cover 60 is securely attached to base 40.
[0031] A hydrophilic gel is dispersed within cavity 130 of base 40 to provide moisture resistance two wires, 20, 30, including the electrical connection between wires 20, 30. The hydrophobic gel can be your various kinds known in the field. Suitable hydrophobic gels include: Dynatex and Super Lube. Any other type of hydrophobic gel such as silicone or similar products may be used within the scope of the disclosed invention. Top the top cover 60 and base 40 may be made from flame retardant nylon, polycarbonate, or any other material that ensures good connectivity and good conductivity for the wires 20, 30 to prevent corrosion and or UV deterioration.
